Cell cap assembly with recessed terminal and enlarged insulating gasket
Granted: June 3, 2010
Application Number:
20100136387
A simplified cell design is provided for a battery utilizing the 18650 form-factor, the simplified cell design reducing manufacturing cost, battery weight and the risk of shorting between the battery case and the battery terminal. In the cap assembly of the disclosed battery, the safety vent element, which is recessed relative to the top of the cell case, also serves as the battery terminal. Additionally, the insulating gasket positioned between the cell case and the cap assembly is…
Battery capacity estimating method and apparatus
Granted: June 3, 2010
Application Number:
20100138178
A method for accurately estimating battery capacity based on a weighting function is provided. The disclosed system monitors battery current and uses the monitored battery current to calculate the state of charge (SOCbyAh) of the battery. The system also measures the open circuit voltage (OCV) of the battery when the system is at rest, rest being determined by achieving a current of less than a preset current value for a period of time greater than a preset time period. The state of…
Battery charging time optimization system
Granted: June 3, 2010
Application Number:
20100138092
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…
Multi-wall battery for maintaining cell wall integrity during thermal runaway
Granted: June 3, 2010
Application Number:
20100136424
A battery is provided in which a thermal insulator or other material is interposed between the electrode assembly and the inner surface of the cell casing, the additional layer(s) inhibiting the formation of wall perforations in the battery casing during a thermal runaway event.
Cell cap assembly with recessed terminal and enlarged insulating gasket
Granted: June 3, 2010
Application Number:
20100136421
A simplified cell design is provided for a battery utilizing the 18650 form-factor in which the CID and PTC elements are eliminated, thereby reducing manufacturing cost and battery weight. To reduce the risk of shorting between the battery case and the battery terminal, the battery terminal is recessed relative to the top of the cell case and the insulating gasket positioned between the cell case and the cap assembly is designed to cover a large portion of the outer surface of the…
Method and apparatus for the external application of battery pack encapsulant
Granted: June 3, 2010
Application Number:
20100136413
A method and apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell contraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the…
Battery cell with a partial dielectric barrier for improved battery pack mechanical and thermal performance
Granted: June 3, 2010
Application Number:
20100136409
The adverse effects of the dielectric material covering the cylindrical case of a conventional 18650 cell are eliminated by replacing it with a ring-shaped dielectric material, wherein the ring-shaped dielectric material does not extend down or otherwise cover the cylindrical outer surface of the cell's casing. The ring-shaped dielectric material provides access to the battery terminal corresponding to the cap assembly while preventing shorting between the battery terminal and the edge…
Battery cell with a partial dielectric barrier for improved battery pack mechanical and thermal performance
Granted: June 3, 2010
Application Number:
20100136407
The adverse effects of the dielectric material covering the lateral outer surface of a conventional battery are eliminated by replacing it with a dielectric barrier that covers less than 20 percent of the lateral outer surface of the cell case; more preferably less than 15 percent of the lateral outer surface of the cell case; still more preferably less than 10 percent of the lateral outer surface of the cell case; and yet still more preferably less than 5 percent of the lateral outer…
Thermal barrier structure for containing thermal runaway propagation within a battery pack
Granted: June 3, 2010
Application Number:
20100136404
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.
Sealed battery enclosure
Granted: June 3, 2010
Application Number:
20100136402
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.
Cell Separator for Minimizing Thermal Runaway Propagation within a Battery Pack
Granted: June 3, 2010
Application Number:
20100136396
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…
Active Thermal Runaway Mitigation System for Use Within a Battery Pack
Granted: June 3, 2010
Application Number:
20100136391
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…
Method and apparatus for maintaining cell wall integrity during thermal runaway using an outer layer of intumescent material
Granted: June 3, 2010
Application Number:
20100136385
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.
Liquid cooling manifold with multi-function thermal interface
Granted: April 29, 2010
Application Number:
20100104938
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…
FLUX CONTROLLED MOTOR MANAGEMENT
Granted: April 15, 2010
Application Number:
20100090629
A motor in an electric vehicle can be controlled by receiving at least one of a user input or vehicle information, selecting one of a plurality of available flux modes using at least one of the user input or the vehicle information, and calculating a control signal, using the selected flux mode, to control the motor of the electric vehicle.
Cell Thermal Runaway Propagation Resistance Using Dual Intumescent Material Layers
Granted: April 8, 2010
Application Number:
20100086844
A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of a pair of intumescent material layers coating the battery casing, or at least a portion thereof.
Battery charging time optimization system
Granted: March 25, 2010
Application Number:
20100072954
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…
Cell thermal runaway propagation resistant battery pack
Granted: March 25, 2010
Application Number:
20100075213
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.
Cell thermal runaway propagation resistance using an internal layer of intumescent material
Granted: March 25, 2010
Application Number:
20100075221
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.
Electric vehicle thermal management system
Granted: February 4, 2010
Application Number:
20100025006
A method for managing thermal loads within an electric vehicle using an efficient thermal management system (100) that utilizes a single heat exchanger (133) is provided. A refrigeration subsystem (103) cools the heat exchanger (133). A first coolant loop (139) in thermal communication with the heat exchanger (133) is used to cool the energy storage system (137). A second coolant loop (151) corresponding to the HVAC subsystem (107) is also in thermal communication with the heat exchanger…
