Patent Publication Number: US-2022238972-A1

Title: Battery system, battery pack handling system and electrolyte evacuation and refill station

Description:
INTRODUCTION 
     This disclosure relates generally to battery systems, battery pack handling systems and electrolyte evacuation and refill stations for battery systems. 
     Batteries are becoming more frequently used in a wide variety of applications, including automotive vehicles. Most batteries rely on chemical reactions within the battery cells to generate electricity and/or to store electrical charge. However, chemical-based batteries produce gas byproducts such as carbon dioxide and ethene, and the chemicals used within batteries may deteriorate with age which decreases their ability to produce electrical current and/or to store electrical energy. 
     It is common practice to replace batteries at prescribed intervals or when a battery&#39;s performance falls below a predetermined level. However, this approach can be expensive for the owner and a burden for the supply chain. 
     SUMMARY 
     According to one embodiment, a battery system includes a generally prismatic enclosure having opposed first and second major walls with respective first and second perimeters, a perimetral wall connecting the first and second major walls along the first and second perimeters, and an interior defined by the first and second major walls and the perimetral wall, wherein the enclosure is configured for containing an anode assembly, a cathode assembly and an electrolyte operatively disposed within the interior. A longitudinal embossment is formed in the perimetml wall extending outward from the interior and extending along opposed adjacent portions of the first and second perimeters. A wall port is defined in the perimetral wall in fluid communication with the interior, wherein the wall port is configured for permitting flow of the electrolyte therethrough into and out of the interior. First and second electrodes extend through the perimetral wall and are configured for electrical connection with the anode assembly and cathode assembly, respectively. 
     Each of the first and second major walls may be generally rectangular with each having a respective width and a respective height smaller than the respective width, wherein the longitudinal embossment has a length extending along the respective heights. The battery assembly may further include the aforementioned anode assembly, cathode assembly and electrolyte operatively disposed within the interior of the enclosure. The longitudinal embossment may define a conduit on an interior side thereof, wherein the conduit is configured for permitting flow of a gas byproduct therethrough. 
     The battery system may further include a manifold having an inner channel therein and a plurality of fittings each in fluid communication with the inner channel, each of the fittings being configured for coupling with the wall port for permitting flow of the electrolyte between the inner channel of the manifold and the interior of the enclosure. The battery system may further include: (i) the anode assembly, the cathode assembly and the electrolyte operatively disposed within the interior of the enclosure, wherein the first and second electrodes are electrically connected with the anode assembly and cathode assembly, respectively; (ii) a gas handler operatively connected with the manifold for receiving and/or filtering gas byproduct from the interior of the enclosure, wherein the manifold is operatively connected with the enclosure; and (iii) a refill port operatively connected with the manifold for evacuating electrolyte from the interior of the enclosure and for introducing electrolyte into the interior of the enclosure, wherein the refill port is configured for fastenable extension through a housing wall of a housing, wherein the housing is configured for containing the enclosure, the manifold and the gas handler. 
     The battery system may further include a first duct operatively connecting the manifold and the gas handler, a first valve disposed in the first duct and configured to open and close flow through the first duct, a second duct operatively connecting the manifold and the refill port, and a second valve disposed in the second duct and configured to open and close flow through the second duct. The battery system may also include: (i) a boot cover having a wrap-around wall surrounding and defining a plenum therewithin, an opening in the wrap-around wall defined by a lip about the opening, and a gas port and a liquid port each defined in the wrap-around wall, wherein the gas port is in fluid communication with the plenum, and wherein the liquid port has an inner connector portion disposed within the plenum and configured for coupling with the refill port when the boot cover is placed over the refill port with the lip in sealed engagement with an outer surface of the housing wall; (ii) a first pump operatively connected with the gas port and configured for applying suction to the gas port; and (iii) a second pump operatively connected with the liquid port and configured for applying suction to the liquid port. Additionally, the battery system may include a third duct operatively connecting the gas port and the first pump, and a fourth duct operatively connecting the liquid port and the second pump. 
     The battery system may further include a gas byproduct tank configured for receiving gas byproduct from the first pump via a fifth duct operatively connecting the first pump and the gas byproduct tank, and a used electrolyte tank configured for receiving electrolyte from the second pump via a sixth duct operatively connecting the second pump and the used electrolyte tank. The battery system may also include a fresh electrolyte tank configured for supplying electrolyte to the liquid port, wherein the second pump is operatively connected with the liquid port and/or the fresh electrolyte tank and is further configured to cause electrolyte from the fresh electrolyte tank to be pumped to the liquid port. Alternatively, the battery system may also include a fresh electrolyte tank configured for supplying electrolyte to the liquid port, and a third pump operatively connected with the liquid port and/or the fresh electrolyte tank and configured to cause electrolyte from the fresh electrolyte tank to be pumped to the liquid port. The battery system may additionally include a collector/tester configured for receiving and/or testing a sample of electrolyte from the enclosure, wherein the collector/tester is operatively connected with at least one of the liquid port, the fourth duct, the sixth duct and the second pump. 
     According to another embodiment, a battery pack handling system for an automotive vehicle having an exterior body panel and carrying a battery pack includes a gas handler configured for receiving gas byproduct from the battery pack, a first duct configured for conveying the gas byproduct from the battery pack to the gas handler, a refill port configured for fastenable extension through the exterior body panel and for connecting with the battery pack (wherein the refill port is configured for evacuating electrolyte from the battery pack and for introducing electrolyte into the battery pack), and a second duct configured for conveying electrolyte between the battery pack and the refill port. The gas handler may be configured to be disposed above the battery pack, and the gas handler may be further configured for filtering the gas byproduct received from the battery pack. 
     According to yet another embodiment, an electrolyte evacuation and refill station for servicing a battery pack carried on-board an automotive vehicle, the automotive vehicle having a refill port operatively connected with the battery pack and extending through an exterior body panel, includes: (i) a boot cover having a wrap-around wall surrounding and defining a plenum therewithin, an opening in the wrap-around wall defined by a lip about the opening, and a gas port and a liquid port each defined in the wrap-around wall, wherein the gas port is in fluid communication with the plenum, and wherein the liquid port has an inner connector portion disposed within the plenum and configured for coupling with the refill port when the boot cover is placed over the refill port with the lip in sealed engagement with the exterior body panel; (ii) a first pump operatively connected with the gas port and configured for applying suction to the gas port; (iii) a second pump operatively connected with the liquid port and configured for applying suction and/or pressure to the liquid port; (iv) a gas byproduct tank operatively connected with a first outlet of the first pump and configured for receiving gas byproduct from the battery pack via the refill port and the first pump; (v) a used electrolyte tank operatively connected with a second outlet of the second pump and configured for receiving electrolyte from the battery pack via the refill port and the second pump; and (vi) a fresh electrolyte tank configured for supplying electrolyte to the liquid port. 
     The second pump may be operatively connected with the liquid port and/or the fresh electrolyte tank and may be further configured to cause electrolyte from the fresh electrolyte tank to be pumped to the liquid port. The electrolyte evacuation and refill station may further include a third pump operatively connected with the liquid port and/or the fresh electrolyte tank and configured to cause electrolyte from the fresh electrolyte tank to be pumped to the liquid port. The electrolyte evacuation and refill station may further include a collector/tester configured for receiving and/or testing a sample of electrolyte from the battery pack, wherein the collector/tester is operatively connected with at least one of the liquid port, the fourth duct, the sixth duct and the second pump. 
     The above features and advantages, and other features and advantages, of the present teachings are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the present teachings, as defined in the appended claims, when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective of one configuration of a battery system. 
         FIG. 2  is a schematic front view of another configuration of a battery system. 
         FIG. 3  is a schematic top view of the battery system of  FIG. 2 . 
         FIG. 4  is a schematic cross-sectional top view of the battery system of  FIG. 2  as viewed along line  4 - 4 . 
         FIGS. 5-6  are schematic cross-sectional side views of the battery system of  FIGS. 2-3  as viewed along lines  5 - 5  and  6 - 6 , respectively. 
         FIG. 7  is a schematic side view of the battery system of  FIGS. 2-3 . 
         FIG. 8  is a schematic front view of yet another configuration of a battery system. 
         FIG. 9  is a schematic perspective view of first and second perimeters of the battery system of  FIG. 8 . 
         FIG. 10  is a schematic perspective view of a battery system including a manifold. 
         FIG. 11  is a schematic cross-sectional side view of the manifold of  FIG. 10 . 
         FIG. 12  is a schematic view of a battery pack handling system for an automotive vehicle. 
         FIG. 13  is a block diagram of a sample collector and/or tester and possible connection points within an electrolyte evacuation and refill station. 
         FIGS. 14-17  are schematic views of first through fourth configurations, respectively, of an electrolyte evacuation and refill station. 
         FIG. 18  is a schematic cross-sectional side view of a boot cover for use in an electrolyte evacuation and refill station. 
         FIG. 19  is a schematic diagram of a battery system, a battery pack handling system and an electrolyte evacuation and refill station for an automotive vehicle. 
         FIGS. 20-21  are schematic front views of two alternative configurations of a battery system. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, wherein like numerals indicate like parts in the several views, a battery system  20 , a battery pack handling system  100  for an automotive vehicle  10 , and an electrolyte evacuation and refill station  200  for servicing a battery pack  20  carried on-board an automotive vehicle  10  are shown and described herein. Note that as used herein, “battery system” and “battery pack”, including single or multiple cells thereof, may sometimes be used interchangeably. Also note that certain reference numerals in the drawings have subscripts, such as the longitudinal embossments  42   FH  and  42   PH  of  FIGS. 1-4, 7-8 and 10 . Subscripts are used in the drawings and in the present description to refer to individual elements and/or to a specific type of element, while the use of reference numerals without subscripts may refer to the collective group of such elements and/or to a singular but generic one of such elements. Thus, reference numeral  42   FH  refers to a specific individual embossment or a specific type of embossment, while reference numeral  42  (without the subscript) may refer to all the embossments, the group of embossments, or a singular but generic embossment (i.e., any embossment). 
       FIG. 1  shows a schematic perspective view of one configuration of a battery system  20 , and  FIG. 2  shows a schematic front view of another configuration of a battery system  20 . Note that the configurations shown here feature two different arrangements of longitudinal embossments  42 , as described in more detail below. Additionally,  FIG. 3  shows a schematic top view of the battery system  20  of  FIG. 2 ,  FIG. 4  shows a schematic cross-sectional top view of the battery system  20  of  FIG. 2  as viewed along line  4 - 4 ,  FIGS. 5-6  show schematic cross-sectional side views of the battery system  20  of  FIGS. 2-3  as viewed along lines  5 - 5  and  6 - 6 , respectively, and  FIG. 7  shows a schematic side view of the battery system  20  of  FIGS. 2-3 . Further,  FIG. 8  shows a schematic front view of yet another configuration of a battery system  20 , and  FIG. 9  shows a schematic perspective view of first and second perimeters  30 ,  32  of the battery system  20  of  FIG. 8 . 
     According to the configurations shown, the battery system  20  includes a generally prismatic enclosure  22  having a first major wall  24  and an opposed second major wall  26 , with the first and second major walls  24 ,  26  having respective first and second perimeters  30 ,  32 . A perimetral wall  28  extends between the first and second major walls  24 ,  26  and connects the first and second major walls  24 ,  26  along and around the full extent of the first and second perimeters  30 ,  32 . (That is, the first major wall  24  is connected to the perimetral wall  28  along the first perimeter  30 , and the second major wall  26  is connected to the perimetral wall  28  along the second perimeter  32 .) For example, the enclosure  22  may have the shape of a rectangular prism in which the first and second major walls  24 ,  26  are generally flat and parallel with each other, with each having the same size and same generally rectangular shape as each other. In such an arrangement, the first and second perimeters  30 ,  32  would have generally the same rectangular shape and size as each other, and the perimetral wall  28  would connect the first and second major walls  24 ,  26  together at their respective first and second perimeters  30 ,  32 , thus forming a closed container (i.e., the enclosure  22 ). In this rectangular prismatic configuration, the first and second major walls  24 ,  26  may be viewed as front and back surfaces  23 ,  25 , respectively, and the perimetral wall  28  may be viewed as four contiguous circumferential walls or surfaces, such as opposed top and bottom surfaces  27 ,  29  and opposed left and right surfaces  31 ,  33 . In alternative arrangements, the first and second major walls  24 ,  26  may be circular, ellipsoidal or shaped as rectangles having rounded corners. In any case, the perimeters  30 ,  32 define a circumferential direction about the enclosure  22 ; thus, it can be said that the perimetral wall  28  extends circumferentially about the enclosure  22 . (Note that as used herein, the directional use of the word “about” may mean “along”, “along the length of”, “coextensive with”, “around” and/or “oriented in the same major direction as”, depending on the context.) 
     An interior  34  is defined by and within the first and second major walls  24 ,  26  and the perimetral wall  28 , with the enclosure  22  being configured for containing or housing an anode assembly  36 , a cathode assembly  38  and an electrolyte  40  operatively disposed within the interior  34 . An intermediate layer  37  (e.g., a polymer separator) may optionally be disposed between the anode and cathode assemblies  36 ,  38 , with the electrolyte  40  permeating the anode and cathode assemblies  36 ,  38  and the optional intermediate layer  37 . 
     One or more longitudinal embossments or protrusions  42  are formed in and along the perimetral wall  28 , such that each embossment  42  extends or protrudes outward from the interior  34  and extends along and between opposed adjacent portions  44 ,  46  of the first and second perimeters  30 ,  32 . These embossments  42  are described as “longitudinal” because each one extends along some length circumferentially about the perimeters  30 ,  32  and the perimetral wall  28 , thus giving each embossment  42  an elongated linear shape having a length much longer than its thickness. The longitudinal embossment  42  may define a conduit or channel  54  on an interior side  56  of the embossment  42 , wherein the conduit  54  is configured for permitting flow of a gas byproduct  58  therethrough, as further described below. 
     While the longitudinal embossments  42  may assume various shapes and configurations, several exemplary configurations are illustrated in the drawings. For example,  FIGS. 1 and 10  show “full-height” longitudinal embossments  42   FH  whose lengths L 42FH  extend along the entire height of an enclosure  22 , such that each end of each longitudinal embossment  42   FH  terminates in a respective end face  43  that is flush with the adjacent top or bottom surface  27 ,  29 . Alternatively,  FIGS. 2-7  show “partial-height” longitudinal embossments  42   PH  whose lengths L 42PH  extend along most of the height of an enclosure  22  but not along its entire height, with each end of each longitudinal embossment  42   PH  tapering to become flush with the surrounding flat surface of the perimetral wall  28 . (Note that reference numeral  42  may be used herein to refer to either or both of the full-height and partial-height longitudinal embossments  42   FH ,  42   PH , and reference numeral L 42  may be used to refer to either or both of the respective lengths L 42FH , L 42PF  of the full-height and partial-height longitudinal embossments  42   FH ,  42   PH .) In some configurations, each of the first and second major walls  24 ,  26  may be generally rectangular with each wall  24 ,  26  having a respective width W 24 , W 26  and a respective height H 24 , H 26  smaller than the respective width W 24 , W 26  (i.e., H 24 &lt;W 24  and H 26 &lt;W 26 ), wherein each of the one or more longitudinal embossments  42  has a respective length L 42  extending along (i.e., in the same direction as) one or both of the respective heights H 24 , H 26 . 
       FIG. 8  shows a schematic front view of yet another configuration of a battery system  20  that is a “hybrid” of the configuration shown in  FIGS. 1 and 10  and the other configuration shown in  FIGS. 2-7 , and  FIG. 9  shows a schematic perspective view of the first and second perimeters  30 ,  32  of this hybrid configuration. More specifically, the hybrid configuration of  FIG. 8  has a partial-height longitudinal embossment  42   PH  on its left side and a full-height longitudinal embossment  42   FH  on its right side, with  FIG. 9  showing the various dimensions of the configuration&#39;s walls  24 ,  26  and embossments  42 . Note that the first perimeter  30  (shown in dotted lines) has a rectangular shape with a width W 24  and a height H 24 , and the second perimeter  32  (shown in dashed lines and behind the first perimeter  30 ) has the same rectangular size and shape as the first perimeter  30 , with a width W 26  and a height H 26 . Since both perimeters  30 ,  32  have the same size and rectangular shape, then W 24 =W 26  and H 24 =H 26 . 
       FIGS. 20 and 21  show schematic front views of two alternative configurations of a battery system  20 . In these two configurations, the enclosure  22  has a generally rectangular prismatic shape in which the perimetral wall  28  has four “corners” (formed by the meeting of the top, bottom, left and right surfaces  27 ,  29 ,  31 ,  33 ), and the longitudinal embossments  42  extend or wrap around the two lower corners. For example, in  FIG. 20 , the longitudinal embossment(s)  42  extend continuously along parts of the left and right surfaces  31 ,  33  and along the entirety of the bottom surface  29 , with a “partial height wrap-around” embossment  42   PHW  on each of the left and right surfaces  31 ,  33  and a “full width wrap-around” embossment  42   FWW  on the bottom surface  29 . And in  FIG. 21 , the longitudinal embossment(s)  42  extend continuously along the entireties of the left and right surfaces  31 ,  33  and along the entirety of the bottom surface  29 , with a “full height wrap-around” embossment  42   FHW  on each of the left and right surfaces  31 ,  33  and a “full width wrap-around” embossment  42   FWW  on the bottom surface  29 . Each of these configurations may be viewed as having three individual longitudinal embossments  42  which meet at the two lower corners, or one continuous embossment  42  which wraps around the two lower corners. Although not shown in the drawings, one or more longitudinal embossments  42  may also be formed in the top surface  27  as well. 
     The full-height longitudinal embossment  42   FH  on the right side of the hybrid configuration extends along and between (and coextensive with) respective first and second right-side portions  44   R ,  46   R  as illustrated on the right sides of  FIGS. 8-9 . Note that reference numeral H 44RF  represents the height of the first right-side portion  44   R  of the first perimeter  30 , which may be viewed as being on the right-front side of the enclosure  22  and which extends along the full height H 24  of the first (front) major wall  24 . Similarly, reference numeral H 46RB  represents the height of the second right-side portion  46   R  of the second perimeter  32 , which may be viewed as being on the right-back side of the enclosure  22  and which extends along the full height H 26  of the second (rear/back) major wall  26 . Here, H 44RF =H 46RB , with each of these heights H 44RF , H 46RB  also being the same as the length L 42FH  of the full-height embossment  42   FH  on the right side of the enclosure  22 , with the embossment  42   FH  extending along the full height H 24 , H 26  of both walls  24 ,  26 . 
     On the other hand, the partial-height longitudinal embossment  42   PH  on the left side of the hybrid configuration extends along and between (and coextensive with) respective first and second left-side portions  44   L ,  46   L  of the first and second perimeters  30 ,  32 , as illustrated on the left sides of  FIGS. 8-9 . Note that reference numeral H 44LF  represents the height of the first left-side portion  44   L  of the first perimeter  30 , which may be viewed as being on the left-front side of the enclosure  22  and which extends along a portion of (i.e., less than) the full height H 24  of the first (front) major wall  24 . Similarly, reference numeral H 46LB  represents the height of the second left-side portion  46   L  of the second perimeter  32 , which may be viewed as being on the left-back side of the enclosure  22  and which extends along a portion of (i.e., less than) the full height H 26  of the second (rear/back) major wall  26 . Here, H 44LF =H 46LB , with each of these heights H 44LF , H 46LB  also being the same as the length L 42PH  of the partial-height embossment  42   PH  on the left side of the enclosure  22 , with the embossment  42   PH  extending along a portion of (i.e., less than) the full height H 24 , H 26  of both walls  24 ,  26 . 
     Note that while the hybrid configuration of  FIGS. 8-9  show a partial-height longitudinal embossment  42   PH  on the left and a full-height longitudinal embossment  42   FH  on the right, the locations of these embossments  42   PH ,  42   FH  may be reversed. Also, one end of a partial-height longitudinal embossment  42   PH  may be flush with a top or bottom surface  27 ,  29  of the enclosure  22 . Additionally, while the drawings show one longitudinal embossment  42  on each of the left and right sides or surfaces  31 ,  33 , there may be two or more longitudinal embossments  42  on one or the other or both sides or surfaces  31 ,  33 . In each configuration or arrangement of the enclosure  22  and battery system  20 , each longitudinal embossment  42  extends along and between (and coextensive with) opposed adjacent portions  44 ,  46  of the first and second perimeters  30 ,  32  of the first and second major walls  24 ,  26 . 
     A wall port  48  is defined in and extends through the perimetml wall  28  in fluid communication with the interior  34  of the enclosure  22 . For example, as illustrated in the drawings, the wall port  48  may be formed in the top surface  27 , and optionally may be located closer to one side (e.g., the left surface  31 ) than the other side. The wall port  48  is configured for permitting flow of the liquid electrolyte  40  therethrough, such as for flow of electrolyte  40  into the interior  34  for filling the enclosure  22  and flow of electrolyte  40  out of the interior  34  for partially or fully evacuating or emptying the enclosure  22 . The wall port  48  may also be disposed in fluid communication with the respective conduits or channels  54  of the one or more longitudinal embossments  42 , such that the conduit(s)  54  permit flow of gas byproduct  58  therethrough. That is, the gas byproduct  58  that is produced by the anode/cathode assemblies  36 ,  38  may be vented along the conduit(s)  54  and through the wall port  48 , and thus vented out of the enclosure  22 . In some configurations, a void  57  may be provided along the top of the interior  34 , above the anode/cathode assemblies  36 ,  38 , such that the void  57  provides a fluid path (i.e., fluid communication) between the one or more longitudinal embossments  42  on the right side of the enclosure  22  with the one or more longitudinal embossments  42  on the left side of the enclosure  22 , In this way, gas byproduct  58  may be conveyed along longitudinal embossments  42  on both the left and right sides of the enclosure  22  and then conveyed through the wall port  48  and out of the enclosure  22 . 
     In addition to the wall port  48 , first and second electrodes  50 ,  52  extend through the perimetral wall  28  as well, with the first electrode  50  being configured for electrical connection with an anode assembly  36  operatively disposed within the interior  34 , and with the second electrode  52  being configured for electrical connection with a cathode assembly  38  also operatively disposed within the interior  34 . As illustrated in  FIG. 6 , a first portion  51  of the first electrode  50  may extend into the interior  34  and electrically connect with the anode assembly  36 , and a second portion  53  of the second electrode  52  may extend into the interior  34  and electrically connect with the cathode assembly  38 . The battery assembly  20 may further include the aforementioned anode assembly  36 , cathode assembly  38  and electrolyte  40  operatively disposed within the interior  34  of the enclosure  22 , along with an optional intermediate layer  37  sandwiched between the anode and cathode assemblies  36 ,  38 . As mentioned above, the anode and cathode assemblies  36 ,  38  and optional intermediate layer  37  may be configured and arranged so as to be permeated by liquid electrolyte  40 . The anode and cathode assemblies  36 ,  38  and optional intermediate layer  37  may be stacked, rolled or otherwise disposed with respect to each other within the interior  34 . 
     As illustrated in  FIGS. 10-11 , the battery system  20 may further include a manifold  60  configured for connection with multiple enclosures  22 , thus forming a multi-cell battery pack  20 (wherein each enclosure  22  comprises a single battery cell). The manifold  60  has a main body  61  having an inner channel  62  therein and a plurality of fittings  64  each in fluid communication with the inner channel  62 . The fittings  64  may be configured for sealably coupling with the wall ports  48  of multiple enclosures  22  for permitting flow of electrolyte  40  between the inner channel  62  of the manifold  60  and the interiors  34  of the enclosures  22 . The fittings  64  and inner channel  62  may also be configured for conveying gas byproduct  58  from the fittings  64  (i.e., from each of the enclosures  22  attached to the fittings  64 ) to a coupling  65  which is in fluid communication with the inner channel  62  and which is configured for sealably interfacing with a first duct D 1  (discussed in further detail below). Note that as used herein, a “duct” may include a pipe, tube, conduit or other generally closed passageway for conveying fluids such as gasses or liquids. 
       FIG. 12  shows a schematic diagram of the battery system  20  which further includes a gas handler  66  operatively connected with the manifold  60  for receiving and/or filtering gas byproduct  58  from the interior  34  of each enclosure  22  that is operatively connected with the manifold  60 . The gas handler  66  may be operatively connected with the coupling  65  of the manifold  60  via a first duct D 1 , such that the gas handler  66  may “passively” receive gas byproduct  58  via the first duct D 1  due to pressure built up by the gas byproduct  58 , and/or such that the gas handler  66  may “actively” receive the gas byproduct  58  via the first duct D 1  by generating suction which draws the gas byproduct  58  into the gas handler  66 . The gas handler  66  may be configured to store the gas byproduct  58 , and/or it may be configured to pass along the gas byproduct  58  to a receptacle or other device. The battery system  20  may further include a refill port  68  operatively connected with the manifold  60  for evacuating electrolyte  40  from the interiors  34  of the enclosures  22  (i.e., for fully or partially emptying used electrolyte  40  from the enclosures  22 ) and for introducing electrolyte  40  into the interiors  34  of the enclosures  22  (i.e., for fully or partially filling the enclosures  22  with fresh electrolyte  40 ). The refill port  68  may be configured for fastenable extension through a housing wall  12  of a housing  14  (such as through an exterior body panel  12  of an automotive vehicle  10 , or through an outer wall  12  of a building  14 ), wherein the housing  14  is configured for containing the enclosure  22 , the manifold  60  and the gas handler  66  within the housing  14 . The refill port  68  may include an inner and outer tubular portions  68   1T ,  68   OT  which may be held in place against the inner and outer surfaces  16 ,  18  of the housing wall  12  by inner and outer flanges  68   1F ,  68   OF  with a channel  69  defined through the refill port  68  for conveying electrolyte  40  and/or gas byproduct  58  therethrough. The refill port  68  may also include a cover or other device (not shown) for closing and opening the channel  69  and refill port  68 , such that when the channel  69  is open fluids may pass therethrough, and when the channel is closed the flow of fluids therethrough is prevented. (Note that as used herein, a “fluid” may be a liquid, a gas or a combination thereof.) 
     The battery system  20  may further include the first duct D 1  operatively connecting the manifold  60  and the gas handler  66 , a first valve V 1  disposed in the first duct D 1  and configured to open and close flow of gas byproduct  58  through the first duct D 1 , a second duct D 2  operatively connecting the manifold  60  and the refill port  68 , and a second valve V 2  disposed in the second duct D 2  and configured to open and close flow of electrolyte  40  and/or gas byproduct  58  through the second duct D 2 . 
       FIGS. 14-17  show schematic views of first, second, third and fourth arrangements, respectively, of additional elements which may be incorporated into the battery system  20 . These additional elements may be viewed as comprising an electrolyte evacuation and refill station  200  which may be added to, used along with, and/or included as part of the battery system  20 , as further described below. To assist in understanding these four arrangements, TABLE 1 is provided below, which shows the valve states (i.e., whether each valve is open or closed) among the third, fourth, fifth and sixth valves V 3 , V 4 , V 5 , V 6  and whether each configuration is set up to evacuate the enclosures  22  of liquid electrolyte  40  or to fill the enclosures  22  with liquid electrolyte  40 . 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Valve States in the Four Configurations of FIGS. 14-17 
               
            
           
           
               
               
               
               
               
            
               
                   
                 First Configuration 
                 Second Configuration 
                 Third Configuration 
                 Fourth Configuration 
               
               
                   
                 (FIG. 14) 
                 (FIG. 15) 
                 (FIG. 16) 
                 (FIG. 17) 
               
               
                   
                 Second Pump/1-way 
                 Second Pump/2-way 
                 Second Pump/1-way + 
                 Second Pump/1-way + 
               
               
                   
                 (No Third Pump) 
                 (No Third Pump) 
                 Third Pump/Suction 
                 Third Pump/Pressure 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Valve 
                 Evacuate 
                 Fill 
                 Evacuate 
                 Fill 
                 Evacuate 
                 Fill 
                 Evacuate 
                 Fill 
               
               
                   
               
               
                 V3 
                 Open 
                 Closed 
                 — 
                 — 
                 Open 
                 Closed 
                 Open 
                 Closed 
               
               
                 V4 
                 Open 
                 Closed 
                 Open 
                 Closed 
                 — 
                 — 
                 — 
                 — 
               
               
                 V5 
                 Closed 
                 Open 
                 Closed 
                 Open 
                 Closed 
                 Open 
                 Closed 
                 Open 
               
               
                 V6 
                 Closed 
                 Open 
                 — 
                 — 
                 — 
                 — 
                 — 
                 — 
               
               
                   
               
            
           
         
       
     
     As shown in  FIGS. 14-17 , the battery system  20 may further include a boot cover  70 , a first pump  86  and a second pump  88 . The boot cover  70  (shown in schematic cross-sectional view in  FIG. 18 ) may have a wrap-around wall  72  surrounding and defining a plenum or chamber  74  therewithin, an opening  76  in the wrap-around wall  72  defined by a lip  78  about the opening  76 , and a gas port  80  and a liquid port  82  each defined in the wrap-around wall  72 . For example, the wrap-around wall  72  may be made of a flexible elastomeric material which is chemically resistant to the liquid electrolyte  40 , and may optionally be configured in a bellows-like shape. The gas port  80  and liquid port  82  may each sealably extend through the wrap-around wall  72 , with one or more optional reinforcing members  85  disposed on one or both sides of the wrap-around wall  72  so as to hold the ports  80 ,  82  in place, seal the ports  80 ,  82  against gas or liquid leakage around the ports  80 ,  82 , and reinforce the ports  80 ,  82  for repeated usage. The gas port  80  may be disposed in fluid communication with the plenum  74  for conveying gas through the gas port  80 , and the liquid port  82  may be configured for conveying liquid and gas through the liquid port  82 . The liquid port  82  may include an inner connector portion  84  disposed within the plenum  74  and configured for coupling with the refill port  68  (such as with the outer tubular portion  68   OT  of the refill port  68 ). This configuration may include the use of mating and interlocking features on the inner connector portion  84  and on the refill port  68 , such as threads, quick-connect fittings, etc. 
     The boot cover  70  may be configured for placement over the refill port  68  with the inner connector portion  84  connected with the refill port  68  and the lip  78  in sealed engagement with an outer surface  18  of the housing wall  12 . With the inner connector portion  84  and boot cover  70  thusly positioned, and with the refill port  68  opened, liquid electrolyte  40  and gas byproduct  58  may be suctioned from the enclosures  22 , through the manifold  60 , the first and second ducts D 1 , D 2  and the refill port  68 , and out through the liquid port  82 . Also, with the wrap-around wall  72  of the boot cover  70  covering the refill port  68  with the lip  78  placed against the outer surface  18  of the housing wall  12 , the plenum  74  should be able to capture any stray gas byproduct  58  which might inadvertently leak due to poor coupling between the inner connector portion  84  and the refill port  68 , with the gas port  80  being available for conveying away any such leaked gas byproduct  58 . 
     The first pump  86  may be operatively connected with the gas port  80  and configured for applying suction to the gas port  80 , while the second pump  88  may be operatively connected with the liquid port  82  and configured for applying suction to the liquid port  82 . The battery system  20  may further include a third duct D 3  operatively connecting the gas port  80  and the inlet  86   I  of the first pump  86 , and a fourth duct D 4  operatively connecting the liquid port  82  and the inlet  88   I  of the second pump  88 . Note that in all four configurations of  FIGS. 14-17  the flow path or flow direction of the first pump  86  is shown as a one-way flow in the direction of the dotted-lined arrow from the inlet  86   I  to the outlet  86   O . However, in the first, third and fourth configurations of  FIGS. 14 and 16-17  the flow direction of the second pump  88  is shown as one-way (1-way) in the direction indicated by the dotted-lined arrow from the second pump&#39;s inlet  88   I  and its outlet  88   O , while in the second configuration of  FIG. 15  the flow direction is shown as two-way (2-way), meaning that the second pump  88  may selectively pump in either of the two directions (i.e., from the first inlet/outlet  88   I  to the second inlet/outlet  88   2 , or vice versa). This 1-way or 2-way characteristic of the second pump  88  is reflected in the top row of TABLE 1. 
     The battery system  20 may further include a gas byproduct tank  90  configured for receiving gas byproduct  58  from the first pump  86  via a fifth duct D 5  operatively connecting the outlet  86   O  of the first pump  86  and the gas byproduct tank  90 , and a used electrolyte tank  92  configured for receiving used electrolyte  40  from the second pump  88  via a sixth duct D 6  operatively connecting the outlet  88   O  of the second pump  88  and the used electrolyte tank  92 . The sixth duct D 6  may optionally have a fourth valve V 4  therein, as shown in the first and second configurations of  FIGS. 14-15 . 
     The battery system  20  may also include a fresh electrolyte tank  94  configured for supplying fresh (unused) electrolyte  40  to the liquid port  82 . The electrolyte  40  from the fresh electrolyte tank  94  may be supplied to the liquid port  82  by use of the second pump  88  as illustrated in the first and second configurations of  FIGS. 14-15 , or by use of a third pump  96  as illustrated in the third and fourth configurations of  FIGS. 16-17 . 
     In the first and second configurations of  FIGS. 14-15 , the second pump  88  is operatively connected with the liquid port  82  and/or the fresh electrolyte tank  94  and is further configured to cause electrolyte  40  from the fresh electrolyte tank  94  to be pumped to the liquid port  82 . For example, in the first configuration of  FIG. 14 , the second pump  88  is capable of 1-way flow, with the inlet  88   I  of the second pump  88  operatively connected with the fluid port  82  via the fourth duct D 4 , and the outlet  88   O  of the second pump  88  operatively connected with the sixth duct D 6 . By selectively opening and closing certain valves in the ducts (as described below), the second pump  88  may be used for evacuating the used electrolyte  40  from the enclosures  22  and into the used electrolyte tank  92 , as well as for delivering fresh electrolyte  40  from the fresh electrolyte tank  94  to the enclosures  22 . In this first configuration of  FIG. 14 , a seventh duct D 7  operatively connects the fresh electrolyte tank  94  with the fourth duct D 4  at a second junction J 2 , and an eighth duct D 8  operatively connects the sixth duct D 6  at a first junction J 1  with the fourth duct D 4  at a third junction J 3 , with a third valve V 3  being disposed between the second and third junctions J 2 , J 3  and a fourth valve V 4  being disposed between the first junction J 1  and the used electrolyte tank  92 . A fifth valve V 5  may be disposed in the seventh duct D 7  between the second junction J 2  and the fresh electrolyte tank  94 , and a sixth valve V 6  may be disposed in the eighth duct D 8  (i.e., between the first and third junctions J 1 , J 3 ). 
     As noted in TABLE 1, when the first configuration is placed in “Evacuate” mode, the third and fourth valves V 3 , V 4  are open and the fifth and sixth valves V 5 , V 6  are closed. This arrangement permits the used electrolyte  40  to be suctioned through the fourth duct D 4  and into the second pump  88 , and then pumped through the sixth duct D 6  into the used electrolyte tank  92 , while the closed fifth valve V 5  prevents any flow of used electrolyte  40  into the fresh electrolyte tank  94  and the closed sixth valve V 6  prevents any backflow of used electrolyte  40  through the eighth duct D 8 . Then, when the first configuration is placed in “Fill” mode, the settings of the valves are reversed from that of the Evacuate mode. That is, in Fill mode, the third and fourth valves V 3 , V 4  are closed and the fifth and sixth valves V 5 , V 6  are open. This Fill mode arrangement permits the fresh electrolyte  40  to be suctioned through the seventh duct D 7  to the second junction J 2  and into the second pump  88  (via the portion of the fourth duct D 4  between the second junction J 2  and the second pump&#39;s inlet  88   I ), and then the fresh electrolyte  40  may be pumped through the sixth duct D 6  up to the first junction J 1 , then through the eighth duct D 8 , and then through the portion of the fourth duct D 4  that is between the third junction J 3  and the liquid port  82 . 
     On the other hand, in the second configuration of  FIG. 15 , the second pump  88  is capable of 2-way flow (i.e., flow in either of two directions). In this configuration, the second pump  88  has two ports, each of which may be an inlet or an outlet depending on the direction of flow selected. One of these two ports may be referred to as the first inlet/outlet  88   1  and the other port may be referred to as the second inlet/outlet  88   2 . The first inlet/outlet  88   1  is operatively connected with the fluid port  82  via the fourth duct D 4 , and the second inlet/outlet  88   2  is operatively connected with the used electrolyte tank  92  via the sixth duct D 6 . Whereas in the first configuration of  FIG. 14  the seventh duct D 7  connected the fresh electrolyte tank  94  to the fourth duct D 4  at the second junction J 2 , in the present second configuration of  FIG. 15  the seventh duct D 7  connects the fresh electrolyte tank  94  to the sixth duct D 6  at the first junction J 1 . Similar to the first configuration, in the present second configuration the fourth valve V 4  may be disposed in the sixth duct D 6  between the first junction J 1  and the used electrolyte tank  92 , and the fifth valve V 5  may be disposed in the seventh duct D 7 . As shown in TABLE 1, when the second configuration is in the Evacuate mode, the fourth valve V 4  is open and the fifth valve V 5  is closed. (Note that the second configuration does utilize the third or sixth valves V 3 , V 6 .) In this Evacuate mode arrangement, used electrolyte  40  may be suctioned from the liquid port  82  into the first inlet/outlet  88   1  of the second pump  88  via the fourth duct D 4 , with the used electrolyte  40  then being pumped into the used electrolyte tank  92  via the sixth duct D 6 . With the fifth valve V 5  being closed, used electrolyte  40  is prevented from being conveyed into the fresh electrolyte tank  94  via the seventh duct D 7 . Then, with the valve states switched into the Fill mode arrangement, the flow direction of the second pump  88  may be reversed, so that fresh electrolyte  40  may be suctioned up from the fresh electrolyte tank  94  via the seventh duct D 7  and into the second inlet/outlet  88   2 , and then the fresh electrolyte  40  may be pumped from the first inlet/outlet  88   1  to the liquid port  82  via the fourth duct D 4 . 
     Alternatively, in the third and fourth configurations of  FIGS. 16-17 , the battery system  20 includes a third pump  96  operatively connected with the liquid port  82  and/or the fresh electrolyte tank  94  and configured to cause electrolyte  40  from the fresh electrolyte tank  94  to be pumped to the liquid port  82 . In both the third and fourth configurations, the third pump  96  is capable of 1-way flow in the direction indicated by the dotted-line arrow from the inlet  96   I  to the outlet  96   O  of the third pump  96 . For example, in the third configuration of  FIG. 16 , a fluid  97  (e.g., air) may be drawn into the inlet  96   I  and pumped from the pump outlet  96   O  into an inlet on the fresh electrolyte tank  94  via a tenth duct D 10 . If the fresh electrolyte tank  94  is properly sealed, the pressurized pumping of fluid  97  into the tank  94  may cause fresh electrolyte  40  to be forced out of the outlet of the tank  94 , and into the seventh duct D 7 . According to TABLE 1, when the valves of the third configuration are placed into the Evacuation mode arrangement, the third valve V 3  will be open and the fifth valve V 5  will be closed. (Note that the third configuration does not include the fourth and sixth valves V 4 , V 6 .) This arrangement permits used electrolyte  40  to be conveyed from the liquid port  82  to the second pump  88  via the fourth duct D 4  and then onto the used electrolyte tank  92  via the sixth duct D 6 . In this Evacuation mode for the third configuration, the second pump  88  is operating but the third pump  96  is not. Meanwhile, with the fifth valve V 5  being closed, used electrolyte  40  is prevented from entering into the fresh electrolyte tank  94  via the seventh duct D 7 . Then, when the third configuration is placed into Fill mode, the third valve V 3  is closed, the fifth valve V 5  is open, the second pump  88  may be turned off, and the third pump  96  may be turned on. This arrangement permits fresh electrolyte  40  to be conveyed from the fresh electrolyte tank  94  to the fourth joint J 4  and then to the liquid port  82 , while preventing flow of fresh electrolyte  40  past the closed third valve V 3 . 
     And in the fourth configuration of  FIG. 17 , the inlet  96   I  of the third pump  96  may be operatively connected with the fresh electrolyte tank  94  via an eleventh duct D 11 , while the outlet  96   O  of the third pump  96  may operatively connect with the fourth duct D 4  at the fourth junction J 4  via the seventh duct D 7  As in the third configuration, the third valve V 3  may be disposed in the fourth duct D 4  between the fourth junction J 4  and the inlet  88   1  of the second pump  88 , and the fifth valve V 5  may be disposed in the seventh duct D 7 . As shown in TABLE 1, when the fourth configuration is in the Evacuate mode, the third valve V 3  is open and the fifth valve Vs is closed. (Note that like the third configuration, the fourth configuration does not include the fourth and sixth valves V 4 , V 6 .) In the Evacuate mode arrangement, used electrolyte  40  may be suctioned from the liquid port  82  to the inlet  88   I  of the second pump via the fourth duct D 4 , and then may be conveyed to the used electrolyte tank  92  via the sixth duct D 6 . Then, in the Fill mode arrangement, the third valve V 3  is closed and the fifth valve V 5  is opened. This arrangement permits fresh electrolyte  40  to be suctioned from the fresh electrolyte tank  94  to the inlet  96   I  of the third pump  96  via the eleventh duct D 11 , and then conveyed through the seventh duct D 7  to the fourth joint J 4  and then to the liquid port  82  via the fourth duct D 4 , while preventing flow of fresh electrolyte  40  past the closed third valve V 3 . 
     Optionally, a gas/liquid separator  99  may be disposed in the fifth duct D 5 , which may be configured to separate out any electrolyte  40  or other liquids from the gas byproduct  58 . For example, the gas/liquid separator  99  may comprise or include an evaporator or chiller. The optional gas/liquid separator  99  has two outlets: one outlet attached directly or indirectly to the gas byproduct tank  90  for conveyance of the gas byproduct  58 , and the other outlet for conveyance of any electrolyte  40  or other liquids and which may be connected with an optional ninth duct D 9  (shown in parentheses and as a dashed line) connected with the sixth duct D 6 . Although not explicitly shown in  FIGS. 14-17 , the battery system  20  may additionally include a sample collector and/or tester  98  configured for receiving and/or testing a sample of electrolyte  40  from the enclosure  22 . As illustrated in  FIG. 13 , the collector/tester  98  may be operatively connected with at least one of the liquid port  82 , the fourth duct D 4 , the sixth duct D 6  and the second pump  88 . The collector/tester  98  may be used to collect and/or test a sample of used electrolyte  40  to determine its initial fluoroethylene carbonate/ethyl methyl carbonate (FEC/EMC) molar ratio, which may be used to determine the amount of fresh electrolyte  40  that should be added, depending on the concentration of the fresh electrolyte  40 . The collector/tester  98  may be configured to receive and store a sample of used electrolyte  40  which can be tested by a nuclear magnetic resonance (NMR) tester or other apparatus (e.g., in a separate testing lab) to determine the FEC/EMC molar ratio of the harvested sample of electrolyte  40 ; or, the collector/tester  98  may also include or comprise an in situ NMR tester or other apparatus for evaluating the harvested sample of electrolyte  40 . 
     Returning once again to  FIG. 12 , and with additional reference to  FIG. 19 , another embodiment of the present disclosure includes a battery pack handling system  100  for an automotive vehicle  10 , where the automotive vehicle  10  has a housing wall or exterior body panel  12  as part of its exterior  14  and carries an on-board battery pack/battery system  20 . The battery pack handling system  100  includes a gas handler  66  configured for receiving gas byproduct  58  from the battery pack  20  (e.g., from a manifold  60  operatively connected with one or more enclosures  22 ), a first duct D 1  configured for conveying the gas byproduct  58  from the battery pack  20  to the gas handler  66 , a refill port  68  configured for fastenable extension through the exterior body panel  12  and for connecting with the battery pack  20  (wherein the refill port  68  is configured for evacuating used electrolyte  40  from the battery pack  20 and for introducing fresh electrolyte  40  into the battery pack  20 ), and a second duct D 2  configured for conveying electrolyte  40  between the battery pack  20  and the refill port  68 . The gas handler  66  may be configured to be disposed above the battery pack  20 (since gas byproduct  58  may be lighter than air), and the gas handler  66  may be further configured for filtering the gas byproduct  58  received from the battery pack  20 . A first valve V 1  may be disposed in the first duct D 1  and configured to open and close flow of gas byproduct  58  through the first duct D 1 , and a second valve V 2  may be disposed in the second duct D 2  and configured to open and close flow of electrolyte  40  and/or gas byproduct  58  through the second duct D 2 . 
     Returning to  FIGS. 14-17 , first through fourth configurations, respectively, are shown of yet another embodiment according to the present disclosure. Each configuration is of an electrolyte evacuation and refill station  200  for servicing a battery pack  20 carried on-board an automotive vehicle  10 , in which the automotive vehicle  10  has a refill port  68  operatively connected with the battery pack  20 and extending through an exterior body panel  12  of the vehicle  10 . Each configuration includes: (i) a boot cover  70  having a wrap-around wall  72  surrounding and defining a plenum  74  therewithin, an opening  76  in the wrap-around wall  72  defined by a lip  78  about the opening  76 , and a gas port  80  and a liquid port  82  each defined in the wrap-around wall  72 , wherein the gas port  80  is in fluid communication with the plenum  74 , and wherein the liquid port  82  has an inner connector portion  84  disposed within the plenum  74  and configured for coupling with the refill port  68  when the boot cover  70  is placed over the refill port  68  with the lip  78  in sealed engagement with the exterior body panel  12 ; (ii) a first pump  86  operatively connected with the gas port  80  and configured for applying suction to the gas port  80 ; (iii) a second pump  88  operatively connected with the liquid port  82  and configured for applying suction and/or pressure to the liquid port  82 ; (iv) a gas byproduct tank  90  operatively connected with a first outlet  86   O  of the first pump  86  and configured for receiving gas byproduct  58  from the battery pack  20  via the refill port  68  and the first pump  86 ; (v) a used electrolyte tank  92  operatively connected with a second outlet  88   O  of the second pump  88  and configured for receiving electrolyte  40  from the battery pack  20  via the refill port  68  and the second pump  88 ; and (vi) a fresh electrolyte tank  94  configured for supplying electrolyte  40  to the liquid port  82 . 
     The second pump  88  may be operatively connected with the liquid port  82  and/or the fresh electrolyte tank  94  and may be further configured to cause electrolyte  40  from the fresh electrolyte tank  94  to be pumped to the liquid port  82 . The electrolyte evacuation and refill station  200  may further include a third pump  98  operatively connected with the liquid port  82  and/or the fresh electrolyte tank  94  and configured to cause electrolyte  40  from the fresh electrolyte tank  94  to be pumped to the liquid port  82 . The electrolyte evacuation and refill station  200  may further include a collector/tester  98  (e.g., an NMR tester) configured for receiving and/or testing a sample of electrolyte  40  from the battery pack  20 , wherein the collector/tester  98  is operatively connected with at least one of the liquid port  82 , the fourth duct D 4  , the sixth duct D 6  and the second pump  88 . 
     Note that while  FIG. 19  shows the battery system  20 , the battery pack handling system  100 , and the electrolyte evacuation and refill station  200  as three separate blocks, the battery pack handling system  100  and/or the electrolyte evacuation and refill station  200  may be included as part of the battery system  20 . Also note that the manifold  60  may be part of the battery pack handling system  100 , or it can be part of the battery system  20 . 
     The above description is intended to be illustrative, and not restrictive. While the dimensions and types of materials described herein are intended to be illustrative, they are by no means limiting and are exemplary embodiments. In the following claims, use of the terms “first”, “second”, “top”, “bottom”, etc. are used merely as labels, and are not intended to impose numerical or positional requirements on their objects. As used herein, an element or step recited in the singular and preceded by the word “a” or “an” should be understood as not excluding plural of such elements or steps, unless such exclusion is explicitly stated. Additionally, the phrase “at least one of A and B” and the phrase “A and/or B” should each be understood to mean “only A, only B, or both A and B”. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. And when broadly descriptive adverbs such as “substantially” and “generally” are used herein to modify an adjective, these adverbs mean “for the most part”, “to a significant extent” and/or “to a large degree”, and do not necessarily mean “perfectly”, “completely”, “strictly” or “entirely”. Additionally, the terms “operatively connected” and “operatively connecting” may be used herein to describe connections that may be direct, or indirect, or either direct or indirect, as the case may be or may permit. 
     This written description uses examples, including the best mode, to enable those skilled in the art to make and use devices, systems and compositions of matter, and to perform methods, according to this disclosure. It is the following claims, including equivalents, which define the scope of the present disclosure.