Abstract: A system and method for collecting, storing and using the oxygen-rich effluent generated when charging a metal-air battery pack is provided.

Abstract: A system and method for maintaining an ambient oxygen concentration below a preset concentration while charging a metal-air battery pack is provided, the system utilizing an on-board means for collecting and storing the oxygen-rich effluent generated during the charge cycle.

Abstract: A method and apparatus is provided in which a layer of an intumescent material surrounds the casing of a battery, the layer helping to prevent the formation of perforations in the battery casing during a thermal runaway event and, if a perforation is formed, inhibiting the flow of hot, pressurized gas from within the battery. A sleeve, surrounding the cell, may be used to contain the intumescent material during the thermal event.

Abstract: A method for actively cooling the battery pack of an electric vehicle after the vehicle has been turned off, thereby limiting the adverse effects of temperature on battery life, is provided. Different battery pack cooling techniques are provided, thus allowing the cooling technique used in a particular instance to be selected not only based on the thermal needs of the battery pack, but also on the thermal capacity and energy requirements of the selected approach.

Abstract: A method for controlling the relative humidity within a battery pack enclosure is provided in which the volume of air within the battery pack is exposed to a volume of desiccant contained within a desiccant enclosure. The system is configured to heat and reactivate the desiccant at predetermined time intervals or when the humidity within the system reaches a preset level, thereby allowing the desiccant to regain its potential for absorbing/adsorbing water vapor.

Abstract: A system and method for mitigating the effects of a thermal event within a battery pack is provided in which the hot gas and material generated during the thermal runaway of at least one non-metal-air cell of a plurality of non-metal-air cells is directed through one or more metal-air cells, the metal-air cells absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers, bystanders, first responders and property are limited.

Abstract: A method and apparatus is provided in which a layer of an intumescent material surrounds the casing of a battery, the layer helping to prevent the formation of perforations in the battery casing during a thermal runaway event and, if a perforation is formed, inhibiting the flow of hot, pressurized gas from within the battery. A sleeve, surrounding the cell, may be used to contain the intumescent material during the thermal event.

Abstract: A method for detecting and responding to a battery thermal event within a sealed battery pack is provided. The method includes the steps of monitoring and characterizing the pressure within the battery pack over time, where identifying a battery thermal event is based on the pressure data fitting a specific curve shape, and performing a preset response when a battery thermal event is identified. The method may additionally monitor for a secondary effect associated with the battery thermal event.

Abstract: An apparatus and method for these embodiments of the present invention, useful in manufacturing for example, includes a plurality of battery modules serially intercoupled together, each module including a housing with an anode connector and a cathode connector, each housing including a memory for storing a module identifier and wherein an anode connector of a first module is coupled to a cathode connector of a second module; and a processing system, coupled to each the module, for determining a plurality of positional attributes of each the module, one positional attribute associated with each the module of the plurality of modules, the processing system writing an ID into the memory of each particular module responsive to the associated positional attribute for the particular module.

Abstract: A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses an insulated conductive member mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A voltage measuring system is coupled to the conductive core of the insulated conductive member, the voltage measuring system outputting a first signal when the temperature corresponding to the battery or batteries is within a prescribed temperature range and a second signal when the temperature exceeds a predetermined temperature that falls outside of the prescribed temperature range.

Abstract: An apparatus and method providing for detecting and responding to high voltage electrolysis within an electric vehicle battery enclosure to limit possible excessive thermal condition of the individual battery cells and modules. A microprocessor-implemented response system for high voltage electrolysis in a battery pack an evaluator to monitor, using the microprocessor, a high voltage electrolysis flag indicative of a possible high voltage electrolysis within an enclosure including a plurality of electrically-coupled battery modules storing energy for the battery pack and a coolant distribution system disposed among and electrically isolated from the plurality of battery modules; and a remediation system, coupled to the enclosure and responsive to the possible high voltage electrolysis when the evaluator detects a likelihood of the possible high voltage electrolysis, to decrease risks associated with the possible high voltage electrolysis when operated.

Abstract: A battery module for use in an electric vehicle is disclosed. The battery module includes a plurality of cells arranged in a predetermined pattern within the module. The battery module also includes an optical pyrometer arranged inside the module. The optical pyrometer is installed within the module after being tuned to detect a predetermined frequency or band of frequencies. The pyrometer will be used to detect an increase in short wave radiation density from one of the battery cells within the module wherein that battery cell has a temperature above a predetermined threshold. The optical pyrometer will be used to communicate an electric signal to a control system of the electric vehicle wherein that control system will implement a predetermined mitigation process to contain the thermal event of that one cell within the battery module.

Abstract: A method for detecting cell failure within a battery pack based on variations in the measured electrical isolation resistance of the battery pack is provided. The method includes the steps of monitoring the isolation resistance; determining when the isolation resistance falls below a first preset value; determining how long it takes for the electrical isolation resistance to recover to greater than a second preset value; determining when the isolation resistance falls below a third preset value; and performing a predetermined response after the electrical isolation resistance falls below the first preset resistance value and recovers to greater than the second resistance value and then falls below the third preset resistance value and if the time period is within a preset time range.

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 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 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 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 method for detecting cell failure within a battery pack based on variations in the measured electrical isolation resistance of the battery pack is provided. The method includes the steps of monitoring the isolation resistance; determining when the isolation resistance falls below a preset value; and performing a predetermined response when the isolation resistance falls below the preset value. The method may include additional steps such as (i) determining how long the isolation resistance remains below the preset value; (ii) determining the rate of change in the isolation resistance; (iii) determining how long it takes for the electrical isolation resistance to recover; (iv) determining when the isolation resistance falls below a third preset value, wherein this step is performed after the isolation resistance recovers to greater than the second preset value; and (v) monitoring for a secondary effect associated with cell failure.

Abstract: Improved battery systems have been developed for lithium-ion based batteries. The improved battery systems consist of two-additive mixtures in an electrolyte solvent. Such battery systems are prepared by assembling a positive electrode and a negative electrode in the sealed cell, removing residual water from the sealed cell, filling the sealed cell with a nonaqueous electrolyte under an inert atmosphere, vacuum-sealing the sealed cell, carrying out a formation process comprising charging and discharging the sealed cell until the sealed cell achieves an initial capacity. The nonaqueous electrolyte includes lithium ions, a first nonaqueous solvent comprising a carbonate solvent, a second nonaquaeous solvent comprising methyl acetate, and an additive mixture of a first operative additive of either vinylene carbonate or fluoroethylene carbonate and a second operative additive of 2-furanone. Gas formation is suppressed in the battery system during the formation process.