Abstract: A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of a layer of intumescent material covering the interior surfaces of the battery pack.

Abstract: A sealed battery enclosure to extend the life of the batteries contained therein is provided, the sealed battery enclosure significantly reducing contamination from water or other liquids and gases.

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 means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of a layer of intumescent material covering the interior surfaces of the battery pack.

Abstract: A battery assembly is provided that includes a layer of intumescent material that coats the sidewall and bottom surface of the cell casing, excluding at least one case contact region.

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 means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of at least one layer of intumescent material interposed between the interior surface of the casing of a battery and the corresponding electrode assembly.

Abstract: A system and method disperses a sudden increase in heat generated by one battery cell to a large area including multiple battery cells, thereby preventing the sudden increase from being absorbed primarily by a small number of other battery cells, such as a single battery cell, that could otherwise cause the other battery cells to fail or release their own heat.

Abstract: An apparatus and method providing for coolant agent ingress of a high energy density battery enclosure during an internal thermal event. A solution includes a specialized battery enclosure and, in some embodiments, an associated vehicle structure providing a normally closed, pressure activated fill port. Preferably the fill port is positioned so an operator of the fill port is clear from any hot gases exiting from the enclosure.

Abstract: A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells.

Abstract: A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells.

Abstract: A method and apparatus is provided in which at least one layer pair comprised of an inner, thermally insulating layer and an outer, high yield strength layer, surrounds the casing of a battery, the at least one layer pair inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.

Abstract: A method and apparatus is provided in which a sleeve comprised of one or more layers of a high yield strength material surrounds the casing of a battery, the sleeve inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.

Abstract: A method and apparatus is provided in which a pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.

Abstract: A battery pack dehumidifier system for controlling the relative humidity within a battery pack enclosure is provided, the dehumidifier system including a desiccant that absorbs/adsorbs water vapor from the battery pack enclosure. The system heats and reactivates 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 for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.

Abstract: A method and apparatus is provided in which a pre-formed sleeve or pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed sleeve/secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.

Abstract: A system for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.

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 battery cells and modules. The present invention includes embodiments directed towards detection algorithms and apparatus for promoting the use of voltage, current, humidity, temperature, and pressure sensors for the purpose of detecting high voltage electrolysis. Additionally, the present invention includes response processes and structures to address high-voltage electrolysis.

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.