Abstract: Systems and methods are disclosed herein for determining the remaining useful life of a battery cell that includes the battery cell's internal resistance and/or shock loading. In one example implementation, the systems and methods disclosed herein monitor acceleration information over time based on information received from an accelerometer integrated in a battery cell and electrical information for at least one electrical parameter of the battery cell over time. The information is stored for determining remaining useful life. In another example implementation, the systems and methods disclosed herein determine a voltage drop across the battery cell and a current output of the battery cell. The systems and methods determine an internal cell resistance of the battery cell based on charge or discharge voltage and current information.

Abstract: Systems and methods are disclosed herein for determining the remaining useful life of a battery cell that includes the battery cell's internal resistance and/or shock loading. In one example implementation, the systems and methods disclosed herein monitor acceleration information over time based on information received from an accelerometer integrated in a battery cell and electrical information for at least one electrical parameter of the battery cell over time. The information is stored for determining remaining useful life. In another example implementation, the systems and methods disclosed herein determine a voltage drop across the battery cell and a current output of the battery cell. The systems and methods determine an internal cell resistance of the battery cell based on charge or discharge voltage and current information.

Abstract: Systems and methods are disclosed herein for determining the remaining useful life of a battery cell that includes the battery cell's internal resistance and/or shock loading. In one example implementation, the systems and methods disclosed herein monitor acceleration information over time based on information received from an accelerometer integrated in a battery cell and electrical information for at least one electrical parameter of the battery cell over time. The information is stored for determining remaining useful life. In another example implementation, the systems and methods disclosed herein determine a voltage drop across the battery cell and a current output of the battery cell. The systems and methods determine an internal cell resistance of the battery cell based on charge or discharge voltage and current information.

Abstract: In accordance with some embodiments of the present disclosure, a battery cell includes a cooling structure, a plurality of energy units thermally coupled to the cooling structure via a first interface, and a thermally conductive potting material that thermally couples the plurality of energy units to each other and to the cooling structure via a second interface. In some embodiments, the thermally conductive potting material is electrically conductive. In some embodiments, the first interface is between a side of the cooling structure and respective ends of the cylindrical energy units, and the second interface is between the side of the cooling structure and respective cylindrical sides of the energy units. In some embodiments, the plurality of energy units are electrically coupled in parallel. In some embodiments, the battery cell also includes an adhesive that thermally couples the plurality of energy units to the cooling structure via the first interface.

Abstract: In accordance with some embodiments of the present disclosure, an apparatus includes a first electrical conductor electrically coupled to rim terminals of energy units, where the first electrical conductor includes openings around respective center terminals of the energy units, a second electrical conductor electrically coupled to the center terminals of the energy units through the openings, and an insulator layer arranged between the first and second electrical conductors. In some embodiments, the second electrical conductor is electrically coupled to the center terminals using a plurality of tabs. In some embodiments, the second electrical conductor includes a plurality of bar segments, and the plurality of tabs extend from the plurality of bar segments. In some embodiments, openings of the first electrical conductor provide a lateral constraint to the ends the energy units.

Abstract: In accordance with some embodiments of the present disclosure, a battery cell includes a housing including an opening, a removable side configured to, in an installed position, cover the opening, and at least one energy unit coupled to the removable side such that removal of the removable side causes the at least one energy unit to be removed from the housing. In some embodiments, in the installed position, the removable side is coupled to the housing and forms a front panel of the housing. In some embodiments, in the installed position, the removable side covers the opening to form a sealed enclosure around the at least one energy unit. In some embodiments, the removable side is coupled to a frame member that is configured to, in the installed position, be arranged adjacent to an inner surface of the housing.

Abstract: In accordance with some embodiments of the present disclosure, an apparatus includes a plurality of pouch energy units comprising a plurality of electrical tabs, each having bent end, and a current collector arranged across the plurality of pouch energy units. The current collector comprises a plurality of tines extending behind the bent ends; and each bent end is electrically coupled to a corresponding tine. In some embodiments, the plurality of electrical tabs each comprise a first end portion extending outward from a respective pouch energy unit and a second end portion comprising the bent end, and the bent end is approximately perpendicular to the first end portion. In some embodiments, the plurality of electrical tabs each comprises a middle portion between the first end portion and the second end portion, and the middle portion comprises a curve or one or more bends.

Abstract: In accordance with some embodiments of the present disclosure, a battery cell includes a housing including at least one inlet port and at least one outlet port, at least one coolant line extending between the at least one inlet port and the at least one outlet port, at least one energy unit arranged within the housing, and a cooling structure coupled to the at least one coolant line, wherein the cooling structure is thermally coupled to the at least one energy unit. In some embodiments, respective ends of the coolant line include respective sockets, each configured to couple to one of the at least one inlet port and the at least one outlet port. In some embodiments, at least one of the sockets is configured to mate with a cooling line of an additional battery cell.

Abstract: In accordance with some embodiments of the present disclosure, a battery cell includes an exhaust plate including first and second sides and a passageway therebetween, a plurality of energy units, each including a vent at an end, where the ends of a first subset of the energy units are affixed to the first side, the ends of a second subset of the energy units are affixed to the second side, and the vents of the energy units are configured to vent into the passageway, and a vent structure coupled to the passageway and configured to cause gas released from one or more of the energy units to vent out of the battery cell. In some embodiments, a first end of the vent structure is coupled to the exhaust plate and a second end of the vent structure has an opening vented outside of the battery cell.

Abstract: A battery module and a method of assembling the battery module are provided. The battery module includes a cooling surface having a first area and a second area with different cooling capacities, an adhesive including a first component having a first thermal conductivity and a second component having a second thermal conductivity, and a first battery and a second battery. The first battery is secured to the first area by a first portion of the adhesive and the second battery is secured to the second area by a second portion the adhesive. The first portion of the adhesive has a first ratio of the first component to the second component and the second portion of the adhesive has a second ratio of the first component to the second component. The first and second ratios are different and compensate for the different cooling capacities of the first and second areas.

Abstract: An apparatus includes a component having an edge feature that has a radius of curvature. The apparatus includes an underlayer arranged over the edge feature and configured to increase the radius of curvature of the edge feature. The apparatus includes a powder coating arranged over the component and over the underlayer to form a continuous layer. The underlayer is configured to remain under the powder coating. The underlayer helps the powder coating achieve a more uniform thickness over the edge feature. The apparatus is formed by applying an underlayer to a first region of the component to form an underlaid component. The first region includes the edge feature. A powder coating is applied to the underlaid component. A masking layer may be applied to a region other than the first region, and after powder coating, the masking may be removed to expose a surface of the component.

Abstract: Systems and methods are provided herein for disassembling a battery system. Further, systems and methods are provided herein for a battery apparatus configured for disassembly of a battery system. In addition, systems and methods are provided herein for preparing a battery system including a first plurality of members bonded with a first adhesive and a second plurality of members bonded with a second adhesive for disassembly of the battery system.

Abstract: Systems and methods are disclosed herein for determining the remaining useful life of a battery cell that includes the battery cell's internal resistance and/or shock loading. In one example implementation, the systems and methods disclosed herein monitor acceleration information over time based on information received from an accelerometer integrated in a battery cell and electrical information for at least one electrical parameter of the battery cell over time. The information is stored for determining remaining useful life. In another example implementation, the systems and methods disclosed herein determine a voltage drop across the battery cell and a current output of the battery cell. The systems and methods determine an internal cell resistance of the battery cell based on charge or discharge voltage and current information.

Abstract: Systems and methods are provided herein for disassembling a battery system. Further, systems and methods are provided herein for a battery apparatus configured for disassembly of a battery system. In addition, systems and methods are provided herein for preparing a battery system including a first plurality of members bonded with a first adhesive and a second plurality of members bonded with a second adhesive for disassembly of the battery system.

Abstract: A barrier structure, a battery module including the barrier structure, and a method of assembling the battery module are provided. The barrier structure includes a plurality of first sidewalls oriented in a first direction, and a plurality of second sidewalls oriented in a second direction. The plurality of first sidewalls interlock with the plurality of second sidewalls to form a grid structure comprising a plurality of cells, each having an open-ended top and an open-ended bottom and configured to be arranged around a cylindrical section of at least one of a plurality of battery cells. The battery module includes a plurality of cylindrical battery cells arranged in a predetermined pattern and a barrier structure for separating the battery cells.

Abstract: A battery support beam and battery module including the battery support beam are provided. The battery support beam includes a first end, a second end opposite the first end, and a battery support section between the first end and the second end. The battery support section includes a plurality of cylindrical sleeves arranged in a predetermined pattern, each having a cylindrical sidewall having an open-ended top and an open-ended bottom. Each of the cylindrical sidewalls is configured to be arranged around a cylindrical middle section of one of a plurality of cylindrical battery cells. The battery module includes a plurality of cylindrical battery cells including a plurality of groups of battery cells arranged in the predetermined pattern. The battery module further includes a battery support section for each of the plurality of groups of battery cells.

Abstract: Methods and systems for welding contacts of a plurality of battery cells are provided. A method includes using a detector to perform a scan of the cell electrode contact area for each of the plurality of battery cells. Based upon the scan of each cell electrode contact area, a determination is made of whether one or more possible weld sites for each electrode contact area are viable for welding. In response to determining that one or more weld sites are viable, one or more of the viable weld sites are selected and a welder is used to weld at least one of the selected weld sites.

Abstract: A battery module and a method of assembling the battery module are provided. The battery module includes a cooling plate having a cooling surface, an adhesive standoff disposed on a first portion of the cooling surface, and a securing adhesive disposed on a second portion of the first cooling surface. The securing adhesive is disposed on the cooling surface after the adhesive standoff is substantially cured. The battery module further includes a plurality of battery cells. A first end of each of the plurality of battery cells is secured to the cooling surface by the securing adhesive. The adhesive standoff maintains the first end of each of the plurality of battery cells a distance away from the cooling surface while the securing adhesive cures.

Abstract: An apparatus includes a component having an edge feature that has a radius of curvature. The apparatus includes an underlayer arranged over the edge feature and configured to increase the radius of curvature of the edge feature. The apparatus includes a powder coating arranged over the component and over the underlayer to form a continuous layer. The underlayer is configured to remain under the powder coating. The underlayer helps the powder coating achieve a more uniform thickness over the edge feature. The apparatus is formed by applying an underlayer to a first region of the component to form an underlaid component. The first region includes the edge feature. A powder coating is applied to the underlaid component. A masking layer may be applied to a region other than the first region, and after powder coating, the masking may be removed to expose a surface of the component.

Abstract: A fluid-affected fuse includes a structural housing, a pair of electric terminals, one or more fuse elements, and a fluid arranged in an internal volume of the structure. The structure provides rigidity to the fuse. The terminals are coupled to the structural housing and are configured to be coupled to an electric power circuit of a battery circuit. The one or more fuse elements are electrically connected in series to the pair of electric terminals and are arranged in the internal volume. The fluid is configured to affect a temperature of the fuse element. A fluid-filled fuse is filled with fluid, optionally sealed, and operated with the increased heat capacity of the fluid to affect temperature of the fuse. A fluid-cooled fuse is filled with the fluid, undergoing a stream of the fluid thus allowing control of fuse temperature. A control system controls the fluid stream and fuse operation.