Safety Protection in EV Battery Systems

A method for safely charging a traction battery in electric vehicles to avoid overcharging and potential safety issues. The method involves monitoring battery parameters like the state of charge (SOC) during charging and discharging or stopping charging when the parameter changes by a certain threshold. This prevents continuous charging if the battery is already full, preventing overheating, lithium plating, and other problems.

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Smart connection sheet for battery packs that can provide automatic EV battery safety. The smart connection sheet has a conductive member to connect adjacent battery cells and a cut-off device that can be triggered to sever the conductive member. When a fault condition like a short circuit, overheat, or collision is detected, the cut-off device can be activated to disconnect the battery cells and prevent further damage.

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Chassis design for electric vehicles to provide a secure connection between the vehicle chassis and the traction battery housing that will prevent detachment in the event of a rear impact. The chassis features projections that fit into corresponding recesses on the battery housing. This three-dimensional form fit engagement locks the battery housing securely onto the chassis beams in all directions.

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A battery design to enhance safety by using individual battery cell housings, boxes, and an isolation component. The battery packs multiple battery cells into individual boxes that have pressure relief regions. These boxes are then enclosed in a larger box. If a battery cell has a thermal runaway event, its housing can vent pressure into the first box without affecting nearby cells. The pressure relief regions prevent the boxes and larger enclosure from exploding. An isolation component between the boxes absorbs heat and gases from venting cells.

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A thermal management system for energy storage systems that uses oscillating heat pipes (OHPs) to keep individual cells at their desired temperature while insulating them if one cell goes into thermal runaway. The system includes a cold plate cell holder to cool the cells via heat absorption from one surface, and OHP covers around the other surface of the cells to cool them via additional heat absorption.

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Battery pack with a safety device to prevent fire or explosion propagation to adjacent modules when one module malfunctions. The device connects a resistor to the malfunctioning module to absorb its energy and prevent thermal runaway. An event detector identifies the bad module and a controller activates a switch to connect the resistor when needed. This isolates the faulty module from the others and prevents fires or explosions from spreading.

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A lithium metal battery with improved cycle stability and safety by using a negative electrode plate with a polymer protective film on the lithium-metal surface. The protective film contains a citric acid copolymer with carboxyl and hydroxyl groups that can react with lithium metal. This forms a strong, flexible film that reduces dendrite growth, electrolyte consumption, and improves coulomb efficiency. The film coating on the lithium metal surface improves cycle stability and safety.

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Vehicle battery with integrated safety feature to prevent fires. The battery has a cell assembly with cells that have degassing elements to release hot gas if cells fault. Inside the battery housing is a deactivating device filled with a combustion promoter. On contact with hot gas, the device releases the promoter to burn off the gas inside the housing, preventing ignition outside the battery.

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A motor vehicle with an electric drive that prevents thermal runaway of the battery system by conducting hot gas produced during a cell thermal event away from the battery. The vehicle has an underride protection plate under the battery that abuts the battery walls in certain regions to increase mechanical stability. This creates a gas channel between the plate and battery to direct hot gas out of the vehicle rather than allowing it to contact the battery. The underride plate abutting the battery walls provides load resistance, while the open channel routes the gas.

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Battery protection apparatus for electric vehicles that effectively protect the battery pack during collisions without adding excessive weight compared to previous battery pack protection systems. The battery protection apparatus includes a separate main body fixed under the vehicle that extends up to shield the battery pack side. This main body has a cavity and gaps to absorb and disperse collision forces from impacts rather than transmitting them directly to the battery pack. A protrusion on the vehicle sill between the main body and battery helps absorb forces.

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Smart fuse protection for the electrical systems of highly variable load applications like vehicles. The fuse protection uses parallel legs with different fuses and switches that can be separately controlled. A thermal fuse and solid state switch are in parallel. The switch can be activated based on current conditions to bypass the thermal fuse. A controller monitors the current and activates the switch when appropriate. This prevents nuisance failures from transient loads while still providing overcurrent protection.

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A power supply device for an electric vehicle with enhanced thermal insulation between stacked battery cells to prevent thermal runaway propagation. The device uses a thermal insulation sheet between cells that is made from inorganic fibers. This sheet provides effective thermal insulation while also having low rigidity to prevent displacement of adjacent cells. The inorganic fiber sheet reduces the risk of thermal runaway propagation through the battery stack.

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A thermal runaway barrier for use in preventing thermal runaway in battery modules. The barrier is a nonwoven fibrous insulation layer that contains inorganic fibers, fumed silica particles dispersed in the fiber matrix, and a binder to hold it together. This insulation layer is sandwiched between optional organic and inorganic encapsulation layers.

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A thermal suppression system for electrified vehicle battery packs that can mitigate and manage battery thermal events like fires or overheating. The system uses aerosol devices integrated into the battery array and/or pack. When triggered by high temperatures, the aerosol devices release aerosol particles that disperse over the battery cells to suppress thermal propagation. This helps contain and extinguish battery thermal events. The aerosol devices can be implanted within the battery array or pack, and are activated by temperature sensors and control modules.

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Battery box design to improve safety of batteries in electric vehicles and other applications. The box has a chamber filled with a fire suppressant agent like CO2 that can be released into the battery compartment if a cell overheats or vents gases. This prevents thermal runaway fires by flooding the battery area with a fire-extinguishing medium. The box also has relief mechanisms to vent pressure and avoid explosions.

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Lithium-ion batteries that are safe and fire-resistant for use in applications like electric vehicles. The key is using a fire-resistant electrolyte to prevent thermal runaway if the battery short circuits. The electrolyte contains a lactone compound, g-butyrolactone, that provides stability at high temperatures without igniting. The battery also uses electrodes with graphene for high performance and low internal resistance.

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Increasing lithium ion battery safety by preventing adhesive from blocking pressure relief mechanisms. A battery cell with a pressure relief mechanism is designed to have an isolation component that prevents adhesive from being applied between the cell and the component it attaches to. This allows the relief mechanism to function properly and vent gases if needed. The isolation component can have features like protrusions that surround the relief mechanism area to block adhesive access.

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Battery module design that protects against potentially dangerous high current conditions like short circuits. The battery module contains multiple battery cells, each of which has a cell blocking portion that can interrupt the current path if a high current flows. This protects against issues like a short circuit in one cell causing excessive current flow. The cells are also connected in series through a module fuse. The current level at which the cell blocking portion interrupts is set higher than the fuse blowout current, so the fuse will blow first in the event of a high current fault.

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Battery temperature adjustment system for electric vehicles to prevent battery deterioration. The system has a battery, cooling device and control system. When the vehicle is connected to an external power source, the control system selects either the battery or external power to cool the battery based on a deterioration sensitivity map. If cooling with external power would cause more deterioration than using battery power, it cools with battery power.

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Battery cell design to prevent gas accumulation and swelling/exploding of battery cells by allowing gas pressure to be released through a gas-permeable film. The film is connected to the inside of the cover plate and/or housing and covers through holes in the plate/housing. This allows gas to escape while keeping electrolyte in. A backing material supports the film to prevent deformation. The design avoids problems of sealing and separation over time that can occur with prior art venting designs.

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Electric vehicle battery packs with improved thermal event management to contain and mitigate the effects of battery fires. The battery packs have a multi-layered vent management system that can guide vented byproducts along a desired path, reduce internal volume, and absorb solid particles. The layers include insulation, baffles, filters, and thermal protection to contain and filter vent gases while minimizing heat transfer. This prevents propagation of thermal events within the battery pack and reduces the risk of fire.

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Electric vehicle battery pack with a simplified configuration to efficiently vent toxic gases that may be generated during abnormal conditions. The battery pack has a separate exhaust channel that normally closes off from the cooling air channel. In an abnormal condition when gas is detected, the exhaust channel opens to allow the cooling air flow to carry the fumes outside the vehicle. A temperature sensor triggers increased airflow to ensure complete venting.

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A method for safely connecting electric battery units to electrical systems, like connecting a battery pack to a vehicle electrical system. The method involves short-circuiting the electrical system first. Then, while the system is short-circuited, connecting a battery unit that is already short-circuited locally. Once connected, the local short-circuit is removed. By doing this, the battery unit is protected from electrical shock during connection.

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A battery module for electric vehicles and power storage that enables compact and safe battery packs. The module has stacked battery cells, end plates, and a circuit board for voltage detection. The circuit board is mounted on the outer surface of the end plates, not on top of the battery stack like conventional designs. This lowers the height of the module while preventing damage from hot gas ejected during failures.

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Battery design to protect electrode terminals from damage and prevent short circuits when the battery case is impacted. A protective member inside the case extends perpendicular to the battery cells, with a protruding portion that covers the terminals and creates a gap between them and the case. This allows the protruding member to absorb impact forces and protect the terminals from damage. The protrusion creates a gap to prevent contact when the case is deformed.

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Battery housing design to enhance safety by isolating and directing emissions from pressure relief mechanisms away from internal battery components. The housing separates an electrical cavity containing battery cells from a collection cavity that captures emissions. When pressure relief occurs, emissions enter the collection cavity instead of the electrical cavity. The collection cavity is further divided into two compartments with an exhaust vent between them. A baffle forms a long S-shaped flow channel within one compartment to extend the path and cool the emissions. This reduces risk of combustion and damage to internal components.

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Heat insulation pad for battery assemblies that significantly improves safety performance of battery assemblies by reducing the risk of thermal runaway propagation between cells. The heat insulation pad contains a mixture of silicon rubber and aerogel particles. The aerogel provides thermal insulation while the silicon rubber provides strength and flexibility. The pad is placed between adjacent battery cells to insulate and separate them. The pad must have specific properties like low thermal conductivity, high compressive strength, and elastic modulus.

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Battery pack for electric vehicles that prevents damage to battery modules during impacts. The pack has a tray with enclosing edge beams and a vapor chamber on top. The vapor chamber edges clamp onto the tray beams. This couples the vapor chamber to the tray to increase strength and prevent beam deformation when squashed. The chamber also protects the battery from above.

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Battery module with enhanced fire safety by adding a fireproof component between battery units. The battery module has multiple battery units connected by busbars, enclosed by upper and lower covers. A fireproof component is vertically positioned within the module between the battery units. Each battery unit has a vent facing towards the fireproof component. This prevents flames or high temperature particles from one unit igniting adjacent units during thermal runaway. The fireproof component has extensions that reach between adjacent battery arrays.

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Battery pack exhaust duct design to prevent ignition and smoke production outside the battery pack when hot, pressurized gas is discharged. The duct has an inlet connected to the battery housing and an outlet outside the housing. Inside the duct are two guide components on opposite sides. The guides extend into the flow path to make it meander. This increases travel distance to lower gas temperature and pressure. The guides also collect particles in the flow to prevent ignition.

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Battery design with improved heat dissipation for power batteries used in electric vehicles, electronics, and energy storage. The battery has an air-cooling structure with an air duct penetrating the body to draw air through an opening in the box. This airflow cools the battery cells inside. A fan can also be added to further enhance cooling. The air-cooling structure is fixed to the box and covers the battery cells. This allows direct airflow over the cells for better heat dissipation compared to traditional enclosures.

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Battery design to enhance safety by improving thermal management and emission containment. The key idea is to attach a thermal management component to a wall of the battery cell that does not have the pressure relief mechanism. This allows significant temperature adjustment when the battery is operating normally. Meanwhile, the emissions from pressure relief during thermal runaway are discharged in a direction away from the thermal management component. This prevents the emissions from breaking through the thermal management component and causing safety issues.

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Battery design that reduces the risk of explosion by optimizing the bracket to allow pressure relief of the battery cell. The battery cells have protrusions on the side walls and the brackets have grooves that snap fit together to limit axial movement. This secures the battery cells while still allowing the end covers to detach for pressure relief.

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Battery cell design to improve safety by reducing the risk of short circuits in the cell. The design uses insulating components that isolate the electrode tabs from the metal shell. This prevents contact and shorting if the electrode tabs shift. The insulating components have a main body to isolate the battery core from the end cap, and an extended part that goes between the core and shell to isolate the tabs.

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Battery design to enhance safety by isolating gas emissions when pressure relief valves activate. A battery box has separate electrical and collection chambers with an isolating component. The isolator has openings aligned with pressure relief valves that allow gas to escape into the collection chamber. This prevents gas from shorting electrical components.

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System for protecting the electrical components of electrified vehicles from overloading and damage by monitoring current and temperature of the electrical distribution system and implementing mitigation actions when the values approach component limits. Mitigation actions include reducing traction battery discharge and charge limits, pulling down engine sooner, reducing regenerative braking, lowering EV mode speed limit, disabling certain drive modes, increasing NVH thresholds, and reducing auxiliary loads and external device power.

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Battery pack for electric vehicles that improves safety, energy density and compactness compared to conventional battery packs. The battery cells have vents that allow gas to escape in case of overheating. The battery cells are housed in a pack case with the vents facing downwards so any gas released moves away from occupants. This improves safety. The pack design eliminates the need for top covers and heat sinks that reduce energy density. The exposed vents also allow better cooling.

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Smart power supply device that regulates output power to a secondary battery to prevent overcharging. The device includes a fuel cell, secondary battery, power converter, current detector, and controller. When the charging current to the battery exceeds a limit, the controller signals the power converter to reduce output. If charging current is below the limit, the converter can increase output. This prevents overloading the battery while still utilizing it when possible.

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Battery pack for electric vehicles that can discharge venting gas from the battery during thermal runaway to prevent it from flowing into the vehicle cabin. The pack has an outlet duct with a switching wall that can direct air from cooling the battery cells back into the vehicle during normal operation, but switch to venting gas out of the vehicle when thermal runaway is detected.

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Battery cell binding design that reduces risk of battery failure from cell expansion. The design involves placing battery cells in a configuration where the largest walls are parallel to the horizontal plane. This allows a reinforcing portion of the binding component to enhance its strength and binding force specifically to the largest walls. This prevents excessive expansion and deformation of the cells compared to if the binding force were evenly distributed.

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All-solid-state battery with improved durability by preventing dendrite formation and short circuits. The battery has an adjusted shape with a planar surface having area-to-circumference ratio of 0.7 or less. This reduces surface energy at the solid-gas interface of the edge compared to the inside, preventing lithium ions from moving and depositing there. This prevents uneven lithium growth that causes shorts and dead lithium.

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Battery tray with a molded tub component that provides structural support for the batteries, reduces component count, and protects against leaks and impacts. The tray has an integral tub with a floor and upward-extending perimeter wall that encloses the batteries. It also has cross members dividing the tub into compartments. A separate support structure attaches to the tub sides. A cover seals the top opening. This design eliminates leak-prone joints and uses the molded tub for battery support. It also provides impact protection and separate compartments.

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A gas flow optimized battery top assembly that improves safety in secondary batteries. The assembly has a deformable plate that protrudes when internal pressure exceeds a threshold. A conductive plate above it has a gas hole surrounded by an upward protrusion. This allows gas to quickly escape, enhancing sensitivity of the deformable plate. The protrusion prevents liquid from entering and short-circuiting the plates. The gas hole has an inner surface with a smooth, tapered transition that accelerates gas flow. This design prevents pressure buildup and short-circuits, improving battery safety.

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Detecting thermal runaway of battery cells in a vehicle to prevent accidents and fires before they occur. The detection method uses a gas sensor and powder coating on the cell surface. When the cell surface reaches a specific temperature, gas is released from the coating. The sensor detects the gas and alerts the driver. This provides advance warning of imminent thermal runaway so the driver can stop safely. Coating the cells with a powder that vaporizes at a temperature below runaway allows early detection without costly cell sensors.

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Battery pack design to quickly and efficiently vent gas in case of off-gassing to prevent thermal runaway and damage to battery cells. The battery pack uses venting valves that communicate with installation spaces between battery modules and structural members. The vents provide a dedicated discharge path to efficiently emit any gases generated away from the battery cells and critical components.

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Battery cell design to improve safety by reducing risk of short circuit caused by particles. The design includes an insulating member inside the cell that attaches to the cell body. This isolates the cell body from the outer shell and prevents particles from penetrating through the separator and causing a short circuit.

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Cylindrical battery cell design with improved safety by preventing microcracks and leaks at the welds. The cell uses a separate current collector that is welded to the end cap and electrode tab, allowing electrical connection without directly welding the two parts together. This avoids welding to bumpy surfaces and reduces cracking risks. The end cap has protrusions and recesses to separate the welds.

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A power storage device such as a battery that restricts movement of the electrode body to prevent damage from shocks. The device includes a can housing the electrode body, and a movement restricting member inside the can. The member has a portion bonded to the electrode body and a portion fixed to the can. This restricts movement of the electrode body inside the can if the device is impacted.

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Prevent foreign matter from entering a battery module in a vehicle battery pack to improve safety. The battery pack contains a number of battery modules stacked together, each with gas release valves. The valves connect to a duct inside the pack that releases gas to the outside if pressure rises too high. A check valve is inserted in the duct to allow gas out but prevent foreign matter like dust, water, or debris from entering the duct and reaching the battery cells.

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A pouch-type lithium-ion battery design that reduces the risk of explosion if it is penetrated by a sharp object like a nail. The pouch of the battery is made of layers including an outer surface protection layer, a gas barrier layer, a metal foil layer, and an inner sealant layer. Portions of the outer layers are removed in a specific area where the metal foil layer is exposed. If the battery is penetrated, this design enables heat and gas to escape through the exposed metal layer instead of building up pressure and exploding.

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