Abstract: A perforation tool for a battery enclosure system of a vehicle battery pack, comprising: an engaging tip configured to mechanically breach a thermal-control-agent-retaining enclosure of a traction battery pack including a plurality of interconnected batteries with the enclosure reinforced for mechanical protection of the batteries when installed in an electric vehicle; a port for receiving a thermal-control agent having a pressure in a range of about 5-100 psi; and a housing, coupled to the tip and to the port, wherein the tip includes an aperture and wherein the housing includes a channel communicating the port to the aperture wherein the pressurized thermal-control agent is produced at the tip at about the pressure.

Abstract: An energy storage system includes: multiple cells, each cell having a first end with anode and cathode terminals, and a second end opposite the first end, the cells arranged so that the second ends are aligned; for each of the cells, electrical connections coupled to the anode and cathode terminals at the first end; and a heat pipe having a flat evaporation surface facing the second ends.

Abstract: A method includes: assembling a thermal-exchange tube in a module housing for an energy storage pack; assembling cells in the module housing, wherein the thermal-exchange tube runs between rows of the cells; applying an adhesive that affixes the cells and the thermal-exchange tube to the module housing; curing a first portion of the adhesive by radiation, wherein a second portion of the adhesive is shielded from the radiation by the cells or the thermal-exchange tube; and curing at least the second portion of the adhesive by a chemical cure mechanism.

Abstract: A spacer assembly for use with a cell mounting bracket in a battery pack is provided. The spacer assembly, comprised of one or more spacers, maintains the positions of the batteries within the battery pack during a thermal event and after the cell mounting bracket loses structural integrity due to the increased temperature associated with the thermal event. By keeping the battery undergoing thermal runaway in its predetermined location within the battery pack, the minimum spacing between cells is maintained, thereby helping to minimize the thermal effects on adjacent cells while ensuring that the cooling system, if employed, is not compromised. As a result, the risk of thermal runaway propagation is reduced.

Abstract: A liquid cooling manifold assembly for use in the thermal management system of a battery pack is provided. The liquid cooling manifold assembly includes a coolant channel portion through which the coolant channels run, and a dual layer thermal interface interposed between the coolant channel portion and the cells of the battery pack. The outer material layer of the dual layer thermal interface is comprised of an electrically non-conductive, high dielectric material that is preferably tear resistant, deformable and has a high tensile strength and a relatively low surface friction. The inner material layer of the dual layer thermal interface is comprised of a highly compressible material.

Abstract: A battery pack thermal management system for use in an electric car. The battery pack thermal management system includes a plurality of thermistors connected to a plurality of cells of a battery pack. A battery monitor board is connected to the thermistors. The system also includes a manifold and a plurality of cooling tubes connected to the manifold. A tube seal plug is arranged over an end of the cooling tube and an end fitting is arranged on an end of the cooling tube. The thermal management system will cool the battery pack to predetermined temperatures to increase the longevity of the battery pack within the electric vehicle.

Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is overmolded onto the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.

Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is attached to the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.

Abstract: One embodiment includes an electrical cell that includes a flat housing, at least one electrode and an electrically and heat conductive tab coupled to the electrode and extending through the housing for electrically and thermally coupling to a collector panel, the tab being capable of conducting both current and a substantial amount of heat out of the housing to a temperature control system. The cells may be stacked to form a battery having a temperature panel interfaced to the temperature control system by a thermal interface. The battery may propel an electrically-powered vehicle or the like.

Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is attached to the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.

Abstract: A battery pack, or battery pack module, is provided that is configured to respond to a short circuit of moderate current in a manner that minimizes the risk of an initial thermal runaway event propagating throughout the battery pack/battery pack module. In general, the battery pack/battery module allows pre-selection of which cell of the cells comprising the battery pack/battery pack module will be the last cell to respond to the short circuit. As a result, a thermal isolation barrier may be used to separate the preselected cell from the other cells of the battery pack/battery pack module, thereby minimizing the risk of excessive heating and extensive collateral damage.

Abstract: A power source comprised of a metal-air battery pack and a non-metal-air battery pack is provided, wherein thermal energy from the metal-air battery pack is used to heat the non-metal-air battery pack. In one aspect, a thermal energy transfer system is provided that controls the flow of thermal energy from the metal-air battery pack to the non-metal-air battery pack. In another aspect, the flow of thermal energy from the metal-air battery pack to the non-metal-air battery pack is controlled and used to heat the non-metal-air battery pack prior to charging the non-metal-air battery pack.

Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is overmolded onto the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.

Abstract: A controller identifies a condition of a hazardous internal short by comparing patterns of series element voltages to the last known balance condition of the series elements. If the loaded or resting voltage of one or more contiguous series elements uniformly drop from the previously known condition by an amount consistent with an over-current condition, an over-current internal short circuit fault is registered. The desired response is to prevent the affected series elements from heating to a hazardous temperature by summoning the maximum heat rejection capability of the system until the short ceases and the affected elements cool, the cooling function is no longer able to operate due to low voltage, or the affected series string has drained all of its energy through the short. Also includes are responses that allow the battery pack to continue to power the cooling system even though it may enter an over-discharged state.

Abstract: A dual mode, thermal management system for use in a vehicle is provided. At a minimum, the system includes a first coolant loop in thermal communication with a battery system, a second coolant loop in thermal communication with at least one drive train component (e.g., electric motor, power electronics, inverter), a dual mode valve system that provides means for selecting between a first mode where the two coolant loops operate in parallel and a second mode where the two coolant loops operate in series, and a coolant reservoir that is coupled to both coolant loops when the two coolant loops are operating in series and only coupled to the drive train coolant loop when the two coolant loops are operating in parallel.

Abstract: A battery pack, or battery pack module, is provided that achieves improved battery pack performance, system reliability and system safety while impacting only a small region of the battery pack/battery module, and thus having only a minor impact on battery pack cost, complexity, weight and size. The battery pack/battery module is designed such that the fusible interconnects associated with a single battery, or a specific fusible interconnect associated with a single battery, will be the last interconnect(s) to fuse during a short circuit event. The risk of sustained arcing for the predetermined interconnect(s) is minimized through the use of rapid clearing interconnects. As a result, the risk of damage and excessive heating is also minimized.

Abstract: One embodiment includes a housing, a first battery cell having a first cell thermal capacitance, the first cell fixedly disposed in the housing, a second battery cell having a second cell thermal capacitance, the second cell fixedly disposed in the housing a minimum air gap away from the first cell, the minimum air gap having an air gap thermal resistance and a heat conductor disposed adjacent each of the cells, with the heat conductor having a heat conductor heat capacitance. A combination of the first cell thermal capacitance, the second cell thermal capacitance, the heat conductor thermal capacitance and the air gap is sufficient to restrict heat flow from the first cell to the second cell during a thermal runaway event of the first cell, the heat flow restricted such that the second cell temperature remains less than a temperature sufficient to cause thermal runaway in the second cell.

Abstract: A battery coolant jacket for use with a plurality of cells is provided, the jacket comprised of a hollow enclosure configured to permit a liquid coolant to flow through the enclosure, entering via a coolant inlet and exiting via a coolant outlet; a plurality of cell apertures that extend completely through the hollow enclosure, where each cell aperture is sized to fit a cell; and a plurality of coolant segregation walls that are integrated into the hollow enclosure and separate the cells into groups of cells, and where each coolant segregation wall forms a barrier between the cell group contained within that coolant segregation wall and the liquid coolant flowing through the hollow enclosure. The coolant jacket may include at least one flow control wall integrated within the hollow enclosure that controls the coolant flow pathway between the enclosure's coolant inlet and outlet, for example causing the coolant flow pathway to alternate directions between adjacent cell groups.

Abstract: A battery coolant jacket for use with a plurality of cells is provided, the jacket comprised of a hollow enclosure configured to permit a liquid coolant to flow through the enclosure, entering via a coolant inlet and exiting via a coolant outlet; a plurality of cell apertures that extend completely through the hollow enclosure, where each cell aperture is sized to fit a cell; and a plurality of coolant segregation walls that are integrated into the hollow enclosure and separate the cells into groups of cells, and where each coolant segregation wall forms a barrier between the cell group contained within that coolant segregation wall and the liquid coolant flowing through the hollow enclosure. The coolant jacket may include at least one flow control wall integrated within the hollow enclosure that controls the coolant flow pathway between the enclosure's coolant inlet and outlet, for example causing the coolant flow pathway to alternate directions between adjacent cell groups.

Abstract: An energy storage pack includes a coolant inlet manifold, a coolant outlet manifold, and a plurality of thermal-exchange tubes extending between the coolant inlet manifold and the coolant outlet manifold to exchange heat between coolant passing through the plurality of thermal-exchange tubes and a plurality of battery cells mounted adjacent to and among the plurality of thermal-exchange tubes within the energy storage pack. In one embodiment, at least one of coolant inlet manifold and the coolant outlet manifold includes a plurality of thermal-exchange tube terminating structures and a plurality of hose segments intercoupling the plurality of thermal-exchange tube terminating structures. The energy storage pack may further include a coolant inlet opening located on the coolant inlet manifold and a coolant outlet opening located on the coolant outlet manifold.