Advancements and Innovations: All-Weather EV Batteries

Battery tray design for electric vehicles that provides impact protection, weight distribution, and environmental sealing for battery packs. The tray has a molded tub component with an integral support structure and optional compartment dividers. This reduces components and potential leak points compared to separate tray and support structures. The tub surrounds the battery area to contain and protect the modules. It seals with a cover to enclose the batteries. The tub provides structural support and impact resistance while also sealing against liquids and gases.

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Battery casing for vehicle battery that has a fluid seal between the casing cover and sealing flange to prevent corrosive infiltration into the seal. The fluid seal provides protection of the zero gap region between the cover and flange. This prevents electrolyte from the battery penetrating into the gap and attacking the casing surfaces that could lead to corrosive infiltration and leaks. Applying a fluid seal like a sprayable sealing medium to the zero gap area before joining the casing halves allows complete wetting of the surfaces to stop corrosion.

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Weatherproofing of EV battery system by adjusting reserve capacity based on weather forecasts. The battery controller receives weather data and checks if the current reserve capacity is sufficient to keep the battery operational under those conditions. If not, it increases the reserve capacity to prevent damage or capacity loss due to weather. This avoids situations where remote vehicles can't be moved or charged enough to prevent cold weather damage.

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Battery pack for electric vehicles that has a pressure relief mechanism to prevent gas buildup inside the pack. The pressure relief mechanism includes a labyrinth structure that allows gas to escape without allowing water ingress. The labyrinth structure prevents water from entering the battery pack while still allowing gases to be safely vented.

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Battery pack for electric vehicles that addresses reduced discharge power and poor consistency in cold weather. The pack contains two types of batteries with different discharge powers at low temperatures. The first type has lower discharge power at low temps while the second type has higher discharge power at low temps. By using a mix of these battery types in the pack, it compensates for the temperature difference between inner and outer pack areas. This improves overall discharge power and consistency in cold weather.

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Sulfide-based solid electrolyte for lithium batteries that has improved moisture resistance compared to existing sulfide electrolytes. It uses a two-layer design with a core of cubic argyrodite structure and a surface layer of non-argyrodite structure. The surface layer composition has a higher sulfur ratio to enhance moisture resistance. The electrolyte is produced by coating the argyrodite core particles with a mixture of phosphorus sulfide and lithium sulfide.

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Secondary battery module design that prevents coolant leakage and damage to cells. The module has a waterproof structure to prevent coolant leakage from damaging the battery cells. This is achieved through a multi-layered structure around the cells that prevents coolant from escaping.

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A battery management system that uses weather forecast data to adjust the reserve capacity level of a battery system to prevent damage from extreme conditions. The system receives weather forecasts and determines if the current reserve capacity is sufficient to maintain battery operation in the forecasted conditions. If not, it increases the reserve capacity level to avoid damage. This helps preserve battery life by preventing over-discharge in cold temperatures or overcharging in hot temperatures.

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Sealing the interface between two battery pack enclosure pieces to prevent ingress of moisture into the enclosure. The interface gasket is compressed horizontally from outside the interface rather than being sandwiched between the enclosure pieces. This allows an effective seal without the need for an interior-facing flange that would impede battery installation and removal.

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Power supply device for electric vehicles, hybrid cars, and power storage systems that prevents short circuits due to condensation and water ingress. The device has a battery stack with insulation between the battery cells and the outer case. The insulation has grooves that channel condensation and water towards drainage points. This prevents dew and water from bridging cell terminals and causing shorts. The grooves have shapes that promote capillary action.

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Power supply device such as battery pack for electric vehicles that prevents electrical leakage due to condensation between stacked battery cells. The device uses an insulating separator with protruding rib structures on the bottom surface. When stacked, the ribs of each separator layer nest together to form a curved path that increases the creepage distance between the battery can bottoms and insulates them. This prevents dew condensation on the exterior cans from causing electrical shorts.

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A battery case with superior moisture resistance for electric vehicle batteries. The case is made from a polymer composite containing a moisture-absorbing filler. This reduces water vapor transmission into the battery compared to conventional plastic cases. The case can be molded into custom shapes and sizes.

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A water-condensation mitigation system for battery packs that reduces and balances pressure inside a battery housing to prevent condensation and damage. The system uses a flexible diaphragm and pressure valves to allow pressure equalization while preventing moisture ingress. This protects the batteries from overpressure and vacuum and stops humid air from entering to avoid condensation. The valves open/close based on temperature and pressure differentials.

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Electric snowplow with a battery and a battery compartment that allows the battery to be inserted and removed at an angle to prevent water ingress. The battery compartment has electrodes on the upper surface to connect with the battery terminals. The compartment also has features like recesses and projections to interrupt water flow and prevent it from reaching the electrodes.

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Battery pack with dehumidification capability to prevent moisture-related failures in battery systems. The battery pack includes a battery box, a battery module inside the box, and a liquid cooling pipe at the bottom of the module. An area inside the box absorbs moisture to prevent condensation.

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A lithium-ion battery pack for electric vehicles that has an embedded PTC (Positive Temperature Coefficient) polymer layer which acts as a self-regulating heater. The PTC polymer layer covers one surface of the battery cells to warm them up when needed, such as in cold weather. The layer has electrical resistance that increases with temperature, so it heats up initially but then stabilizes and prevents overheating. This allows the battery to warm up without external heating devices or fluids. The other surface of the battery cells is left exposed for cooling.

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Onboard battery for electric vehicles that can operate reliably even in cold conditions. The battery has a housing with cavities and depressions to accommodate battery modules. Heaters are placed in the depressions below the battery modules without contacting them. This protects the heaters from being damaged by the weight of the batteries during vehicle operation.

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Battery pack with an efficient drainage system that can remove water from inside the pack while preventing moisture from entering. The drainage system has a body that can be attached over a drainage hole in the battery pack case. Inside the body is a floating ball that rises when fluid enters through the hole, closing it to seal the pack. This prevents outside moisture from entering. When water collects inside the pack, the ball floats up and opens the hole so the water can drain out.

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Battery pack with improved water drainage to prevent short circuits due to accumulated humidity. The battery pack has an inclined flange with drainage ports. If high humidity air enters the pack, any condensed water flows down the inclined surface and through the ports for complete discharge. The inclined drainage prevents water from pooling and causing shorts, improving reliability.

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