Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: Systems and methods for monitoring a state of a battery system based on information related to a measured pressure within the battery system are presented. In certain embodiments, the disclosed systems and methods may utilize a pressure-sensitive smart foam material in connection with measuring a pressure within the battery system. Based on the measured pressure information, a variety of information relating to the battery system may be determined. For example, information relating to a state of a battery system, certain events occurring within the battery system, and/or battery lifecycle information may be determined based on the measured pressure information.

Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: A method of assembling a battery module assembly includes a step of preparing a plurality of battery cell stacks. Each battery cell stack is constructed by positioning a pre-compressed foam unit interposed between a first battery cell and a second battery cell. Each battery cell stack is positioned in a receiving frame. After such positioning, the pre-compressed foam unit of each battery cell stack is expanded.

Abstract: A battery module is described. The battery module includes the battery module includes a plurality of repeating frames; a plurality of battery cells positioned between the plurality of repeating frames, the battery cells having a flexible heat conducting covering, an edge of the heat conducting covering folded over an outside edge of the repeating frame; and a heat sink contacting the edge of the heat conducting covering folded over the edge of the repeating frame. A method of cooling a battery module is also described.

Abstract: System and methods for mitigating battery damage in a vehicle including a liquid-cooled battery system. In certain embodiments, a system for mitigating damage caused by leaks of liquid coolant in a battery system may include a one or more coolant leak sensors. A coolant leak detection system communicatively coupled to the coolant leak sensors may be configured to detect an occurrence of a liquid coolant leak in the battery system based on information provided by the coolant leak sensors. One or more valves communicatively coupled with the coolant leak detection system may actuate by the coolant leak detection system when a leak of liquid coolant is detected, thereby allowing leaked liquid coolant to drain from the battery system.

Abstract: A battery pack with a drain plug. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A first lead and a second lead are configured to signally connect an impedance element that is cooperative with the carrier, to a circuit such that when the continuity of the circuit is interrupted, the circuit provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: A battery assembly includes a plurality of stacked battery cartridges. Each battery cartridge includes a first receptacle unit, a battery cell stack, and a second receptacle unit positioned within first receptacle unit. The battery cell stack includes a first battery cell, a second battery cell, and a foam layer interposed between the first battery cell and the second battery cell. The battery cell stack is positioned within the first receptacle unit, with the second receptacle unit compressing the battery cell stack. The battery module assembly also includes a receiving assembly that holds the plurality of battery cartridges.

Abstract: A method of assembling a battery module assembly includes a step of preparing a plurality of battery cell stacks. Each battery cell stack is constructed by positioning a pre-compressed foam unit interposed between a first battery cell and a second battery cell. Each battery cell stack is positioned in a receiving frame. After such positioning, the pre-compressed foam unit of each battery cell stack is expanded.

Abstract: A prismatic repeating frame assembly for a battery pack includes a main body and a hollow compression limiter. The main body is formed from a first polymer. The main body has an aperture formed therein. The hollow compression limiter is formed from a second polymer. The compression limiter is disposed in the aperture of the main body and permits a compression rod to be disposed therethrough. The second polymer is configured to withstand forces during an assembly of the battery pack and frequency inputs during an operation of the battery pack.

Abstract: System and methods for mitigating battery damage in a vehicle including a liquid-cooled battery system. In certain embodiments, a system for mitigating damage caused by leaks of liquid coolant in a battery system may include a one or more coolant leak sensors. A coolant leak detection system communicatively coupled to the coolant leak sensors may be configured to detect an occurrence of a liquid coolant leak in the battery system based on information provided by the coolant leak sensors. One or more valves communicatively coupled with the coolant leak detection system may actuate by the coolant leak detection system when a leak of liquid coolant is detected, thereby allowing leaked liquid coolant to drain from the battery system.

Abstract: A battery module is described. The battery module includes the battery module includes a plurality of repeating frames; a plurality of battery cells positioned between the plurality of repeating frames, the battery cells having a flexible heat conducting covering, an edge of the heat conducting covering folded over an outside edge of the repeating frame; and a heat sink contacting the edge of the heat conducting covering folded over the edge of the repeating frame. A method of cooling a battery module is also described.

Abstract: A composite article for dissipating thermal energy from a secondary battery cell includes a first graphite layer, a second graphite layer spaced away from and arranged parallel to the first graphite layer, and a metal layer sandwiched between and disposed in contact with each of the first graphite layer and the second graphite layer. The composite article has a thermal conductivity of greater than or equal to about 1,200 W/mK and an electrical conductivity of greater than or equal to about 10,000 S/cm. A secondary battery module includes the composite article and a secondary battery cell having a length and an average measurable temperature along the length during operation of the secondary battery module. The composite article is disposed adjacent and in contact with the secondary battery cell to thereby dissipate thermal energy from the secondary battery cell during operation of the secondary battery module.

Abstract: A blower motor assembly for use in a heating, ventilation and air-conditioning system of a vehicle and a method of diverting water are disclosed. The blower motor assembly may include a motor housing, configured to surround internal components of the blower motor assembly, and including a cooling channel/air intake opening. The blower motor assembly may also include a motor support flange extending radially outward from the motor housing and having an upward facing surface, and at least one water diversion vane extending upward from the upward facing surface and extending radially outward in an arcuate shape to divert water off of the flange.

Abstract: A prismatic repeating frame assembly for a battery pack includes a main body and a hollow compression limiter. The main body is formed from a first polymer. The main body has an aperture formed therein. The hollow compression limiter is formed from a second polymer. The compression limiter is disposed in the aperture of the main body and permits a compression rod to be disposed therethrough. The second polymer is configured to withstand forces during an assembly of the battery pack and frequency inputs during an operation of the battery pack.

Abstract: A composite article for dissipating thermal energy from a secondary battery cell includes a first graphite layer, a second graphite layer spaced away from and arranged parallel to the first graphite layer, and a metal layer sandwiched between and disposed in contact with each of the first graphite layer and the second graphite layer. The composite article has a thermal conductivity of greater than or equal to about 1,200 W/mK and an electrical conductivity of greater than or equal to about 10,000 S/cm. A secondary battery module includes the composite article and a secondary battery cell having a length and an average measurable temperature along the length during operation of the secondary battery module. The composite article is disposed adjacent and in contact with the secondary battery cell to thereby dissipate thermal energy from the secondary battery cell during operation of the secondary battery module.

Abstract: An injection molded piston formed integrally of polymer material includes a body extending along an axis and providing a mounting surface, first and second partial cylindrical surfaces located above the mounting surface and formed with a concave recesses, a first shoe located above the mounting surface and radially outboard of the cylindrical surfaces, and a second shoe located above the mounting surface and radially outboard of the cylindrical surfaces.

Abstract: A blower motor assembly for use in a heating, ventilation and air-conditioning system of a vehicle and a method of diverting water are disclosed. The blower motor assembly may include a motor housing, configured to surround internal components of the blower motor assembly, and including a cooling channel/air intake opening. The blower motor assembly may also include a motor support flange extending radially outward from the motor housing and having an upward facing surface, and at least one water diversion vane extending upward from the upward facing surface and extending radially outward in an arcuate shape to divert water off of the flange.