Abstract: A battery housing assembly for housing battery components of an electric vehicle includes a battery tray, a lid, and a sealant. The battery tray includes a channel located outwardly relative to the battery components. The lid is secured to the battery tray and includes an end portion disposed within the channel. The lid further includes at least one alignment feature configured to align the lid and the battery tray. The sealant is disposed within a portion of the channel of the battery tray and is configured to secure the battery tray and the lid to each other. The sealant is further configured to seal an internal cavity of the battery housing assembly.

Abstract: A battery assembly includes a base including a first locking feature, a lid including a second locking feature, and a metal joint fusing the first locking feature to the second locking feature. The metal joint is configured to melt to disconnect the first locking feature from the second locking feature.

Abstract: A system for recycling a component of a battery assembly includes a removal tool and a cover of the battery assembly. The cover includes a component removal zone configured to be removable from the cover by the removal tool to expose the component and a locator identifying the component removal zone for removal by the removal tool.

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 battery housing assembly for housing battery components of an electric vehicle includes a battery tray, a lid, and a sealant. The battery tray includes a channel located outwardly relative to the battery components. The lid is secured to the battery tray and includes an end portion disposed within the channel. The lid further includes at least one alignment feature configured to align the lid and the battery tray. The sealant is disposed within a portion of the channel of the battery tray and is configured to secure the battery tray and the lid to each other. The sealant is further configured to seal an internal cavity of the battery housing assembly.

Abstract: A method of stabilizing Nickel-rich (NMC) cathode materials includes mixing a feedstock of transition metal sulfates, ammonia, and a basic solution to under bubbling of an inert gas to form a reaction solution, precipitating transition metal hydroxide particles from the reaction solution over a first period of time to precipitate the transition metal hydroxide particles therein to form a metal sulfate solution. The method further includes altering the pH of the metal sulfate solution, supplying a Mn-rich feedstock to the metal sulfate solution to form a Mn-rich solution, and precipitating Mn-rich hydroxide nanoparticles from the Mn-rich solution onto surfaces of the transition metal hydroxide particles over a second period of time to form a heterogeneous precursor.

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 vehicle charging system includes a battery bank including at least one repurposed battery and a charging station in electrical communication with the battery bank and configured to deliver a DC output from the battery bank to an electrified vehicle.

Abstract: This disclosure details exemplary home energy storage systems capable of storing electricity locally for later consumption, such as for charging an electrified vehicle, supporting various home energy needs, and supporting alternative energy storage/power source functionality. An exemplary home energy storage system may include a stationary unit, one or more modular units removably connectable to the stationary unit, and a rack mounting and handcart transportation system configured to mount, detach, and transport the modular unit relative to the stationary unit. Once undocked from the stationary unit, the modular unit(s) may be utilized as a portable power source for powering one or more electrical loads. This disclosure further describes various interconnected functionalities (e.g., electrical and wireless communication of state of uses) between the stationary unit and the modular unit of home energy storage systems and between the modular unit and various satellite equipment associated with the modular unit.

Abstract: This disclosure details exemplary home energy storage systems capable of storing electricity locally for later consumption, such as for charging an electrified vehicle, supporting various home energy needs, and supporting alternative energy storage/power source functionality. An exemplary home energy storage system may include a stationary unit, one or more modular units removably connectable to the stationary unit, and a rack mounting and handcart transportation system configured to mount, detach, and transport the modular unit relative to the stationary unit. Once undocked from the stationary unit, the modular unit(s) may be utilized as a portable power source for powering one or more electrical loads. This disclosure further describes various interconnected functionalities (e.g., electrical and wireless communication of state of uses) between the stationary unit and the modular unit of home energy storage systems and between the modular unit and various satellite equipment associated with the modular unit.

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 vehicle traction battery assembly including an array of stacked prismatic can cases and a support structure is provided. Each of the can cases may define a cavity to receive a battery cell and a multi-prong comb-shaped base. The support structure supports the cases. The support structure and the base define channels therebetween configured for coolant to pass therethrough. A lower portion of each of the can cases open to the channels may be of a dielectric material. A dielectric layer may span a length of the can cases and may be located above the channels. Each of the can cases may define a first locating feature sized to integrate with a second locating feature of an adjacent can case to align the can cases.

Abstract: A vehicle charging system includes a battery bank including at least one repurposed battery and a charging station in electrical communication with the battery bank and configured to deliver a DC output from the battery bank to an electrified 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: A vehicle traction battery assembly including an array of stacked prismatic can cases and a support structure is provided. Each of the can cases may define a cavity to receive a battery cell and a multi-prong comb-shaped base. The support structure supports the cases. The support structure and the base define channels therebetween configured for coolant to pass therethrough. A lower portion of each of the can cases open to the channels may be of a dielectric material. A dielectric layer may span a length of the can cases and may be located above the channels. Each of the can cases may define a first locating feature sized to integrate with a second locating feature of an adjacent can case to align the can cases.

Abstract: A battery testing system according to an exemplary aspect of the present disclosure includes, among other things, a penetrating device and an impedance meter electrically connected to the penetrating device.

Abstract: A Li-ion battery module for stop/start vehicle applications is disclosed. The battery module comprises a plurality of unsealed battery cells that are interconnected in series and positioned in a common housing containing an electrolyte that is shared by the battery cells. The electrolyte may have a redox shuttle agent therein.

Abstract: A battery testing system according to an exemplary aspect of the present disclosure includes, among other things, a penetrating device and an impedance meter electrically connected to the penetrating device.

Abstract: A battery system for powering a vehicle is provided. The system may include a first lithium-ion battery pack having a first total energy capacity and a first power to energy ratio (P/E ratio) and a second lithium-ion battery pack connected in parallel with the first lithium-ion battery pack and having a second total energy capacity that is higher than the first total energy capacity and a second P/E ratio that is lower than the first P/E ratio. A method of controlling the battery system is also provided, and may include controlling an operation of a vehicle according to a total power capability of the first and second battery strings, wherein the total power capability is the sum of a first battery string power capability and a second battery string power capability at a same voltage.

Abstract: A system and method is provided for indicating an efficiency level of energy usage by an automotive vehicle to a passenger in the vehicle. The system includes a computer-readable storage medium, a controller, an interior-lighting system, and a display unit. The controller processes energy usage signals to obtain the given operating mode of the vehicle as well as indications of energy usage amounts that the passenger can control. The controller determines the efficiency level of energy usage by the vehicle based on the energy usage amounts and the given operating mode. The interior-lighting system illuminates at least a portion of the passenger compartment with ambient light having defined characteristics including a luminance and a color, the ambient light indicating the efficiency level. The display unit displays a graphical representation of the efficiency level.