Abstract: There is described a battery module comprising: a cell enclosure for housing a plurality of battery cells; and a cooling assembly. The cooling assembly comprises a cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module. The cooling channel is positioned such that heat generated within the cell enclosure may be transferred to a cooling 5 fluid flowing, via the cooling channel, from the first side of the battery module to the second side of the battery module. There is also described a battery module stack comprising multiple such battery modules. The battery modules are arranged in a stacked formation such that the cooling channel of at least one battery module is aligned with the cooling channel of at least one adjacent battery module.

Abstract: A battery module includes an enclosure that has at least one heat sink. Within the module is a stack assembly composed of a series of cell carrier assemblies connected together. The cell carrier assemblies each include a cell carrier that has a first spring that is biased against the heat sink. Each of the cell carrier assemblies also includes a battery cell and a heat conductive sheet that is thermally coupled to the battery cell. The heat conductive sheet is positioned to be pressed against the heat sink by the first spring to facilitate a good thermal connection between the sheet and the heat sink. Heat is accordingly conducted away from the battery cell, along the heat conductive sheet, to the heat sink.

Abstract: A battery module and an intermediate module for use together in a stack of modules permit flexible electrical configurations of the stack. The battery module has multiple electrically conductive paths extending between its top and bottom sides; one of the paths is connected in series with the module's cells, while at least one of the other paths acts as a pass-through that allows power or communications to pass through the module. The intermediate module also contains pass-through electrical paths that route power or communications from one battery module on one of the top and bottom sides of the intermediate module to the pass-through path of the battery module on the other of the top and bottoms ides of the intermediate module. This allows the modules in a stack to be electrically connected together in different series-connected groups.

Abstract: A system comprising one or more battery modules mounted in a rack assembly has a structure which defines a cooling air pathway for flowing cooling air across the side and/or bottom of each battery module thereby cooling the battery module, or alternatively, across the energy calls in the battery module. Further, the system has a structure which defines a thermal runaway gas pathway for flowing thermal runaway gases from a battery module out of the system. The system structure is configured to ensure that the cooling air pathway and thermal runaway gas pathway are physically separated, thereby minimizing the risk of the thermal runaway gas substantially mixing with cooling air thereby potentially resulting in a spontaneous ignition and an explosion.

Abstract: There is described a battery module comprising: a cell enclosure for housing a plurality of battery cells; and a cooling assembly. The cooling assembly comprises a cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module. The cooling channel is positioned such that heat generated within the cell enclosure may be transferred to a cooling 5 fluid flowing, via the cooling channel, from the first side of the battery module to the second side of the battery module. There is also described a battery module stack comprising multiple such battery modules. The battery modules are arranged in a stacked formation such that the cooling channel of at least one battery module is aligned with the cooling channel of at least one adjacent battery module.

Abstract: There is provided a backplane assembly with a power substructure and a cooling substructure. Battery modules may be engaged with the backplane assembly. When engaged, power connectors in the power substructure engage with corresponding power connectors on the battery modules. A cooling fluid moving through the cooling substructure is directed toward the battery modules so as to cool the battery modules during operation. The backplane assembly may additionally include an exhaust substructure. Gases vented by the battery modules move through the exhaust substructure and are directed away from the backplane assembly.

Abstract: A battery module includes an enclosure that has at least one heat sink. Within the module is a stack assembly composed of a series of cell carrier assemblies connected together. The cell carrier assemblies each include a cell carrier that has a first spring that is biased against the heat sink. Each of the cell carrier assemblies also includes a battery cell and a heat conductive sheet that is thermally coupled to the battery cell. The heat conductive sheet is positioned to be pressed against the heat sink by the first spring to facilitate a good thermal connection between the sheet and the heat sink. Heat is accordingly conducted away from the battery cell, along the heat conductive sheet, to the heat sink.

Abstract: There is provided a backplane assembly with a power substructure and a cooling substructure. Battery modules may be engaged with the backplane assembly. When engaged, power connectors in the power substructure engage with corresponding power connectors on the battery modules. A cooling fluid moving through the cooling substructure is directed toward the battery modules so as to cool the battery modules during operation. The backplane assembly may additionally include an exhaust substructure. Gases vented by the battery modules move through the exhaust substructure and are directed away from the backplane assembly.

Abstract: A system comprising one or more battery modules mounted in a rack assembly has a structure which defines a cooling air pathway for flowing cooling air across the side and/or bottom of each battery module thereby cooling the battery module, or alternatively, across the energy calls in the battery module. Further, the system has a structure which defines a thermal runaway gas pathway for flowing thermal runaway gases from a battery module out of the system. The system structure is configured to ensure that the cooling air pathway and thermal runaway gas pathway are physically separated, thereby minimizing the risk of the thermal runaway gas substantially mixing with cooling air thereby potentially resulting in a spontaneous ignition and an explosion.

Abstract: A system includes a fuel cell that has an anode chamber that is in a deadheaded configuration. A controller of the system controls a valve that is connected to the anode chamber pursuant to a modulation scheme to purge the anode chamber.

Abstract: A fuel cell system includes a fuel cell stack, a reservoir, a water management circuit, a cooling circuit and a fan. The fuel cell stack communicates a reactant flow and communicates a water flow. The water management circuit is adapted to remove water from the reactant flow and store the water in the reservoir. The cooling circuit is adapted to generate the water flow that is communicated through the fuel cell stack from the water in the reservoir. The fan controls the amount of water that is removed from the reactant flow to regulate a water level of the reservoir and controls removal of thermal energy from the water flow regulate a temperature of the fuel cell stack.

Abstract: This application relates to cast enclosures for battery replacement applications, such as enclosures configured to house power units comprising a fuel cell and an energy storage device. The enclosures function as protective enclosures and counterweights, provide mounting points and conduits for gases, fluids, plumbing and wiring, and serve as thermal energy storage/transfer devices. The enclosures are formed in a mold or die and comprise wall portions defining a plurality of internal subcompartments for receiving the various system components. In one embodiment of the invention channels may be formed in the wall portions of the enclosures for circulating a heat transfer fluid therethrough.

Abstract: Corrugated flow field plates for use in fuel cells typically comprise a plurality of parallel open-faced fluid flow channels for the fuel cell reactants. Complex flow paths, such as serpentine flow paths, may be created in such corrugated flow field plates by incorporating channel couplings within the plate or by attaching coupling subassemblies to the plate. The plates are particularly suitable for use in solid polymer electrolyte fuel cells.

Abstract: A proton exchange membrane (PEM)-type fuel cell is formed from layered undulate MEA structures and separator plates alternating with each other in the stack dimension so that each layered MEA structure is disposed between and attached to an associated pair of separator plates so as to form at least one discrete conduit on each side of each layered MEA structure through which conduit reactant gas may be circulated. Each layered MEA structure is formed from proton exchange membrane material sandwiched between a pair of spaced-apart current collectors with electro-catalyst particles between the membrane material and each current collector so that the membrane material and electro-catalyst particles fill the space between the current collectors, forming together with the current collectors a layered MEA structure.

Abstract: Corrugated flow field plates for use in fuel cells typically comprise a plurality of parallel open-faced fluid flow channels for the fuel cell reactants. Complex flow paths, such as serpentine flow paths, may be created in such corrugated flow field plates by incorporating channel couplings within the plate or by attaching coupling subassemblies to the plate. The plates are particularly suitable for use in solid polymer electrolyte fuel cells.