Weather Protection for 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 thermal management system that optimizes heat dissipation for battery packs in electric vehicles without active cooling. The system uses sensors to monitor battery temperature and environmental conditions. It then calculates an optimal heat dissipation strategy based on factors like battery usage, ambient temperature, and airflow. This involves adjusting factors like fan speed, vent openings, and coolant circulation to efficiently dissipate heat without wasting energy on unnecessary cooling. The system can also predict future heat generation and proactively prepare the cooling system accordingly.

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Battery thermal management system for electric vehicles that combines a vapor chamber and thermoelectric cooling to improve battery life and performance under high-power charging and discharging. The system uses vapor chambers attached to both sides of the battery pack, a thermoelectric cooling plate between the chambers and a liquid cooling plate. A temperature sensor monitors battery temperature. Gaps are sealed with thermal conductive grease. The system has a coolant supply with radiator, pump and controller.

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A power battery temperature control system for electric vehicles that efficiently regulates battery temperature in both cold and hot environments while minimizing energy consumption. The system uses an insulation layer around the battery pack and a circulating medium loop with a temperature control component. This allows heating or cooling the battery pack using an external device based on temperature readings. In winter, the loop recovers waste heat from the motor or uses a natural air cooler. In summer, it uses a vapor compression refrigeration cycle or electric heating. This provides year-round temperature control without passive insulation or inefficient active heating.

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Phase change composite battery thermal management system that integrates cooling, heating, and waste heat recovery to efficiently maintain optimal battery operating temperature. The system uses a phase changer, heat exchanger, electric heater, thermoelectric converter, and valve. Air is circulated through the system to cool the battery during normal operation. In low temperatures, waste heat from thermoelectric conversion is used to heat the battery. This prevents battery degradation and thermal runaway by maintaining optimal temperature.

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Thermal management system for electric vehicle batteries using phase change materials (PCMs) to maintain consistent battery temperatures during operation and when parked in cold environments. The system has a box filled with PCMs that absorbs heat as it melts when battery temperatures rise. It also has insulated air pillows to slow heat loss. When parked in cold, the PCMs solidify releasing stored heat. This prevents battery damage from low temps during starting/charging. The PCM box connects to the battery pack, heat exchangers, pumps, tanks, radiator, and ECU to regulate battery temps.

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Battery thermal management system for electric vehicles that uses phase change materials (PCMs) to equalize and store heat in the battery pack. The system has separate modules for heat equalization and heat storage. The heat equalization module absorbs heat from hot cells and transfers it to cooler cells using PCMs. The heat storage module contains PCMs that float in a coolant tank. When the pack temperature drops, the PCMs release heat to warm the pack. This allows consistent cell temperatures and prevents capacity loss. The system also has a water supply, cooling, and heating system for active cooling/heating.

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Power battery temperature control system for electric vehicles that provides year-round temperature regulation without compromising performance or efficiency. The system uses a circulating coolant loop with a temperature control device like a heater or refrigeration cycle. It also has waste heat recovery and natural cooling options. The control strategy adapts based on vehicle state, battery temp, ambient, and motor heat. This allows optimized heating/cooling depending on conditions instead of fixed high-energy solutions.

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Long-lasting lithium iron phosphate battery pack for use in harsh temperature environments. The battery pack has a casing with upper and lower frames inside. The battery units are placed in the upper frames. Heat dissipation devices are mounted on the sides facing the gaps between adjacent battery units. This allows quick internal heating or cooling to prevent damage from operating outside the temperature range.

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Battery pack design to improve temperature uniformity and prevent aging/fire due to lithium plating. The design involves a heating plate enclosing the battery cells and a separate heating unit enclosing the plate. A control unit regulates the heating unit based on cell temperature readings to prevent excessive cell heating. This provides consistent cell temperature and prevents hotspots that cause aging and fire risk.

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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 thermal management system with integrated fire suppression capability to prevent thermal runaway and fires in battery packs. The system uses a liquid cooling plate inside the battery pack to regulate temperatures. It also has a temperature sensing element that opens a valve when the battery core temperature reaches a threshold. This allows the coolant to flow into the battery cells and directly contact the core. If thermal runaway occurs, the coolant vaporizes at a high temperature, absorbing heat and quickly reducing the core temp. This isolates the core from air to extinguish fires. The system also has a control method to switch between normal thermal management, emergency firefighting, and joint operation modes.

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Thermal management system for power batteries in electric vehicles that improves heating and cooling efficiency, especially in cold weather. The system uses a looped power supply between the battery pack and a supercapacitor to quickly heat the battery when starting in cold conditions. It also has a liquid cooling channel and heat conduction pipes inside the battery case to efficiently dissipate heat. The system monitors battery temperature with a sensor and controls the heating and cooling units accordingly.

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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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