Abstract: A wireless cell array tracker includes a daisy chain connecter and processor each supported on a circuit substrate. The circuit substrate is attached to a battery array. The daisy chain connector physically interfaces with a battery sensing module of the battery array. The processor retrieves data from the battery sensing module via the daisy chain connector, and commands wireless transmission of the data.

Abstract: A method for charging a traction battery of an electric vehicle includes, in response to a request to charge a traction battery, initially discharging the traction battery, for a first duration of time, according to a discharge stage having a constant power; subsequently charging the traction battery, for a second duration of time, according to a charge stage having a constant current; and repeating the discharge stage and the charge stage in sequence until the battery is charged.

Abstract: This disclosure is generally directed to systems and methods for wirelessly charging a battery in a mobile robot. In an example method in accordance with the disclosure, a mobile robot locates and approaches a wireless battery charging station (by using an onboard camera, for example). The mobile robot then executes an alignment procedure to align a wireless charge receiving pad of the mobile robot with a battery charging pad of the wireless battery charging station. The alignment procedure may involve the mobile robot moving the wireless charge receiving pad in any of three axial directions, such as, backwards, forwards, sideways, upwards, and/or downwards. After alignment is completed, the mobile robot may establish a wireless handshake with the wireless battery charging station. The wireless handshake can include a verification of an authentication of the mobile robot to access the wireless battery charging station, followed by a wireless battery charging operation.

Abstract: A method of producing a lithium-ion battery includes filling at least one cell of the battery with an electrolyte followed directly with a first step of sealing the at least one cell and a second step of applying pulsating compression to the at least one cell during formation charging, the pulsating compression comprising alternating a first time period of applying a first compression force F1 greater than zero and a second time period of applying a second compression force F2, wherein F1>F2, and the formation charging includes a first charge of the battery.

Abstract: A method for charging a traction battery of an electric vehicle includes, in response to a request to charge a traction battery, initially discharging the traction battery, for a first duration of time, according to a discharge stage having a constant power; subsequently charging the traction battery, for a second duration of time, according to a charge stage having a constant current; and repeating the discharge stage and the charge stage in sequence until the battery is charged.

Abstract: This disclosure describes exemplary charging systems and methods for fast charging energy storage devices (e.g., battery cells of battery packs). An exemplary charging system may be configured to control charging of a charging circuit by employing repetitive intermittent discharge pulses. The control system may be configured to command the charging circuit to apply a discharge pulse current to the battery cell for a first time period, apply a charging current to the battery cell for a second time period that is significantly longer than the first time period, and then repetitively alternate between applying the discharge pulse current and the charging current until the battery cell reaches a predefined maximum voltage.

Abstract: This disclosure describes exemplary charging systems and methods for fast charging energy storage devices (e.g., battery cells of battery packs). An exemplary charging system may be configured to control charging of a charging circuit by employing repetitive intermittent discharge pulses. The control system may be configured to command the charging circuit to apply a discharge pulse current to the battery cell for a first time period, apply a charging current to the battery cell for a second time period that is significantly longer than the first time period, and then repetitively alternate between applying the discharge pulse current and the charging current until the battery cell reaches a predefined maximum voltage.

Abstract: A vehicle traction battery assembly may include a traction battery cell, a case, and a thermal plate. The case may define a cavity to receive the traction battery cell and has a first side defining a first form feature. The thermal plate may be for positioning adjacent the traction battery cell and define a coolant channel sized for engagement with the case via the first form feature such that traction battery cell is in thermal communication with coolant flowing through the coolant channel. The first form feature may be serpentine-shaped or S-shaped. The first form feature may be castle-shaped from a cross-sectional plan view. The case may be multi-layered and include a first polymer layer, a second polymer layer, and an aluminum layer disposed between the polymer layers.

Abstract: The disclosure provides a battery cell casing for holding a plurality of cell elements, each electrode structure in its own compartment. The disclosed casing eliminates the need for some individual cell walls and replaces them with shared wall partitions.

Abstract: An exemplary battery cell assembly includes, among other things, an extruded case that provides an open area, and an electrode of a battery pack of an electrified vehicle. The electrode is held within the open area. An exemplary electrode housing method includes, among other things, positioning an electrode of an electrified vehicle battery pack within an open area of an extruded case.

Abstract: A battery management controller includes input channels to receive a voltage signal from a battery and output channels to provide diagnostic signals to an operator. The controller is programmed to output a diagnostic signal predictive of a thermal condition in response to the voltage decreasing at a rate greater than a predetermined rate that signals that the voltage is decreasing toward a local minimum that precedes an increase in the voltage indicative of a battery temperature increase rate becoming greater than a threshold. The diagnostic signal may be used to alert the operator of the condition. The controller may be further programmed to issue commands to mitigate the thermal condition based on the diagnostic signal.

Abstract: An exemplary brake assembly includes a brake pad, an actuator that selectively moves the brake pad to contact a rotor, and a thermoelectric generator device housed outside the brake pad. The thermoelectric generator device generates power in response to a temperature difference within the brake assembly.

Abstract: A vehicle traction battery assembly may include a traction battery cell, a case, and a thermal plate. The case may define a cavity to receive the traction battery cell and has a first side defining a first form feature. The thermal plate may be for positioning adjacent the traction battery cell and define a coolant channel sized for engagement with the case via the first form feature such that traction battery cell is in thermal communication with coolant flowing through the coolant channel. The first form feature may be serpentine-shaped or S-shaped. The first form feature may be castle-shaped from a cross-sectional plan view. The case may be multi-layered and include a first polymer layer, a second polymer layer, and an aluminum layer disposed between the polymer layers.

Abstract: A method of mitigating temperature buildup in a passenger compartment of a vehicle is provided. The method includes the steps of: (a) monitoring a temperature differential between a temperature inside the passenger compartment and an ambient temperature of the passenger compartment; (b) generating power utilizing the temperature differential; and (c) actuating a passive mitigation accessory when the temperature differential is above a predetermined threshold. The method may include the additional steps of using the power generated utilizing the temperature differential to actuate said passive mitigation accessory and/or providing the power generated utilizing the temperature differential to said passive mitigation accessory via at least one standard wire harness of the vehicle.

Abstract: An exemplary battery cell assembly includes, among other things, an extruded case that provides an open area, and an electrode of a battery pack of an electrified vehicle. The electrode is held within the open area. An exemplary electrode housing method includes, among other things, positioning an electrode of an electrified vehicle battery pack within an open area of an extruded case.

Abstract: The disclosure provides a battery cell casing for holding a plurality of cell elements, each electrode structure in its own compartment. The disclosed casing eliminates the need for some individual cell walls and replaces them with shared wall partitions.

Abstract: A battery management controller includes input channels to receive a voltage signal from a battery and output channels to provide diagnostic signals to an operator. The controller is programmed to output a diagnostic signal predictive of a thermal condition in response to the voltage decreasing at a rate greater than a predetermined rate that signals that the voltage is decreasing toward a local minimum that precedes an increase in the voltage indicative of a battery temperature increase rate becoming greater than a threshold. The diagnostic signal may be used to alert the operator of the condition. The controller may be further programmed to issue commands to mitigate the thermal condition based on the diagnostic signal.

Abstract: An exemplary brake assembly includes a brake pad, an actuator that selectively moves the brake pad to contact a rotor, and a thermoelectric generator device housed outside the brake pad. The thermoelectric generator device generates power in response to a temperature difference within the brake assembly.

Abstract: In at least one embodiment, a rechargeable battery is provided comprising an electrolyte including an organic solvent and a solution-treated polyolefin separator. A contact angle of the electrolyte including the organic solvent upon the separator may be from 0 to 15 degrees. In one embodiment, the solution-treated polyolefin layer has an increased concentration of ionic functional groups at its surface compared to an untreated polyolefin layer. In another embodiment, the solution-treated polyolefin separator has been treated with a treatment solution having a pH of either at most 2 or at least 12. The separator may be treated with an acid or base solution for at least 30 seconds. The solution-treated separator may exhibit improved wetting with an electrolyte compared to an untreated separator.

Abstract: In at least one embodiment, a rechargeable battery is provided comprising an electrolyte including an organic solvent and a solution-treated polyolefin separator. A contact angle of the electrolyte including the organic solvent upon the separator may be from 0 to 15 degrees. In one embodiment, the solution-treated polyolefin layer has an increased concentration of ionic functional groups at its surface compared to an untreated polyolefin layer. In another embodiment, the solution-treated polyolefin separator has been treated with a treatment solution having a pH of either at most 2 or at least 12. The separator may be treated with an acid or base solution for at least 30 seconds. The solution-treated separator may exhibit improved wetting with an electrolyte compared to an untreated separator.