Abstract: A camber-flow battery cell includes a metallic enclosure, an electrode assembly, and one or more fin inserts. The metallic enclosure includes a top cap plate, a bottom cap plate, a first side wall, and a second side wall. The first and second side walls form a cambered profile defined by an imaginary chord line and an imaginary camber line, where the imaginary camber line is different from the imaginary chord line. The electrode assembly is disposed within the metallic enclosure and includes a plurality of layers of an electrode material, wherein the plurality of layers of electrode material are formed by at least one of rolling the electrode material or folding the electrode material. Each of the one or more fin inserts is fitted between the electrode assembly and the metallic enclosure to fill a respective space between the electrode assembly and the metallic enclosure.

Abstract: Battery assemblies, vehicle with battery assemblies, and methods for applying potential to battery enclosures are provided. A method includes enclosing a first electrode and a second electrode within an enclosure; electrically connecting the first electrode to a first terminal; electrically connecting the second electrode to a second terminal; locating an insert between the electrodes and the enclosure, wherein the insert includes a conductive region electrically connecting the first electrode to the enclosure, and wherein the insert includes an insulative region electrically insulating the first electrode from the enclosure; and establishing an electrical connection from the from the first electrode through the conductive region, wherein the electrical connection is configured to apply a potential to the enclosure.

Abstract: A battery cell group assembly for a vehicle includes a housing including a plurality of panels defining a cavity and one or more battery cells disposed within the cavity of the housing. One or more thermal barriers are coupled to each of the one or more battery cells, and vents are defined proximate to the one or more battery cells. The battery cell group assembly also includes at least one flame arrestor disposed over the vents. The at least one flame arrestor has a thermally conductive surface area and includes a first set of openings. The first set of openings are configured to redirect heat from the one or more battery cells within the cavity of the housing. The battery cell group assembly further includes a thermal mass that is thermally coupled to the at least one flame arrestor.

Abstract: A bipolar electrode for use in a lithium-ion battery includes a current collector, an anode having high aspect ratio conductive carbon particles and an anode binder, and a cathode having cathode active particles in a cathode binder. The high aspect ratio conductive carbon particles in the anode are aligned so that a long axis of the high aspect ratio conductive carbon particles is substantially perpendicular to the current collector. The cathode active particles are paramagnetic, diamagnetic, or magnetic and have been magnetically aligned, the cathode further comprises high aspect ratio conductive particles aligned so that a long axis of the high aspect ratio conductive particles is substantially perpendicular to the current collector, or both. The bipolar electrode can be made by subjecting the current collector coated with slurries including the components for the anode and the cathode to a magnetic field while drying.

Abstract: A power control system for a battery system of a vehicle includes one or more supplemental protection devices that are connected to at least one of a first contactor, a second contactor, one of N fuses, and one of N vehicle loads. A battery management module is configured to measure and store a plurality of state of health parameters for the battery system and to selectively operate the one or more supplemental protection devices in a coverage gap between first and second coverage areas handled by the first contactor and the second contactor and the N fuses based on a calibration function and/or calibration parameters. A telematics system selectively sends the plurality of state of health parameters for the battery system to a remote server and to receive at least one of a new calibration function and new calibration parameters for the vehicle from the remote server.

Abstract: A protection system for a battery system includes a battery control module configured to selectively open at least one contactor to isolate the battery system from a load in response to a sensed current being greater than a first threshold and within a first current range, at least one fuse connected between first and second terminals of the battery system and configured to open to isolate the battery system from the load in response to the sensed current being greater than a second threshold and within a second current range that is greater than and offset from the first current range, and an auxiliary protection module configured to selectively form a short circuit between first and second terminals in response to the sensed current being greater than the first threshold, less than the second threshold, and within a coverage gap region between the first and second current ranges.

Abstract: A power control system for a battery system of a vehicle includes a first contactor, a second contactor, N fuses and N vehicle loads. An active sacrificial protection device includes a third contactor and a first fuse. The active sacrificial protection device is connected to a positive or negative terminal of the battery system. A current sensor is configured to sense a measured load current flowing through one of the first contactor and the second contactor. A battery management module is configured to selectively close the third contactor to reduce current flowing through one of the first contactor or the second contactor and selectively open the one of the first contactor or the second contactor after closing the third contactor.

Abstract: A power control system for a battery system of a vehicle includes one or more supplemental protection devices that are connected to at least one of a first contactor, a second contactor, one of N fuses, and one of N vehicle loads. A battery management module is configured to measure and store a plurality of state of health parameters for the battery system and to selectively operate the one or more supplemental protection devices in a coverage gap between first and second coverage areas handled by the first contactor and the second contactor and the N fuses based on a calibration function and/or calibration parameters. A telematics system selectively sends the plurality of state of health parameters for the battery system to a remote server and to receive at least one of a new calibration function and new calibration parameters for the vehicle from the remote server.

Abstract: A protection system for a battery system includes a battery control module configured to selectively open at least one contactor to isolate the battery system from a load in response to a sensed current being greater than a first threshold and within a first current range, at least one fuse connected between first and second terminals of the battery system and configured to open to isolate the battery system from the load in response to the sensed current being greater than a second threshold and within a second current range that is greater than and offset from the first current range, and an auxiliary protection module configured to selectively form a short circuit between first and second terminals in response to the sensed current being greater than the first threshold, less than the second threshold, and within a coverage gap region between the first and second current ranges.

Abstract: A power control system for a battery system of a vehicle includes a first contactor, a second contactor, N fuses and N vehicle loads. An active sacrificial protection device includes a third contactor and a first fuse. The active sacrificial protection device is connected to a positive or negative terminal of the battery system. A current sensor is configured to sense a measured load current flowing through one of the first contactor and the second contactor. A battery management module is configured to selectively close the third contactor to reduce current flowing through one of the first contactor or the second contactor and selectively open the one of the first contactor or the second contactor after closing the third contactor.