BAE Systems Controls Inc.

A battery assembly includes an enclosure, and a plurality of battery modules within the enclosure. Each battery module includes an array of battery cells, one or more first sensors configured to measure one or more first parameters of the corresponding battery module, and a first processor configured to receive sense signals from the one or more first sensors of the corresponding battery module. One or more second sensors are within the enclosure, but external to the battery modules, and configured to measure one or more second parameters of the battery assembly. A second processor within the enclosure is to receive data from each of first processors and the one or more second sensors, and transmit controller input data to a controller external to the battery assembly, the controller input data based on the data received from the first processors and the one or more second sensors.

A method includes forming a cold plate including conductive material and having a plurality of openings, and coating the cold plate with dielectric coating. The method further includes placing the cold plate proximal to a metal plate including one or more metals, and exposing the cold plate to moisture and/or water. In an example, a minimum lateral distance between the cold plate and the metal plate is at most 0.5 inch. The method further includes, while the cold plate is exposed to the moisture and/or the water, applying a voltage across the cold plate and the metal plate, and measuring a resultant leakage current through the cold plate. A thickness of the dielectric coating on an edge of an opening of the plurality of openings is at least 0.003 inch.

A system for testing thermal runaway in a battery cell includes a first layer of first dielectric material at least in part wrapped around the battery cell, and a wire at least in part wrapped around the first layer of first dielectric material. The system further includes a second layer of second dielectric material at least in part wrapped around the wire, and a power source configured to supply power to the wire. In an example, the first layer of first dielectric material includes a polyimide film, and the second layer of second dielectric material includes mica. The system further includes a temperature sensor in contact with the first layer, the second layer, and/or the battery cell. A controller is to receive a temperature reading from the temperature sensor, and control a power supplied by the power source to the wire, based at least in part on the temperature reading.

A battery assembly includes a first plurality of battery cells, a second plurality of battery cells, and a switch between the first plurality of battery cells and the second plurality of battery cells. In an example, the first plurality of battery cells, the switch, and the second plurality of battery cells are connected in series to a load. In an example, the first plurality of battery cells, the second plurality of battery cells, and the switch are within an enclosure, which is within a pressure regulated section of an aircraft. The load may be external to the enclosure. The battery assembly further includes a controller configured to open the switch and the disconnect the first plurality of battery cells from the second plurality of battery cells, in response to an air pressure proximal to the first and second pluralities of battery cells falling below a threshold level.

A battery assembly includes an enclosure including a plurality of battery cells, and a sensor within the enclosure. The sensor is configured to measure a parameter within the enclosure, and generate a sense signal. The battery assembly further includes a processor within the enclosure, wherein the processor is configured to process the sense signal and generate information associated with the sense signal. A first communication link is configured to transmit, from the enclosure to a system that is external to the enclosure, a discrete signal indicative of whether the sense signal indicates a fault condition. A second communication link is configured to transmit, from the enclosure to the system, a digital signal including the information. Thus, transmitting the discrete signal over the first communication link and the information associated with the sense signal over the second communication link provides redundancy and improves reliability of the battery assembly.

A battery assembly includes an enclosure, an outgas sensor within the enclosure, a pressure relief device within the enclosure, a pressure relief sensor within the enclosure, and a processor within the enclosure. The outgas sensor is configured to sense an outgas event of one or more battery cells within the enclosure and output a first sense signal. The pressure relief device is configured to release gas pressure from the enclosure, in response to pressure within the enclosure exceeding a threshold value. The pressure relief sensor is configured to sense a pressure release event caused by the pressure relief device and output a second sense signal. The processor is configured to receive the first sense signal and the second sense signal, and to transmit information associated with the first and second sense signals to a system that is external to the enclosure.

A battery system, battery packs and battery modules are disclosed. The battery module comprises a plurality of cells mounted within a housing. The housing has a plurality of openings respectively for a corresponding cell. The module has a plurality of groups of cells. Each group comprises a plurality of parallel connected cells from among the plurality of cells. The plurality of groups is connected in series. The module has a plurality of current limiting elements. Each current limiting element are electrically connected in a parallel path to one or both terminals of cells which are parallelly connected. The current limiting elements may be passive or active elements. The current limiting elements may be integrated in or separate from busbars which are connected to terminals of the cells.

A battery system, battery packs and battery modules are disclosed. The battery module comprises a plurality of cells mounted within a housing. The module has a plurality of groups of cells. Each group comprises a plurality of parallel connected cells from among the plurality of cells. The plurality of groups is connected in series. The module has a plurality of current limiting elements. Each current limiting element are electrically connected in a parallel path to one or both terminals of cells which are parallelly connected. The current limiting elements may be integrated in or separate from busbars which are connected to terminals of the cells. Impedance balancing is provided to the parallel fusing scheme to improve the overall reliability of the battery module. The battery module configuration allows for continuity assurance testing of the parallel connections to ensure detection of blown fuses or broken connections in the module.

A lithium-ion battery assembly includes a plurality of battery cells in a spaced-apart and generally parallel arrangement, each cell of the battery cells extending along a central axis and having a first end portion with a negative terminal and a second end portion with a positive terminal. The assembly includes a first capture plate and a second capture plate, where at least the first capture plate defines capture plate openings corresponding to the plurality of battery cells, the first capture plate spaced from and oriented generally parallel to the second capture plate. Each of the plurality of battery cells extends between the first and second capture plates and is coaxially arranged with one of the capture plate openings in the first capture plate. The assembly optionally includes a body between the capture plates, the body defining a void for each battery cell.

A method for charging a battery includes coupling an electrical device in a circuit between the battery and an electrical power source. The electrical device having on and off states that are mechanically different. The method includes charging the battery by setting the electrical device to the on state, measuring current flowing through contacts of the electrical device while in the on state, determining current as a function of time flowing through the contacts of the electrical device, using the current as a function of time as a variable in a thermal model based on heating of the contacts and cooling of the contacts, determining by the thermal model a predicted temperature of the contacts based on the current as a function of time and the heating and cooling of the contacts and controlling the on and off state of the electrical device based on the predicted temperature.