This disclosure relates to thermal event mitigation for battery packs of electrified vehicles. An example electrified vehicle includes a battery assembly with an enclosure assembly surrounding at least one battery array and a bag configured to selectively release nitrogen. The electrified vehicle further includes a controller configured to issue a plurality of corrective action commands in response to a detected thermal event. One of the corrective action commands includes instructing the bag to generate and release nitrogen within the enclosure assembly. Among other benefits, which will be appreciated from the below description, the disclosed arrangement promptly mitigates a thermal event of the battery assembly and takes additional corrective actions, such as providing various prompts and status indicators to the user.

This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack assembly process may include supporting one or more components, such as a heat exchanger plate, of the battery pack against deflection during the assembly process. Supporting the heat exchanger plate to keep the plate relatively flat during the battery pack assembly process improves the flow distribution of a thermal interface material (TIM), thereby achieving improved TIM coverage and improved heat transfer between battery cells and the heat exchanger plate of the battery pack.

This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack assembly process may include supporting one or more components, such as a heat exchanger plate, of the battery pack against deflection during the assembly process. Supporting the heat exchanger plate to keep the plate relatively flat during the battery pack assembly process improves the flow distribution of a thermal interface material (TIM), thereby achieving improved TIM coverage and improved heat transfer between battery cells and the heat exchanger plate of the battery pack.

A battery module allows a swelling amount of battery cells accommodated in a module housing to be intuitionally checked. The battery module includes a cell pressing plate accommodated in the module housing and disposed on at least one of both longitudinal side surfaces of a cell stack that is formed by stacking the battery cells; and a swelling gauge provided to protrude from a surface of the cell pressing plate. When the battery cells swell, the swelling gauge is pushed out of the module housing through a gauge hole formed in the module housing so that a swelling amount of the battery cells may be checked.

A battery module allows a swelling amount of battery cells accommodated in a module housing to be intuitionally checked. The battery module includes a cell pressing plate accommodated in the module housing and disposed on at least one of both longitudinal side surfaces of a cell stack that is formed by stacking the battery cells; and a swelling gauge provided to protrude from a surface of the cell pressing plate. When the battery cells swell, the swelling gauge is pushed out of the module housing through a gauge hole formed in the module housing so that a swelling amount of the battery cells may be checked.

Embodiments described herein include electrochemical cell modules. In some aspects, an electrochemical cell module includes a first electrochemical cell and a second electrochemical cell. The first electrochemical cell includes an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, a separator disposed between the anode material and the cathode material, and a pouch material disposed on the anode current collector and the cathode current collector. The separator extends beyond the anode material and the cathode material and the pouch material extends beyond the separator. The portion of the separator that extends beyond the outer edge of the anode material and the cathode material and the portion of the pouch material that extends beyond the outer edge of the separator are folded at an angle of about 80 degrees to about 110 degrees with respect to the anode material and the cathode material.

A battery system with a passive thermal management system is formed from a plurality of battery cells arranged on a printed circuit board assembly. The printed circuit board assembly may include a flexible printed circuit board that is folded along an axis forming an upper and lower portion of the printed circuit board assembly. The thermal management system may include fire-blocking foam members individually attached to each battery cell along with flame-suppressant grease arranged between the battery cells. The battery cells may be arranged in a grid-like pattern to allow for a spacing arrangement between the battery cells to keep a failing battery cell from negatively affecting an adjacent battery cell. The flexible printed circuit card may include a fuse for each battery cell to shut off any current flow to a faulty battery cell if it begins to fail. The battery system may be a conformal wearable battery.

A personal tactical system including a load-bearing garment, a pouch with one or more batteries enclosed in the pouch, at least one power distribution and data hub, and at least one camera. The camera is incorporated into or removably attachable to the load-bearing garment, the pouch is removably attachable to the load-bearing garment and the one or more batteries are operable to supply power to the at least one power distribution and data hub. The at least one power distribution and data hub is operable to supply power to at least one peripheral device. A plurality of personal tactical systems is operable to form an ad hoc network to share images and other information for determining object direction, location, and movement.

A personal tactical system including a load-bearing garment, a pouch with one or more batteries enclosed in the pouch, at least one power distribution and data hub, and at least one camera. The camera is incorporated into or removably attachable to the load-bearing garment, the pouch is removably attachable to the load-bearing garment and the one or more batteries are operable to supply power to the at least one power distribution and data hub. The at least one power distribution and data hub is operable to supply power to at least one peripheral device. A plurality of personal tactical systems is operable to form an ad hoc network to share images and other information for determining object direction, location, and movement.

A power supply device includes: a plurality of secondary battery cells; a pair of end plates disposed on end surfaces of a battery stack obtained by connecting the plurality of secondary battery cells to sandwich the battery stack; and a fastening member for fixing the end plates to each other. The end plate includes a first band body protruding from a main surface of the end plate on an upper end side of the end plate and second a band body protruding from the main surface of the end plate in a middle of the end plate. A space is formed in the second band body between the second band body and the main surface of the end plate.