Abstract: Disclosed herein is a multi-cell battery pack having optimal temperature distribution throughout the battery pack and optimal air flow through the battery pack. Disclosed herein is a battery pack which provides optimal temperature distribution throughout the battery pack, wherein maximum cell temperature (Tmax) and temperature differential amongst all cells in the battery pack (?Tcell) are optimized for efficient thermal management providing safety, improved performance and extended life of the battery pack and electrochemical cells. Also disclosed herein is a battery pack which provides optimal flow through the battery pack and minimal pressure drop (?P) throughout the battery pack.

Abstract: A device and method are disclosed for providing substantially uniform temperatures to at least a first and second battery cell in a battery pack. A heat transfer control element is operatively coupled to the at least first and second battery cells. The heat transfer control element is adapted to transfer heat between the battery cells and insulate the battery cells from a flow of heat transfer medium. The first battery cell is insulated to a greater amount than the second battery cell.

Abstract: A battery pack is provided which includes at least one electrochemical rechargeable battery cell, and a housing enclosing the battery cell. At least one inlet is formed in the housing configured such that gas can enter into the housing, and at least one outlet is formed in the housing configured such that gas can exit the housing. The outlet includes a breathable membrane configured such that water vapor can pass through the membrane and outside the housing.

Abstract: A battery assembly includes a housing and N charge storage devices within the housing. The system also includes a first tray includes a first side that includes X areas that transfer first current from electrolyte leaked from a first one of the N charge storage devices to a current detector. The tray includes a second side that insulates the housing from the electrolyte. N and X are integers greater than or equal to 1.

Abstract: A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.

Abstract: A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.

Abstract: A battery assembly includes a housing and N charge storage devices within the housing. The system also includes a first tray includes a first side that includes X areas that transfer first current from electrolyte leaked from a first one of the N charge storage devices to a current detector. The tray includes a second side that insulates the housing from the electrolyte. N and X are integers greater than or equal to 1.

Abstract: Disclosed herein is a multi-cell battery pack having optimal temperature distribution throughout the battery pack and optimal air flow through the battery pack. Disclosed herein is a battery pack which provides optimal temperature distribution throughout the battery pack, wherein maximum cell temperature (Tmax) and temperature differential amongst all cells in the battery pack (?Tcell) are optimized for efficient thermal management providing safety, improved performance and extended life of the battery pack and electrochemical cells. Also disclosed herein is a battery pack which provides optimal flow through the battery pack and minimal pressure drop (?P) throughout the battery pack.

Abstract: A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.

Abstract: A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.

Abstract: The present invention discloses is a battery case, comprising a base case and an insert as two parts of the exterior case. The base case is formed of a first polymeric material and the insert is formed of a second polymeric material, wherein the second polymeric material has a higher thermal conductivity than the first polymeric material. The second polymeric material may comprise a base polymer and at least one thermally conductive filler, such as ceramic, glass or carbon fiber. The base polymer of the second polymeric material may be selected from the group consisting of polyphenylene ether, polystyrene, polypropylene, polyphenylene sulfide and the ceramic filler may be selected from the group consisting of alumina, fused silica, a glass ceramic sold under the trademark MACOR®, boron nitride, silicon nitride, boron carbide, aluminum nitride, silicon carbide, zirconia and combinations thereof.

Abstract: A through transmission laser welding system for a battery module enclosure includes a first battery module enclosure component. A second battery module enclosure component interfaces with the first battery module enclosure component. A laser source focuses a laser beam on a junction between the first and second battery module enclosure components in order to form a weld between the first and second battery module enclosure components. The first and second battery module enclosure components comprise polymeric thermoplastics. The first battery module enclosure component is transmissive to a wavelength of the laser beam and the second battery module enclosure component is opaque to a wavelength of the laser beam. Alternatively, both the first and second battery module enclosure components are transmissive to a wavelength of the laser beam, and a laser absorbing coating is applied at an interface between the first and second battery module enclosure components.