Abstract: A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

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 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 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 center pin for a battery cell that is designed to improve the thermal behavior of a cell during a thermal runaway event is provided in which the center pin is comprised, at least in part, of an intumescent material. The intumescent material may be used to fill a void within the center pin, or to cover an outer surface of the center pin. When the intumescent material covers the center pin, a secondary non-intumescent material may surround the intumescent material, for example in the form of a sleeve, thereby minimizing or preventing chemical reactions from occurring between the intumescent material and the materials comprising the electrode assembly.

Abstract: A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

Abstract: A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

Abstract: An active thermal runaway mitigation system is provided that mitigates the effects of a single cell undergoing thermal runaway, thereby preventing the propagation of the thermal runaway event to neighboring cells within the battery pack. The provided system includes at least one, fluid-containing conduit in proximity to the cells within the battery pack. The conduit includes a plurality of breach points in proximity to the subset of cells, where each breach point is configured to form a breach at a preset temperature that is lower than the melting temperature of the conduit. Once a breach is formed, the fluid contained within the conduit is discharged through the breach.

Abstract: A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

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: Some embodiments include a system, that includes an electric motor coupled to propel an electrical vehicle, a battery coupled to power the motor, a preheating system coupled to preheat the battery, a battery temperature comparator to compare a temperature of the battery to a target preheated temperature and to provide a battery below temperature signal when the battery temperature is below a specified temperature, a control circuit to determine the time remaining prior to a scheduled drive start time and to provide a preheating enable signal during a target time interval prior to the scheduled drive start time and a further control circuit to operate the preheating system in response to the battery below temperature signal and the preheating enable signal.

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: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a multi-sided, substantially airtight battery pack enclosure configured to hold a plurality of batteries, where at least one side of the battery pack enclosure includes at least one cavity. An inner wall of the enclosure includes a plurality of perforations configured to pass gas from within the enclosure to the cavity within the at least one side member. The system is further comprised of at least one gas exhaust port integrated into an outer wall of the enclosure and configured to pass gas from within the cavity of the enclosure side member to the ambient environment when one or more batteries contained within the battery pack undergo thermal runaway.

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: 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 system for detecting thermal events, e.g., thermal runaway, within a sealed battery pack based on a characterization of monitored pressure variations within the pack is provided. The system includes at least one pressure sensor coupled to the battery pack and to a pressure monitoring system that outputs pressure data representative of the battery pack pressure over time; a system controller that analyzes the pressure data and outputs a control signal when the pressure data fits a specific curve shape; and a thermal event response subsystem that performs a preset response upon receipt of the control signal from the system controller. The system may include a secondary effect monitoring system, wherein the thermal event response subsystem performs the preset response when the pressure data fits a specific curve shape and the secondary effect is detected by the secondary effect monitoring system.

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 thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a multi-sided, substantially airtight battery pack enclosure configured to hold a plurality of batteries, where at least one side of the battery pack enclosure includes at least one cavity. An inner wall of the enclosure includes a plurality of perforations configured to pass gas from within the enclosure to the cavity within the at least one side member. The system is further comprised of at least one gas exhaust port integrated into an outer wall of the enclosure and configured to pass gas from within the cavity of the enclosure side member to the ambient environment when one or more batteries contained within the battery pack undergo thermal runaway.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway. The system includes a sealed battery pack enclosure configured to hold a plurality of batteries and at least one exhaust nozzle assembly. The exhaust nozzle assembly includes an exhaust nozzle that passes and directs the flow of hot gas from within the battery pack to the ambient environment during a thermal runaway event, a nozzle seal mounted within the exhaust nozzle that seals the exhaust nozzle during normal operation of the battery pack, and a shape memory alloy (SMA) retaining member that is configured to capture an end portion of the nozzle seal and hold the seal within the exhaust nozzle when the SMA retaining member is configured in its first shape, and that is configured to release the seal from the exhaust nozzle when the SMA retaining member is heated to its transformation temperature.