Multi-stage battery off-gas neutralization system

Abstract

Apparatus and related methods relate to multistage catalytic battery off-gas neutralization systems. In an illustrative embodiment, a system includes multiple reaction stages connected in series. Each stage includes a reaction chamber with catalytic material. A first stage incorporates a heat source initiating a catalytic reaction. Downstream stages may, for example, be passively activated when effluent exceeds a predetermined threshold of thermal energy. Thermal coupling may, for example, sustain exothermic propagation across stages. Various embodiments may advantageously offer a compact design and energy-efficient operation.

Description

Docket No. 1036-07WO / USMulti-Stage Battery Off-Gas Neutralization SystemCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional patent application serial no. 63 / 714,347, titled Modular Fire Protection System for Mitigating Battery Fire, Explosion, and Toxicity, filed by Kevin Marr, et al., on October 31, 2024.

[0002] The entire contents of each of the foregoing applications and their priority applications, if any, are incorporated herein by reference.

[0003] This application may share inventor(s) and / or subject matter with one or more of the following applications:• PCT Application Serial No. PCT / US2023 / 061493, titled "Passive automatic injector reactor system", filed by Kevin Marr, et al., on January 27 ,2023; and• US Patent Application Publication No. US2022 / 0094014, titled "Explosive environment neutralization in chemical energy storage," filed by Kevin Marr, et al., on September 21, 2021.

[0004] The entire contents of each of the foregoing applications and their priority applications, if any, are incorporated herein by reference.

[0005] Unless expressly stated, changes in terminology from priority application(s) to this application are made without prejudice or disclaimer of subject matter. Changes from the priority application(s) (e.g., provisional applications(s)) are intended to be broadening and / or additive unless expressly stated otherwise. Replacement of alternative terms with a single representative term, for example, are inclusive unless otherwise defined. Various embodiments may also be found in previous disclosure(s) incorporated by reference. Embodiments of similar languages in this application are not modifications or disclaimer of the embodiments disclosed in previous incorporated disclosures unless otherwise stated.BACKGROUND

[0006] Batteries may serve as sources of electrical power, including one or more electrochemical cells with external connections. Under various operating conditions, the chemicals within the battery may create a gas. Over periods, the gas may leak. Batteries may, for example, include seals to reduce gas leakage. Batteries may emit toxic gas when they are overcharged or exposed to high temperatures, for example. In some examples, batteries may emit flammable gas under similar conditions. Batteries provide an alternative to fossil fuels that may reduce the global release of greenhouse emissions. Batteries are becoming more prevalent in work settings as governments,Docket No. 1036-07WO / US consumers, and companies transition to electrically powered devices. The devices may, for example, include electric vehicles, laptops, and car batteries.

[0007] Batteries may be transported over long distances. They may, for example, be transported across the sea in shipping containers. In some examples, batteries may be transported in trucks. Some examples may include transporting batteries in storage boxes. Batteries may be stored in warehouses, for example. The containers may become hot or lack cooling, for example. In some scenarios, batteries may begin to release toxic gases after reaching certain temperatures. Batteries may also release flammable gases under such conditions, for example.TECHNICAL FIELD

[0008] Apparatus and methods generally relate to safety systems, for example, in mitigating safety risks in battery systems.SUMMARY

[0009] Apparatus and related methods relate to systems configured for passive activation of reaction stages by thermal energy from preceding stages. In an illustrative embodiment, a system may include multiple reaction stages connected in series. Each stage may, for example, include a reaction chamber with catalytic material. A first stage may, for example, incorporate a heat source initiating a catalytic reaction. Downstream stages may, for example, be passively activated when effluent exceeds a predetermined threshold of thermal energy. Thermal coupling may, for example, sustain exothermic propagation across stages. Various embodiments may advantageously offer a compact design and energy-efficient operation.

[0010] Various embodiments may achieve one or more advantages. Some embodiments may, for example, advantageously initiate catalytic activation while reducing total power consumption. For example, some embodiments may advantageously self-heat through exothermic propagation. Some embodiments may, for example, advantageously distribute oxidizer flow according to natural differential pressures, enabling passive operation without complex electronic regulation. For example, some embodiments advantageously sustain reaction continuity and improve gasneutralization efficiency. Some embodiments may, for example, advantageously allow compact installation within confined enclosures while maintaining high throughput capacity. Some embodiments may, for example, advantageously stabilize temperature and flow balance between stages during dynamic operating conditions. Some embodiments may, for example, advantageously maintain outlet gas temperature and composition within safety thresholds. In some examples, some embodiments may advantageously extend applicability across stationary, mobile, and transport configurations.Docket No. 1036-07WO / US

[0011] The details of various embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Various embodiments of the present embodiments are described with reference to the following FIGURES.

[0013] Fig. 1 depicts an example multi-stage catalytic system (MSCS) employed in an illustrative scenario.

[0014] Fig. 2A is a block diagram of an example heated catalyst reaction system generating an effluent gas output.

[0015] Fig. 2B is a top view showing an example heated catalyst.

[0016] Fig. 3 A and Fig. 3B are schematic diagrams showing example embodiments of an active entrainment catalytic system.

[0017] Fig. 4 shows an example catalytic system having a combustion chamber, and an example operating temperature response.

[0018] Fig. 5 A, Fig. 5B, Fig. 5C, and Fig. 5D are block diagrams showing an example sequential catalytic reaction system, an example sequential catalytic reaction system with make up air entrainment, an example parallel catalytic reaction system, and an example a bypass logic integrated catalytic reaction systems, respectively.

[0019] Fig. 6A is a perspective view of a battery unit with an example dual-configurable venting catalytic system.

[0020] Fig. 6B shows an example catalytic heating system installed on top of a battery enclosure.

[0021] Fig. 7A is a perspective view of an example venting catalytic system coupled to a vehicle battery pack.

[0022] Fig. 7B is a block diagram of an example mobile gas treatment system.

[0023] Fig. 8 is a block diagram of an example stationary gas treatment system.

[0024] Fig. 9A is a perspective view of an example fire blanket with an integrated catalytic system and battery.

[0025] Fig. 9B is a diagram of an example venting catalytic system integrated onto a cover or enclosure mounted over a battery system.

[0026] Fig. 10 is a flowchart showing an example multi-stage catalytic system operation method.

[0027] Fig. 11 is a flowchart showing an example multi-stage catalytic system configuration method.Docket No. 1036-07WO / US

[0028] Like reference numerals refer to like parts throughout the various views unless otherwise specified. Embodiments and portions of embodiments illustrated and described herein are nonlimiting and non-exhaustive.DETAILED DESCRIPTION

[0029] In order to assist rapid comprehension, this document introduces an example power safety system (PSS 100) and a multi-stage catalytic system (MSCS 110) in Figs. 1-4. Configurations of sequential, parallel, and bypass-integrated catalytic systems are described with respect to Figs. 5A- 5C. The discussion then turns to example implementations of venting, mobile, stationary, and integrated catalytic systems in Figs. 6A-9B. Methods related to operation and configuration of the MSCS 110 are described with reference to Figs. 10-11. Finally, various additional embodiments and features related to control logic, modular design, and adaptive operation are discussed.

[0030] Fig. 1 depicts an example multi-stage catalytic system (MSCS) employed in an illustrative scenario. In the depicted example, a power safety system (PSS 100) includes a battery enclosure 102. The battery enclosure 102 may, for example, include various types of enclosures. Some enclosures may include battery storage cabinets, for example. Shipping containers may, in some embodiments, be used. Stationary racks may also be included. Some examples may include integrated modules within electric vehicles. In other examples, the system may be used with energystorage systems. Enclosures may, for example, also encompass partially sealed or open structures. Such structures may permit the accumulation of released gases.

[0031] The battery enclosure 102 includes multiple battery modules 104. For example, the battery modules 104 may be mounted on modulated racks within the battery enclosure 102. As shown, each battery modules 104 includes multiple battery cells 106. For example, the battery cells 106 may include Lithium-ion batteries. For example, each of the battery cells 106 may generate an electrical power output of the PSS 100.

[0032] In some examples, the battery modules 104 may release flammable and toxic gases (TFG 108). For example, during a thermal runaway failure, the battery cells 106 may generate the TFG 108 during normal operating conditions based on the battery technologies used. In some examples, if the TFG 108 accumulates and / or exceeds a threshold, the battery enclosure 102 may have a heightened risk of battery fire, explosion, and / or toxicity hazards.

[0033] In this example, the TFG 108 is transferred into a multi-stage catalytic system (MSCS 110). For example, the MSCS 110 may include a venting system that neutralizes and / or eliminates toxic and / or flammable species within the TFG 108. Through chemical and / or absorption mechanisms, for example, the MSCS 110 may draw and / or receive battery gases (e.g., the TFG 108), eliminatesDocket No. 1036-07WO / US and / or neutralizes the gases using one or more physiochemical processes, and releases the resulting gases. As shown, the resulting gas is a safe treated exhaust gas (STEG 112).

[0034] For example, the STEG 112 may be below a (predetermined) permissible exposure limits (PELs) and / or flammable limits. In some implementations, the STEG 112 may be released in hazard areas (e.g., within the battery enclosure 102).

[0035] As shown, the MSCS 110 includes N serially-connected multi-stage catalytic systems, including a first stage catalytic stage 114, a second stage catalytic stage 116, and a N-th stage catalytic stage 118. For example, each of the catalytic systems may reduce hazardous gas species concentrations. The catalyst stages may be arranged in series.

[0036] For example, each of the serially connected catalyst stages may generate an output flow from a preceding catalysts stage into the input flow of a downstream catalyst stage. In other implementations, the catalysts stages may be arranged in parallel. For example, in a parallel connected MSCS, the TFG 108 is passed through multiple catalyst stages through shared input and output flow paths. In some examples, the catalyst stages may also be implemented in any combination of parallel and series orientations. Various implementations are further described with reference to in Figures 1-4 in US2022 / 0094014, the entirety of which is incorporated herein by reference.

[0037] In some embodiments, various reaction stages (e.g., catalytic stages, the first stage catalytic stage 114 until the N-th stage catalytic stage 118) of the MSCS 110 may include multiple heated substrates coated with a catalyst. For example, the reaction stages may include identical or different catalysts. For example, the reaction stages may neutralize, react, and / or oxidize various gases present in a stream (e.g., the TFG 108). In some embodiments, for example, the order of steps or operations may be changed. Some embodiments may perform a series of steps in a single step. In various examples, simultaneous or sequential steps may be performed. The process steps may also be staged in series or parallel. Various embodiments may enhance entrainment, increase flow rate, reduce power requirements, and / or improve other performance characteristics.

[0038] Enhanced entrainment may, for example, be achieved by arranging certain catalytic stages or nozzles to create pressure differentials. These differentials may passively draw surrounding air or gas mixtures into the flow path. This passive induction may increase the availability of oxidizer. It may promote more complete reactions without additional pumps or blowers.

[0039] Increased flow rate may, for example, result from reduced backpressure between adjacent stages. Reduced backpressure may be achieved by varying substrate porosity or nozzle diameters. A lower overall pressure drop may allow a higher volumetric throughput. It may maintain sufficient residence time for catalytic conversion.Docket No. 1036-07WO / US

[0040] Reduced power requirements may, for example, be realized because only the first stage may require active electrical heating to reach light-off conditions. Subsequent stages may self-heat through exothermic neutralization reactions. This progressive heating sequence may reduce energy input. It may reduce the need for multiple powered elements or continuous heater operation.

[0041] Improved performance characteristics may, for example, include more uniform temperature gradients. Faster reaction initiation may also be a characteristic. Greater overall conversion efficiency is another possibility. Distributing the reaction across multiple coated substrates may, for example, prevent localized overheating. It may enhance catalyst longevity. Parallel or hybrid stage arrangements may maintain operational stability across varying flow conditions.

[0042] In some embodiments, the reaction stages (e.g., the first stage catalytic stage 114 until the N-th stage catalytic stage 118 of the MSCS 110) may Each perform distinct neutralization reactions. The first stage catalytic stage 114 may, for example, include an electrically assisted heater. This heater may be configured to initiate a primary chemical reaction, for example, at a light-off temperature. The light-off temperature may refer to the minimum temperature at which a catalytic material in a reaction stage (e.g., the first stage catalytic stage 114 until the N-th stage catalytic stage 118) initiates and sustains a neutralization reaction. This temperature threshold may enable the catalytic material to facilitate oxidation or neutralization of reactive gas species. Achieving and maintaining the light-off temperature may facilitate efficient catalytic activity, reducing the need for continuous external heating sources.

[0043] In some examples, a volume of any of the reaction stages the MSCS 110 may have a volume greater than that of a preceding stage. For example, the progressively larger volume may advantageously provide an effective heat utilization from effluents of preceding stages. This volumetric progression may, for example, facilitate sufficient thermal residency time for the effluent. For example, heat generated from the catalytic reactions of the preceding stage may adequately raise the temperature of the effluent to the light-off temperature of a subsequent stage. Accordingly, for example, downstream stages from the first stage catalytic stage 114 may be passively activated. For example, the MSCS 110 may advantageously reduce a need for additional external energy input to the downstream stages.

[0044] For example, the first stage catalytic stage 114 may utilize heated catalyst to facilitate the toxic gas neutralization process. For example, the single heater arrangement may advantageously reduced reliance on multiple active heaters within the system.

[0045] For example, some stages downstream from the first stage catalytic stage 114 may be activated based on chemical heat release. For example, some stages downstream from the first stage catalytic stage 114 may be activated solely based on chemical heat release. Some stages mayDocket No. 1036-07WO / US include airflow control mechanisms. For example, the airflow control mechanisms may be configured to regulate or redirect airflow between stages to control combustion intensity or temperature distribution. Such mechanisms may include pressure-dependent valves. In some implementations, the pressure-dependent valves may passively modulate airflow. For example, some configurations may advantageously increase operational efficiency. For example, a temperature rise may, for example, be achieved without additional heating element within the downstream stages.

[0046] In some embodiments, the pressure-dependent valves may maintain sufficient pressure for desired air entrainment and chemical reactions. For example, the pressure-dependent valves may advantageously reduce a necessity for electronic controls.

[0047] Some embodiments may, for example, include passive control mechanisms within MSCS 110. In some embodiments, MSCS 110 may incorporate active control mechanisms. Some catalytic stages, such as at the first stage catalytic stage 114 or second stage catalytic stage 116, may be configured to adaptively engage in response to various flow conditions. Such configurations may, for example, reduce manual intervention. Reduced manual intervention may, for example, lead to lower operational costs. Increased reliability may also result from the adaptive engagement of catalytic stages.

[0048] In some embodiments, the battery enclosure 102 and the MSCS 110 may be separated by a control surface. For example, the control surface may include a pressure relief valve. The pressure relief valve may, for example, facilitate controlled release of accumulated pressure. In some implementations, a controlled pressure may facilitating a stable entrainment and enabling activation of downstream catalytic stages with reduced or no external heating. For example, by maintaining a defined pressure differential, the pressure relief valve may allow a predetermined mixture of heated battery gases (e.g., 500-600 °C) and make-up air (e.g., at -40 to 25 °C) to reach a light-off temperature (e.g., about 150 °C).

[0049] For example, the control surface may include a pressure-activated control surface. The pressure-activated control surface may, in some examples, be used to separate the battery enclosure 102 and the MSCS 110. The use of pressure-activated control surfaces may, for example, allow for responsive separation under specified conditions, which may enhance safety.

[0050] For example, the control surface may include a temperature-activated control surface. In some embodiments, the temperature-activated control surface may be utilized to achieve separation of the battery enclosure 102 from the MSCS 110. Temperature-activated control surfaces may, for example, provide advantages in triggering separation when temperatures exceed safe thresholds, thereby increasing operational stability.Docket No. 1036-07WO / US

[0051] For example, the control surface may be passively activated when a critical pressure and / or temperature threshold is reached. For example, when the control surface is activated, battery gases are allowed to flow from the battery enclosure 102 to the system. This configuration may be implemented as shown in Figures 1-4 and 6-8 of PCT / US2023 / 061493.

[0052] The MSCS 110 includes a cooling and conditioning unit (CCU 120) and a flow control unit (FCU 122). For example, the CCU 120 may receive output from one or more of the catalytic stages (e.g., the first stage catalytic stage 114, the second stage catalytic stage 116, .., the N-th stage catalytic stage 118). The CCU 120 may, for example, regulate the temperature and humidity of an effluent gas from the catalytic stages before it exits the MSCS 110. In some implementations, the CCU 120 may include one or more heat exchangers, condensers, and / or filtration modules. For example, the CCU 120 may cool an incoming gas stream. For example, the CCU 120 may regulate moisture, particulates, and / or reactive vapors in the incoming gas stream. For example, the CCU 120 may maintain the incoming gas stream within a controlled temperature range.

[0053] The FCU 122 may, for example, regulate the volumetric flow rate and pressure of the STEG 112. For example the FCU 122 may include adjustable valves, pressure regulators, and / or flow sensors. For example, the FCU 122 may dynamically adjust a flow rate of the STEG 112 based on a real-time pressure readings. For example, the FCU 122 may adjust the flow rate base don a gas concentration data within the battery enclosure 102. In some implementations, the FCU 122 may also interface with safety subsystems (not shown) in response to abnormal operating conditions (e.g., over-temperature or over-pressure events).

[0054] In some implementations, the STEG 112 may be directed through one or more outlet configurations. In some examples, the PSS 100 may include an outward exhaust 124 and / or an inward exhaust 126. The outward exhaust 124 may, for example, release the STEG 112 to an external environment (e.g., outside of the battery enclosure 102, a battery housing). In some examples, the inward exhaust 126 may redirect the STEG 112 back into the battery enclosure 102. For example, the inward exhaust 126 may advantageously to maintain internal circulation of residual battery gases. In some implementations, the outward exhaust 124 and the inward exhaust 126 may be implemented simultaneously. For example, the PSS 100 may be configured to selectively activated the outward exhaust 124 and / or the inward exhaust 126 based on operational conditions (e.g., detected concentration level of various gases, pressure within the battery enclosure 102, or gas concentration of the TFG 108 and / or the STEG 112 with respect to safety thresholds). For example, the PSS 100 may include a flow control algorithm to determine whether to exhaust externally, internally, or through both routes.Docket No. 1036-07WO / US

[0055] As shown, the MSCS 110 includes a first stage heat source 130 and a active or passive air entrainment system 132. For example, the first stage heat source 130 may be operably connected to the first stage catalytic stage 114. For example, the first-stage heater 130 is not connected to other catalytic systems of the MSCS 110.

[0056] In this example, the active or passive air entrainment system 132 generates a make-up airflow 134 supplied to multiple reaction stages. For example, the active or passive air entrainment system 132 may draw and / or induce air from an external environment to be distributed to one or more catalytic stages. In some embodiments, the active or passive air entrainment system 132 may include an active component (e.g., a fan, a blower, or a pump). For example, the active component may be configured to deliver a controlled airflow rate into the MSCS 110. In some embodiments, the active or passive air entrainment system 132 may operate passively. The active or passive air entrainment system 132 may, for example, include components for utilizing temperature differentials between the catalytic stages and an external environment to induce air entrainment. In some embodiments, the active or passive air entrainment system 132 may include a hybrid of active and passive components.

[0057] The make-up airflow 134 may, for example, provide a controlled portion of ambient or conditioned air that is independently delivered to each catalytic stage. As an illustrative example without limitation, for an example three-staged system, the first stage catalytic stage 114 may receive approximately 10 % of the total make-up airflow, the second stage catalytic stage 116 may receive approximately 30 %, and a third catalytic receive the remaining balance. The make-up airflow 134 may be regulated through passive or mechanically actuated valves that respond to differential pressures or designed orifice sizes at each stage. Various embodiments may advantageously allow each downstream catalytic stage to be passively activated when effluent temperatures from preceding stages reach a light-off threshold. For example, as the gas temperature or pressure increases across stages, the distributed make-up airflow 134 may maintain balanced flow and reaction efficiency throughout the MSCS 110.

[0058] In some embodiments, the FCU 122 may direct the make-up airflow 134 through and / or from the other modules. Various flow control methods may be employed. For example, the FCU 122 may include an axial fan. For example, the FCU 122 may include a centrifugal fan. The FCU 122 may include pressure-driven methods configured to induce the make-up airflow 134 by pressure buildup due to gases being released in the battery enclosure 102.

[0059] For example, the PSS 100 may be incorporated onto batteries, battery modules, and / or other energy storage systems. For example, the MSCS 110 may treat, vent, and / or recirculate an area experiencing flammable, explosive or toxic gas build-up caused during a battery failure. In someDocket No. 1036-07WO / US implementations, the make-up airflow 134 may vent to advantageously relieve pressure buildup in a primary and / or any secondary enclosure containing cells, battery modules, packs or the battery system(s). In one example, the PSS 100 can be installed on a shipping container that contains batteries, a battery pack in an electric vehicle, and / or a container housing batteries in a warehouse.

[0060] The first stage heat source 130 may, for example, be configured to thermally activate the first stage catalytic stage 114. In some implementations, the first stage heat source 130 may include an electrically assisted heating element, such as a resistive heater. For example, the first stage heat source 130 may include a positive temperature coefficient (PTC) heater.

[0061] In some implementations, the first stage heat source 130 may include an inherent temperature of incoming battery gas (e.g., the TFG 108) to achieve light-off conditions. For example, under certain operating scenarios, the temperature of the battery gas may yield a flow temperature above a representative light-off threshold (e.g., about 150 °C) of the first stage catalytic stage 114.

[0062] Once initiated, for example, the neutralization reaction in the first stage catalytic stage 114 may generate sufficient thermal energy to propagate chemical reactions through the downstream stages without requiring additional heaters. In some implementations, the MSCS 110 may operate efficiently with minimal electrical input, reduced component complexity, and improved reliability through primarily passive thermal propagation.

[0063] In various implementations, a multi-stage self-initiated progressive-reaction battery gas neutralization system (e.g., the MSCS 110) may include only a first stage heater(e.g., the first stage heat source 130). For example, later stages of the multi-stage self-initiated progressive-reaction battery gas neutralization system may be self-heated by thermal energy received from neutralization reactions of preceding stage(s). In some implementations, the multi-stage self-initiated progressivereaction battery gas neutralization system may include no inter-stage heat exchangers. For example, the multi-stage self-initiated progressive-reaction battery gas neutralization system may include a single-source bypass airflow to each stage (e.g., the make-up airflow 134). In some embodiments, the single-source bypass airflow may be regulated by mechanical (e.g., passive) valves.

[0064] Fig. 2A is a block diagram of an example heated catalyst reaction system generating an effluent gas output. In this example, a heated catalyst reaction system (HCRS 200) includes a reaction chamber 206. The reaction chamber 206 houses an active heater 208 (e.g., first stage heat source 130). For example, the HCRS 200 may the first stage catalytic system 114 described with reference to FIG. 1.

[0065] In some embodiments, the MSCS 110 may includes an integration of chemical (e.g., the heated catalyst 212) and electrical components (e.g., the active heater 208). For example, theDocket No. 1036-07WO / US integration may advantageously reduce energy consumption and overall system cost. For example, complex electronic controls (e.g., complex implementation of software routines) may advantageously be avoided. In some examples, the MSCS 110 may advantageously enhance reliability with by limiting dependence on less durable components (e.g., Integrated Circuit (IC) chips).

[0066] In the depicted example, influent gas 202 is directed into the HCRS 200. For example, the influent gas 202 may be generated from the battery modules 104. Within the reaction chamber 206, the active heater 208 may facilitate a catalytic reaction through applied heat. For example, the catalytic reaction may reduce toxic and / or flammable gas concentration within the influent gas 202.

[0067] The HCRS 200 includes the FCU 122 positioned downstream of the reaction chamber 206. In some embodiments, flow control 122 may regulate the passage of effluent gas 204. This process may be monitored using sensors 210, which may provide feedback regarding operational parameters.

[0068] Effluent gas 204 exits the HCRS 200 after undergoing catalytic transformation. Sensors 210, integrated within the system, may be utilized to ensure efficient operation and adherence to desired processing conditions. This integration may allow for precise monitoring and control of the reaction environment.

[0069] As shown, the reaction chamber 206 includes a heated catalyst 212. The heated catalyst 212 may, for example, include a catalytic substrate coated with one or more active materials configured to facilitate oxidation or neutralization of the influent gas 202. In some implementations, the heated catalyst 212 may be formed of metallic, ceramic, or composite materials designed to withstand elevated temperatures and corrosive environments. The catalytic surface of the heated catalyst 212 may be coated with noble metals (e.g., platinum, palladium, or rhodium) or metal oxides (e.g., manganese oxide, copper oxide, or nickel oxide) selected based on the specific reactive gas composition.

[0070] The active heater 208 may elevate the temperature of the heated catalyst 212 to a light-off threshold that initiates the neutralization reaction. Once activated, the heat generated by the catalytic process may sustain further reactions without continuous external heating. For example, the heated catalyst 212 may promote oxidation of hydrogen, carbon monoxide, and hydrocarbon species within the influent gas 202, converting them into less hazardous compounds such as carbon dioxide and water vapor. In some examples, the thermal energy released by these reactions may be used to maintain the temperature of the reaction chamber 206, enabling efficient operation of the HCRS 200 and stable effluent generation.Docket No. 1036-07WO / US

[0071] In some embodiments, a MSCS may include either or both heated catalyst or non-heated catalyst in one or more of the catalytic stages. Some embodiments of the catalytic stages are described in further details with reference to Figures 1-4 in US2022 / 0094014. Various catalytic stages may, for example, replace or include a catalyst to form a multi-stage reactor system with similar configurations. A multi-stage system may include both catalyst stages. In some embodiments, reactor stages of other types may be included. Reactors may, for example, include combustion in an enclosed can. In some examples, reactors may include annular chambers. Canannular chambers may be used in some embodiments. Various embodiments may use porous media combustors. Other chamber types may also be employed. A flow of incoming gases may, for example, be combusted. Gases may, in certain examples, be oxidized. In some embodiments, gases may be reacted.

[0072] In various examples, the reaction chamber 206, the FCU 122, and the CCU 120 may be configured to create a flow through the system and installed in any order. In some embodiments, a MCSC may include only the heated catalyst 212 (e.g., a heated substrate coated with a catalyst, a heated substrate coated with a catalyst) and either the cooling and conditioning module or the flow control module. The modular arrangement, for example, may advantageously enable compact installation into smaller sized enclosures (e.g., battery housings, containerized systems) while maintaining efficient gas neutralization performance.

[0073] Fig. 2B is a top view showing an example heated catalyst. The heated catalyst 212 may, as shown, include an uncoated heated substrate 214. It may also include a coated heated substrate 216.

[0074] In some examples, the uncoated heated substrate 214 may include a base heating element. This base heating element may be configured to generate and distribute heat across its surface. The uncoated heated substrate 214 may, for example, include an electrically resistive material such as Nichrome. In some instances, it may include a Positive Temperature Coefficient (PTC) heater formed from a doped barium titanate ceramic. The uncoated heated substrate 214 may, for example, facilitate temperature regulation. This may provide thermal activation to the catalytic layer without causing overheating.

[0075] The coated heated substrate 216 may include a catalytic coating. This catalytic coating may be applied over the uncoated heated substrate 214. The coating may, for example, include one or more active materials. These materials may be configured to facilitate oxidation, neutralization, or decomposition of toxic or flammable gases. In some implementations, the coating of the coated heated substrate 216 may include noble metals such as platinum. In some examples, it may include palladium, gold, or silver. Metal oxides such as manganese oxide may be included, for example. Copper oxide, nickel oxide, or chromium oxide may also be used in some examples. CombinationsDocket No. 1036-07WO / US of these materials may, for example, be utilized. Additional coating materials may be included. These may include metal-organic frameworks. In some examples, carbon nanostructures may be included. Graphene-based composites may also be incorporated. These coatings may enhance surface reactivity and thermal stability.

[0076] The layered configuration between the uncoated heated substrate 214 and the coated heated substrate 216 may allow for efficient heat transfer. This configuration may, for example, maintain electrical isolation and structural integrity. The heated catalyst 212 may operate by raising the temperature of the coated surface to a light-off threshold. This threshold may range between approximately 15 °C and 500 °C. The exact temperature may depend on catalyst composition and gas concentration. Once activated, the coated heated substrate 216 may promote neutralization reactions. These reactions may convert hazardous gas species into less reactive or non-toxic compounds. The result may be a treated effluent gas suitable for discharge or further conditioning.

[0077] Fig. 3 A and Fig. 3B are schematic diagrams showing example embodiments of an active catalytic system 300. As shown in FIG. 3A, the active catalytic system 300 includes a passive automatic injector reactive system (PAIR system 302) with an active entrainment unit 304 to supply an oxygen rich gas 306 (e.g., an oxygen-containing fluid, reactant gas) into a mixing chamber 308. For example, some embodiments of the active catalytic system 300 may be described with reference to FIGS. 1-4 and 6-8 in PCT / US2023 / 061493.

[0078] The PAIR system 302 includes an injector 310. For example, the injector 310 may increase a flow velocity of the TFG 108 through a nozzle. For example, the nozzle may then discharge the gas into the inlet of the mixing chamber 308.

[0079] For example, the mixing chamber 308 may be in fluid communication with the active entrainment unit 304. For example, the active entrainment unit 304 may supply oxygen from an external oxygen source. For example, the external oxygen source may be surrounding ambient air. For example, the active entrainment unit 304 may force external oxygen into the mixing chamber 308. Various active entrainment methods can be employed, for example, including but not limited to an axial fan and / or centrifugal fan.

[0080] Battery gas (e.g., the TFG 108) and oxygen-containing gas (e.g., received from the active entrainment unit 304) are mixed within the mixing chamber 308. For example, the gases are mixed prior to entering the reactor 310 where the hazardous gases (e.g., the TFG 108) are chemically neutralized, oxidized, reacted and / or adsorbed. For example, the reactor 310 may include a multistage catalytic system (e.g., the MSCS 110).

[0081] The mixing chamber 308 may include a passive or an active mixing method. For example, the mixing chamber 308 may include mixing nozzles. The mixing nozzles may, for example,Docket No. 1036-07WO / US promote turbulence within the gas stream. The mixing nozzles, for example, may increase dispersion of the toxic or flammable gas 108 with an oxygen-rich gas 306.

[0082] The mixing chamber 308 may include pulse jet mixing components. The pulse jet mixing components may, for example, generate periodic pressure fluctuations within the chamber. The pulse jet mixing component, for example, may increase uniformity of concentration and temperature distribution.

[0083] The mixing chamber 308 may include swirl mixers. The swirl mixers may, for example, impart a rotational motion to the gas flow. The swirl mixers, for example, may increase the residence time and facilitate molecular interaction between reactive species.

[0084] The mixing chamber 308 may include mixing vanes. The mixing vanes may, for example, guide or redirect the flow within the chamber. The mixing vanes, for example, may assist in stabilizing internal flow dynamics and may reduce stratification of gas layers.

[0085] For example, the CCU 120 may cool outlet gases from the reactor 310. For example, the CCU 120 may include heat exchangers (Hx) configured to transfer heat from the reactor 310 to a battery gas stream (e.g., the TFG 108) prior to entering the injector 310. For example, the heat of the STEG 112 a system outlet may be transferred to the surrounding air stream prior to mixing with the TFG 108 (e.g., battery gases). In some implementations, Hx may provide appropriate thermal conditioning to facilitate reactions in the reactor 310.

[0086] In some embodiments, the active catalytic system 300 may receive an input gas, but is not limited to, mixture of hydrogen, carbon monoxide, carbon dioxide, hydrocarbons, oxygen, nitrogen, argon, air, or a combination thereof. For example, the reactor 310 may discharge a non-flammable and non-toxic gas species products through an outlet 314. Gases flowing out of the outlet 314 may, for example, be exhausted outside the battery enclosure 102. In some embodiments, gases may be recirculated back into the enclosure or other enclosed spaces of interest. Some embodiments may include both external exhaust and recirculation. Other enclosed spaces of interest may, for example, include other compartments or containers where batteries may be located. In certain examples, storage tanks can release gases at a later time. Secondary containers may, for example, enclose the primary container.

[0087] In various examples, the active catalytic system 300 may discharge back into a battery chamber (e.g., the battery enclosure 102). In some examples, the active catalytic system 300 may discharge into an outside environment. If the discharge is back into the battery chamber, the discharge of the STEG 112 (e.g., a non-flammable and non-toxic gas species) may prevent buildup of flammable gas concentration (e.g., to below flammable limits) in an area surrounding the battery. For example, the active catalytic system 300 may reduce the oxygen concentration belowDocket No. 1036-07WO / US the limiting oxygen concentration (LOC) to, for example, prevent ignition of a fire, a fire spread, and / or an explosion. The discharge of non-flammable and non-toxic gas species may advantageously reduce toxic species to below PELs. By discharging gases released by a battery in an enclosure, for example, the active catalytic system 300 may advantageously reduce pressure in the battery enclosure.

[0088] As shown in FIG. 3B, a PAIR system is coupled with a power generator 320 to form a power generating ACS (PGACS 316). In the depicted example, the PGACS 316 includes a mixerreactor chamber 318. The mixer-reactor chamber 318 may, for example, include an injector 302 configured to introduce a toxic or flammable gas 108 into a reaction region. The mixer-reactor chamber 318 may receive the oxygen-rich gas 306 from the active entrainment unit 304. The mixerreactor chamber 318 may combine and react these gases through catalytic or neutralization processes.

[0089] The PGACS 316 includes a power generator 320. The power generator 320 may, for example, convert thermal energy from neutralization reactions occurring within the mixer-reactor chamber 318 into electrical energy. The power generator 320 may include, for example, a thermoelectric generator, a thermophotovoltaic device, a micro-turbine, or other thermal-to- electrical conversion mechanisms. The power generator 320 may provide a localized electrical output that may be utilized by components within the PGACS 316.

[0090] The PGACS 316 includes a power transmission line 322. For example, the power transmission line 322 may provide electrical coupling between the power generator 320 and one or more subsystems within the PGACS 316. For example, the power transmission line 322 may transfer electrical energy to the CCU 120. For example, the power transmission line 322 may transfer electrical energy to the FCU 122. For example, the power transmission line 322 may transfer electrical energy to the active entrainment unit 304. The power transmission line 322 may also deliver power to other auxiliary devices (e.g., actuators, the first stage heat source 130, fans, monitoring sensors) within the PAIR system 312.

[0091] In some embodiments, the power generator 320 may advantageously enhance system self- sufficiency. For example, thermal energy that would otherwise dissipate as exhaust heat may be utilized to support catalytic heating and / or airflow generation. The self-contained power supply may, for example, advantageously reduce dependency on external electrical sources and may support operation during power-loss events within a battery enclosure.

[0092] In some embodiments, the power generator 320 may operate continuously. In some examples, the power generator 320 may operate intermittently based on available reaction heat or gas-flow conditions. The generated power may, for example, assist in maintaining operation ofDocket No. 1036-07WO / US control subsystems. In some examples, the generated power may facilitate startup of the catalytic process. The generated power may enable communication and monitoring functions associated with safety systems, for example.

[0093] In some examples, the PGACS 316 may provide dual functionality as both a gasneutralization and energy-harvesting system. The integration of thermal-to-electrical conversion within the catalytic process may advantageously increase reduce thermal waste.

[0094] Various embodiments may utilize stacked or modularly arranged reactor units (e.g., the first stage catalytic stage 114, the second stage catalytic stage 116, the N-th stage catalytic stage 118). Combustion may occur, for example, in an enclosed can, an annular, a can-annular, and / or a porous media combustor. Some embodiments may include other chamber types where a flow of incoming gases is combusted, oxidized, or reacted. Stacking units may, for example, allow for flexible integration into end-use products. Some examples may require operation, storage, and / or protection for a wide range of battery types, battery sizes, or battery use profiles.

[0095] Fig. 4 shows an example catalytic system having a combustion chamber, and an example operating temperature response. In this example, a combustion heated reactor 400 includes an entrance chamber 402, a flame arrestor 404, a combustion chamber 406 and a reactor 310. In some embodiments, the combustion chamber 406 may include an ignitor 410 configured to facilitate a controlled combustion reaction. The flame arrestor 404 may, for example, reduce backfire propagation or flashback into the entrance chamber 402.

[0096] The combustion chamber 406 may generate heat through a combustion process to elevate the temperature of downstream components. This thermal energy may be used to raise the catalytic material within the reactor 310 to at least a minimum activation or light-off temperature. The light- off temperature 510 may, for example, vary depending on the catalyst composition, coating, and concentration of reactive gas species within the incoming flow. In various embodiments, the light- off temperature may range from approximately 15 °C to 500 °C.

[0097] During operation, gases released by a battery during a thermal runaway event may be directed into the entrance chamber 402. The input gas 108 may include a mixture of hydrogen, carbon monoxide, carbon dioxide, hydrocarbons, oxygen, nitrogen, argon, and air. The gases may pass through the flame arrestor 404 into the combustion chamber 406, where ignition occurs. The heat generated by combustion may then thermally activate the reactor 310.

[0098] Fig. 5A, Fig. 5C, Fig. 5D, and Fig. 5D are block diagrams showing an example sequential catalytic reaction system, an example parallel catalytic reaction system, and an example a bypass logic integrated catalytic reaction systems, respectively.Docket No. 1036-07WO / US

[0099] As shown in FIG. 5A, sequential catalytic reaction stages (SCRS 500) includes a first reaction stage 502, a second reaction stage 506, ..., and an N-th reaction stage 508 arranged in series. Each reaction stage (e.g., the first reaction stage 502 through the N-th reaction stage 508) may, for example, correspond to one of multiple catalytic modules within a stacked catalytic reactor system 404.

[0100] In the depicted example , the first reaction stage 502 through the N-th reaction stage 508 (the SCRS 500) are serially arranged as a stacked system of catalytic units. The stages may, for example, include a single outlet out of the SCRS 500. In a serial stacking configuration, as illustrated in this example, an outlet of a reaction stage of the SCRS 500 may be connected to the inlet of a preceding stage. This arrangement may, for example, create a chain of interconnected reaction stages. The serial flow path, for example, may assist in maintaining sustained exothermic propagation through the sequence of modules.

[0101] As shown, each of the reaction stage in the downstream stages 504 may be connected to a preceding stage. For example, an inlet of the second reaction stage 506 is connected to an outlet of the first reaction stage 502. For example, an inlet of the N-th reaction stage 508 is connected to an outlet of an N-l-th reaction stage (not shown). The downstream stages 504 may each receive a partially reacted gas stream from an upstream unit, allowing subsequent stages to continue oxidation or neutralization reactions.

[0102] In some embodiments, as illustrated in FIG. 5B, the SCRS 500 may include the active or passive air entrainment system 132. For example, the active or passive air entrainment system 132 may supply additional air to each catalytic stage. For example, the make-up airflow 134 may be delivered by the active or passive air entrainment system 132 to maintain appropriate oxygen concentration at each stage. Some embodiments may, for example, advantageously facilitate complete catalytic reaction when the incoming battery gases have limited inherent oxygen content (e.g., when the battery modules are directly ducted to the MSCS 110).

[0103] Referring to Figs. 5A-5B, a volume of each downstream stages 504 may have a greater volume than that of a preceding stage. For example, activation of the subsequent stage, when a light-off temperature of that subsequent stage is reached, may be triggered by harnessing the heat of the effluent received from the preceding stage.

[0104] In some implementations, a differential in volume of the downstream stages 504 may, for example, allow the effluent to transfer heat effectively to the catalytic material in the subsequent stage while maintaining a throughout of the STEG 112 in keeping the battery enclosure 102 within a safety threshold. For example, the subsequent stage may be passively activated, reducing the needDocket No. 1036-07WO / US for additional external energy input. This volumetric progression may advantageously improve efficiency by leveraging the thermal energy generated in preceding stages.

[0105] In some embodiments, for each, some, or all of the SCRS 500 may include independently and / or separately arranged outlet. For example, the outlets may discharge the STEG 112 selectively to one or more areas. The exhaust destinations may, for example, include external environments, recirculation zones, or other controlled areas as described herein. For example, multiple separated outlets may facilitate ventilation and gas-flow handling capacity. In some examples, some embodiments may assist in maintaining a controlled flow rate and may increase system throughput.

[0106] In some embodiments, the SCRS 500 may assist in reducing power consumption by distributing the reaction heat across multiple modules within, for example, the MSCS 110. Some examples may advantageously enhance gas-species destruction efficiency. For example, the SCRS 500 may induce progressive catalytic reactions through the stacked arrangement. In some implementations, the modular configuration may allow for a more compact installation footprint. For example, a compact configuration may advantageously facilitate integration into confined or existing enclosures.

[0107] Gases flowing out of the outlet 314 may be exhausted to an area outside the battery enclosure 102. In other embodiments, gases may be redirected or recirculated back into the battery enclosure 102 or other enclosed compartments of interest. Some configurations may include both external exhaust and internal recirculation pathways operating simultaneously. Other enclosed areas of interest may, for example, include adjacent compartments, containment housings, or auxiliary containers associated with energy-storage systems. In some examples, storage tanks or secondary containers may temporarily retain the treated gases for delayed or controlled release.

[0108] Multiple stacked units, for example, may facilitate increased ventilation flow handling. In some embodiments, the multiple stacked units may advantageously reduced power consumption. Some examples may show increased gas species destruction efficiencies. Some embodiments may allow for more compact installation footprints. In a serial stacking configuration, an outlet of one unit may be connected to the inlet of another unit. This configuration may, for example, create a chain of units.

[0109] As shown in FIG. 5C, an example parallel catalytic reaction system (PCRS 410) includes multiple parallel reaction stages 518, including a first parallel reaction stage 512, and a second parallel reaction stage 514 through an N-th parallel reaction stage 516.

[0110] In some embodiments, each of the parallel catalytic stages (the first parallel reaction stage 512 through the N-th parallel reaction stage 516) may receive the make-up airflow 134 supplied by the active or passive air entrainment system 132, as illustrated in FIGS. 5A-5B. The make-upDocket No. 1036-07WO / US airflow 134 may be distributed to each catalytic stage individually. In some examples, the make-up airflow 134 may be distributed as part of the gas input from a preceding stage.

[0111] In this example, the TFG 108 may be directed into a manifold or a shared inlet of the PCRS 510. The manifold may divide the incoming gas flow into multiple flow paths. Each flow path may be directed into one of the parallel venting catalytic stages. For example, the flow paths may be distributed among the first parallel reaction stage 512, the second parallel reaction stage 514, and through the N-th parallel reaction stage 516.

[0112] In some implementations, the SCRS 500 may include catalytic modules arranged as a stacked system. In some examples, some stages may be removable. A modular removable feature of the SCRS 500 may, for example, advantageously scale flexibly based on different battery sizes. In some examples, it may be adaptable to various enclosure geometries. It may also support different safety requirements, for example.

[0113] The SCRS 500 may include a single combined outlet configured to receive output from the parallel reaction stages 518. For example, the of the parallel reaction stages 518 may be fluidly coupled to a single outlet. For example, the STEG 112 may be exhausted through a venting system.

[0114] In some embodiments, some or all of the parallel reaction stages 518 may be separated. For example, the separate outlet flows may be discharged to designated areas as described with reference to FIG. 5 A.

[0115] The parallel configuration of the PCRS 510 may, for example, advantageously distribute the TFG 108 across the parallel reaction stages 518. For example, the SCRS 500 may advantageously increase a total volumetric flow capacity through each individual catalytic module. In some examples, the distributed configuration may advantageously facilitate operation under high pressure gas-release conditions without significantly increasing system resistance.

[0116] In some examples, a combined exhaust outlet may advantageously maintain a uniform attribute of the STEG 112 (e.g., in composition, temperature). In some examples, selective separation of outlet flows may provide directed venting to different locations for specific environmental or safety considerations. For example, the STEG 112 may, for example, meet flammability or toxicity thresholds suitable for a power supply system (e.g., the PSS 100).

[0117] A combination series / parallel stacking configuration, shown in FIG. 5D, uses both series and parallel flow paths. In the depicted example, the SCRS 520 includes a first reaction stage 502, a second reaction stage 506, and through an N-th reaction stage 508. The combined outlet flow from the SCRS 520 may generate the STEG 112.

[0118] Each reaction stage may be coupled with a corresponding bypass logic module. The SCRS 520 includes a first bypass mechanism 522 associated with the first reaction stage 502, a secondDocket No. 1036-07WO / US bypass mechanism 524 associated with the second reaction stage 506, and a n-th bypass mechanism 526 associated with the N-th reaction stage 508. Each bypass mechanism may include one or more flow-diverting components configured to divide an inlet stream into at least two portions. As an illustrative example, an incoming gas of the first bypass mechanism 522 (e.g., the effluent from the first stage catalytic stage 114) may be directed through the second stage catalytic stage 116 or second bypass mechanism 524 based on a temperature of the incoming gas. For example, the first bypass mechanism 522 may direct the incoming gas to the second reaction stage 506 only when a temperature of the incoming gas is greater than a light-off temperature of the second reaction stage 506.

[0119] The first bypass mechanism 522 through the n-th bypass mechanism 526 may each, for example, include a flow regulation system (e.g., include valves, diverter vanes, louvers, deflectors). For example, the flow regulation system may passively divert a fraction of the flow between the catalytic path and the bypass path. In some examples, the flow regulation system may include active component.

[0120] In some implementations, the SCRS 520 may advantageously transfer heat generated at each of the reaction stages downstream through a bypass gas flow. For example, the bypass gas flow may advantageously reduce power requirements used for generating an input gas having a minimum light-off temperature associated with each reaction stages. Some embodiments for leveraging heat generated using the bypass gas flow are described with reference to Figures 1-4 in US2022 / 0094014.

[0121] As shown, a state diagram 528 representing an example control approach for a reactor stage is illustrated. The state diagram 528 may include a bypass state 530 and an activate state 532. The reactor stage may, for example, operate in the bypass state 530 when an effluent of a preceding stage exhibits one or more attributes below a first threshold (e.g., temperature, pressure, or concentration). When the effluent exceeds a defined threshold value (e.g., Threshold 1), the system may transition to the activate state 532, thereby initiating the corresponding catalytic stage. When the effluent later decreases below a lower threshold (e.g., Threshold 2), the system may return to the bypass state 530. For example, the thresholds 1 and 2 may be the same. In some examples, the thresholds may differ in magnitude to reduce hysteresis.

[0122] In some embodiments, some or all of the first reaction stage 502, .., the N-th reaction stage 508 may include integrated software and electronics for coordinated control. The catalytic stages and bypass mechanisms may communicate via wired or wireless interfaces. For example, one unit may function as a master control unit while others act as slave units. The master unit may transmitDocket No. 1036-07WO / US operational commands to the slave units, while the slave units may send feedback signals such as temperature, concentration, or system-status data.

[0123] In some implementations, the master unit may include wireless communication functionality for data transmission to a remote database, a cloud network, or a connected device such as a smartphone, tablet, or computer. A user operating a software application may transmit control commands to initiate, enable, or deactivate specific catalytic stages or bypass operations. In some examples, the state diagram 528, as illustrated, may facilitate control of reactor stages.

[0124] In some examples, the first reaction stage 502 through the N-th reaction stage 508 may be stacked units. The stacked units within the SCRS 520 may also employ various network topologies for control and coordination. These may include, for example, vertical networks, chain networks, circuit networks, wheel-and-spoke networks, and star networks. Such networked control may facilitate synchronized activation across multiple catalytic stages and may enhance adaptability to changing gas conditions.

[0125] In some embodiments, each reaction stage within the SCRS 520 may have a distinct light- off temperature determined by its physical and chemical configuration. For example, the light-off temperature of each stage may depend on factors such as catalyst material composition, catalyst loading, volumetric throughput, chamber volume, and / or heat transfer characteristics. In some implementations, one or more of the reaction stages may include the reactor 310. For example, the reactor 310 may represent an implementation of a single catalytic stage within the SCRS 520. Some example operating characteristics of some embodiments of the reactor 310 are illustrated and described with reference to FIG. 4.

[0126] Fig. 6A is a perspective view of a battery unit with an example dual-configurable venting catalytic system. The dual-configurable battery unit 600 includes a dual-configurable venting catalytic system 610. In some embodiments, a container 602 (e.g., the battery enclosure 102) may house one or more battery modules 104 configured to store and deliver electrical energy.

[0127] The dual-configurable battery unit 600 may operate in a closed-mode configuration 604 or an exhaust-mode configuration 606. In the closed-mode configuration 604, the unit may provide sealed containment to retain treated gases within the enclosure 602. This configuration may facilitate protection of internal components from environmental exposure and support maintenance of a controlled internal atmosphere.

[0128] In the exhaust-mode configuration 606, the unit may be configured to discharge treated gases from the enclosure 602 to the external environment. This mode may, for example, facilitate safe venting and pressure relief during thermal events or gas buildup within the battery unit.Docket No. 1036-07WO / US

[0129] The catalytic system 610 may be integrated within or mounted onto the enclosure 602. The catalytic system 610 may include one or more heated or non-heated catalytic stages configured to convert, oxidize, or chemically neutralize exhaust gases generated by the battery modules 104. The catalytic system 610 may, for example, reduce flammable, explosive, and / or toxic gas species (e.g., hydrogen, carbon monoxide, hydrocarbons) by promoting neutralization reactions that produce nonflammable and non-toxic effluent.

[0130] In some embodiments, the venting catalytic unit 610 may be installed on a battery container or other enclosure used for storage, transport, or operation of batteries. The unit may also be integrated with stacked or modular catalytic systems, each arranged in series or parallel as described in Figs. 7-9B, to accommodate various gas flow rates and configurations.

[0131] In some configurations, treated gases may be recirculated back into the enclosure (closed- loop operation) as implemented in Figs. 1-5 of US 2022 / 0094014, while in other configurations, treated gases may be vented externally. The configuration mode may be predetermined during installation or switchable by redirecting the outlet through a diverter, valve, or flow-control surface. In automated embodiments, one or more sensors within or external to the container 602 may provide feedback to an actuator or flow-control surface to selectively route the treated effluent.

[0132] Gases released during battery failure or thermal runaway may enter the catalytic system 610, where they may be directed through one or more reactive chambers. Each chamber may include catalytic material heated to a light-off temperature sufficient to initiate oxidation, adsorption, and / or decomposition reactions. The reactor may be multi-stage, wherein each downstream stage has a volume at least equal to or greater than its upstream stage, which may enable sequential activation by the heat and chemical composition of the upstream effluent.

[0133] For example, the dual-configurable battery unit 600 may include heat exchangers that thermally condition the gas stream to promote reaction efficiency. The resulting effluent — composed primarily of non-flammable and non-toxic gas species — may be discharged to the environment or recirculated into the enclosure, which may, for example, reduce internal pressure, mitigate fire risk, and lower toxic gas concentration below permissible exposure limits (PELs).

[0134] Fig. 6B shows an example catalytic heating system installed on top of a battery enclosure. In this example, the venting catalytic system 608 integrates multiple functional components designed to process, neutralize, and / or safely discharge gases released from the battery modules 104 housed within the battery enclosure 102.

[0135] The battery modules 104 may, for example, supply electrical power to system components, enabling continuous operation and ensuring the reliability of the mitigation process. For example, the TFG 108 may be introduced into the system through a dedicated inlet or manifold. For example,Docket No. 1036-07WO / US a dedicated inlet of the venting catalytic system 608 may, for example, provide flow control over a flow rate of the TFG 108. For example, the inlet may include a manifold structure may allow for distribution of the TFG 108 within the venting catalytic system 608. For example, the inlet may advantageously improve system safety.

[0136] In operation, for example, an inflow of the TFG 108 may trigger and / or initiate a catalytic reaction for conversion and neutralization of hazardous gases (e.g., produced during normal operation of the battery modules 104, in thermal runaway, in other abnormal events).

[0137] The venting catalytic system 608 includes the heated catalyst 212 in this example. The heated catalyst 212 may, for example, include a noble-metal or metal-oxide catalytic material. In some examples, this material may be disposed on a high-surface-area substrate. Upon reaching a light-off temperature, the heated catalyst 212 may, for example, promote neutralization reactions. These reactions may, for example, elevate the temperature of the flowing gas stream. This elevation in temperature may, for example, facilitate oxidation, adsorption, and decomposition of flammable or toxic gas species.

[0138] Downstream of the reaction chamber, for example, the CCU 120 may regulate gas temperature and remove residual particulates or condensates. The CCU 120 may, for example, act as a thermal control module that ensures the processed gas is conditioned for safe discharge, thereby improving system efficiency and maintaining structural integrity of downstream components.

[0139] In various embodiments, the venting catalytic system 608 may include multiple combustion architectures (e.g., the combustion chamber 406). These may, for example, include an enclosed can combustor. Some embodiments may include an annular combustor. A can-annular combustor may also be included in some embodiments. In some examples, a porous-media combustor may be used. Combustion architectures may, for example, oxidize or react the inflowing gas mixture.

[0140] In operation, gases released during a battery failure event may, for example, be drawn into the venting catalytic system 608 through natural convection, buoyancy, thermally induced flow, pressure differential, or forced convection. Some embodiments may include a fan or blower to actively assist this flow. The gases may pass through the heated catalyst 212, where reactive species are chemically neutralized or oxidized. Following this, in some examples, the gases may move through the CCU 120, where temperature and purity may be conditioned. The treated gases may be discharged through the STEG 112 into the environment surrounding the container 602.

[0141] In some examples, the venting catalytic system 608 may be installed directly on a battery rack or a container. For example, during operation, hazardous gases accumulated within the rack are exhausted through the venting catalytic system 608. Makeup air may be drawn in through dedicated inlets (e.g., the active entrainment unit 304), passive leakage paths, and / or actively regulated airDocket No. 1036-07WO / US supply systems. Various air entrainment systems, such as for the venting catalytic system 608, are described in Figs. 7-8 of US 2022 / 0094014 and Figs. 1-8 of PCT / US2023 / 061493, the entirety of which applications are incorporated herein by reference.

[0142] As shown, treated gas (e.g., the STEG 112) may be exhausted into the environment surrounding the battery enclosure 102. Some of such implementations are described with reference to Fig. 1 in US2022 / 0094014. For example, a venting catalytic unit (e.g., the venting catalytic system 608) may be installed on battery racks inside the battery enclosure 102 (e.g., the container). For example, battery gases that may accumulate in the rack will be vented or exhausted out of the rack into the container. Air may be drawn into the rack through purposely designed ports or leakage paths from the rack, and / or through a make-up air system. The make-up air system may be actively controlled as implemented in Figs. 7-8 in US2022 / 0094014. The make-up air system may also be passively controlled as implemented in Figs. 1-4 and 6-8 in PCT / US2023 / 061493. The entirety of the referenced applications are incorporated herein by reference.

[0143] Fig. 7A is a perspective view of an example venting catalytic system coupled to a vehicle battery pack 700. In an illustrative example without limitation, the vehicle battery pack 700 includes is centrally located (e.g., configured to power a vehicle). The venting catalytic system 608 is positioned along the vehicle chassis, suggesting its role in managing exhaust or emission control for enhanced vehicle performance.

[0144] As shown, the vehicle battery pack 700 is integrated into an electric automobile. In other examples, the vehicle battery pack 700 may be integrated in locomotives, buses, trucks, tractor trailers, construction vehicles, industrial machinery, industrial vehicles, mining vehicles, mining equipment, aircraft, ships, marine vehicles, submarines, submersibles, autonomous vehicles, spacecraft, scooters, motorcycles, bicycles, energy storage systems and / or other battery powered machines.

[0145] The mobile gas treatment system 702 unit is attached to the battery such that battery gases released during a thermal failure or thermal runaway event are passed out of the battery enclosure and into the venting catalytic unit. In some embodiments, the mobile gas treatment system 702 may be releasably deployed. For example, the mobile gas treatment system 702 may be temporarily attached to a vehicle battery pack to address events or to be attached during a specific process point (e.g, euring maintenance, testing, or thermal-management procedures, or positioned near buses, trains) that needs more safety. When attached, for example, toxic battery gases released during a thermal failure or thermal runaway event may be directed through ducts, nozzles, and / or orifices into one or more catalytic units of the mobile gas treatment system 702.Docket No. 1036-07WO / US

[0146] For example, the mobile gas treatment system 702, through physiochemical processes, may eliminate, react, and / or neutralize flammable and toxic species in the battery gas. The STEG 112 are exhausted out of the unit outlet into the environment outside of the vehicle battery pack 700.

[0147] In some embodiments, all or a portion of the STEG 112 may be diverted, exhausted, or recirculated back into the vehicle battery pack 700. The STEG 112 may, in some examples, act as a fire suppressant that dilutes the mixture of flammable battery gases accumulating in the battery headspace preventing them from igniting, suppresses secondary ignition events, and / or extinguishes combustion of the battery gases.

[0148] The mobile gas treatment system 702 may, for example, include fan(s) or blower(s) that may facilitate flow through the unit. Flow through the venting catalytic unit may, for example, be driven by pressure that may develop in the battery pack enclosure due to the release of battery gases into the pack enclosure headspace. Flow may also be facilitated through the unit by a combination of pressure from the pack and single or multiple fan(s). The battery pack enclosure may be in fluid contact with the inlet of the venting catalytic unit. A pressure check valve, pressure relief valve, one-way valve, flap valve, burst disk, or other pressure-activated flow control surface may be integrated between the outlet of the battery pack enclosure and the inlet of the venting catalytic unit. If the battery gases released during thermal runaway fill the headspace in the battery pack enclosure such that a particular pressure is reached, the pressure-activated flow control surface may actuate, burst, and / or open to permit battery gases to flow from the battery pack enclosure into the inlet of the venting catalytic unit. A PAIR system (e.g., the PAIR system 312) may, for example, be used to supply additional oxygen to the venting catalytic unit.

[0149] Fig. 7B is a block diagram of an example mobile gas treatment system. As shown, a mobile gas treatment system 702 includes an Input snorkel 704 and a catalytic system 706. The input snorkel 704 is the entry point through which gases are directed into the system. Within this system, the catalytic system 706 facilitates chemical reactions to process the gases. The internal fan 708 aids in circulating the gases, ensuring thorough treatment. For example, the internal fan 708 may facilitate flow through the mobile gas treatment system 702.

[0150] For example, the mobile gas treatment system 702 may be mounted on wheels and / or other transport mechanisms to allow relocation between different sites or enclosures. In some embodiments, the mobile gas treatment system 702 may be moved from one event location to another to treat battery gas release incidents as they occur. In other embodiments, the system may be temporarily attached to the outlet of a battery enclosure or energy storage container during maintenance, charging, or testing operations to provide supplemental catalytic treatment. Once the process is completed, the mobile gas treatment system 702 may be detached and redeployed to aDocket No. 1036-07WO / US different unit. The treated gas exits at the STEG 112, demonstrating the system’s effectiveness in transforming hazardous gases into safer forms.

[0151] In some embodiments, the Input snorkel 704 may direct battery gases into a catalytic chamber (e.g., the reaction chamber 206, the mixer reactor chamber 318, the first stage catalytic stage 114). The input snorkel 704 may, for example, include a flexible duct. In some examples, it may include a rigid duct. The input snorkel 704 may, for example, include a canopy. Some examples may include a combination of multiple conduits. These multiple conduits may, for example, channel gases from one or more sources into a single catalytic unit. In some examples, the conduits may channel gases into multiple catalytic units.

[0152] Partial enclosures may, for example, include fixed or temporary structures. Some examples may involve walls. Curtains may be used in some embodiments. In some implementations, rigid panels may be included. Various examples may utilize flexible covers. Liquid curtains may be used, for example, in certain situations. Some embodiments may incorporate gas curtains. The use of these structures may limit the spread of battery gases, for example.

[0153] Fig. 8 is a block diagram of an example stationary gas treatment system 800. In this example, the TFG 108 enters through the input snorkel 704. The catalytic system 706, in conjunction with the internal fan 708, processes the gas within the stationary setup. The treated gas exits at 112, indicating the system's capability to function effectively without mobility, distinguishing it from the mobile system in Fig. 7B.

[0154] For example, mobility may not be required. Instead of relocating the gas treatment system (e.g., the mobile gas treatment system 702), a battery system may be positioned near the stationary gas treatment system 800. For example, the input snorkel 704 may be attached to a gas outlet and / or placed over the battery system. For example, the stationary gas treatment system 800 may be used in controlled environments (e.g., maintenance facilities, charging stations) where the stationary gas treatment system 800 may provide a permanent or semi-permanent safety measure.

[0155] Fig. 9A is a perspective view of an example fire blanket 900 with an integrated catalytic system and battery. The fire blanket 900 may, for example, provide thermal insulation and protection for the components it covers, such as the underlying battery 904 and catalytic system 902. This configuration may help contain heat during a thermal event, reduce heat loss, and improve the efficiency of thermal regulation within the overall system.

[0156] The catalytic system 902, which may include or correspond to a multistage catalytic system (MSCS 110), is positioned on or integrated within the fire blanket 900. The fire blanket 900 may, for example, provide thermal insulation and protection for components it covers. In this example, the fire blanket 900 covers a catalytic system 902 and a battery 904. For example, the fire blanketDocket No. 1036-07WO / US900 may advantageously contain heat during a thermal event. In some examples, the fire blanket 900 may advantageously improve the efficiency of thermal regulation within the overall system.

[0157] In some implementations, the battery 904 may provide electrical energy to operate active components such as an electrically assisted heater or fan. In some implementations, the catalytic system 902 may include a separate power source.

[0158] The fire blanket 900, as illustrated, covers a battery unit. The catalytic system 902 is positioned on top of the fire blanket 900. In other embodiments, the catalytic system 902 may, for example, be located at other positions on the fire blanket 900. This positioning may, for example, facilitate improved operational efficiency. In some embodiments, the catalytic system 902 may be positioned within the fire blanket 900. Some configurations may, for example, enable more effective thermal management.

[0159] In some embodiments, the fire blanket 900 may be deployed over a failing battery (e.g., of a electric vehicle). For example, the fire blanket 900 may be installed over the electric vehicle that, for example, is experiencing a thermal event. As an illustrative example, the fire blanket 900 may smother active flames and prevent heat propagation to nearby equipment or systems. In some examples, gases released from failing battery may escape through vents (not shown) of the fire blanket 900. For example, the gases may be directed into the catalytic system 902 through these vents to be neutralized by the catalytic system 902.

[0160] In some implementations, the fire blanket 900 may include the Input snorkel 704 configured to establish a fluid communication with a region beneath the fire blanket 900. For example, the Input snorkel 704 may allow battery gases generated during a failure event to be directed from under the fire blanket 900 toward the catalytic system 902. In some implementations, the catalytic system 902 may include the PAIR system 312.

[0161] The catalytic system 902, for example, may be attached to and / or integrated with the fire blanket 900. For example, the fire blanket 900 may include one or more ducts, nozzles, and / or orifices that channel gases into a single or a multiple stacked catalytic systems. Within the catalytic system 902, chemical and physiochemical processes oxidize, react, and neutralize flammable or toxic gas species. The treated gases (e.g., the STEG 112) may be discharged through an outlet to a surrounding environment. In some embodiments, some or all of the treated gases may be redirected beneath the fire blanket to act as a suppressant, diluting and cooling the gas mixture accumulated under the cover. This process helps prevent ignition, suppress secondary combustion, and / or extinguish existing flames.

[0162] Flow through the catalytic system 902 may be promoted the internal fan 708 (e.g., fans, blowers). In some examples, the catalytic system 902 may include a passively induced airflow (e.g.,Docket No. 1036-07WO / US pressure driven airflow). In some examples, the catalytic system 902 may include a hybrid airflow system having both active and passive flow. For example, the hybrid airflow system may advantageously maintain a steady discharge of the STEG 112.

[0163] The fire blanket 900 may, in some examples, be in fluid communication with the catalytic unit catalytic system 902 through a pressure-activated flow control surface (e.g., a check valve, a relief valve, a flap valve, a burst disk, other one-way vent). When the internal pressure beneath the fire blanket 900 reaches a predetermined threshold, for example, the control surface may open or rupture to allow accumulated gases to flow into the catalytic system 902.

[0164] Fig. 9B is a diagram of an example venting catalytic system integrated onto a cover or enclosure mounted over a battery system. As shown, a catalytic system 906 is integrated within an enclosure 908. The catalytic system 906 may be configured to facilitate a series of toxic gas neutralization reactions in some embodiments. An example advantage may include increased control over reaction conditions.

[0165] The enclosure 908 houses a battery containing system 910. The battery containing system 910 may provide power to initiate reactions within the catalytic system 906. This configuration may reduce external power requirements.

[0166] The catalytic system 906 is mounted upon a mounting surface 912. The mounting surface 912 may, for example, offer stability and support for the overall assembly. This configuration could support maintaining system reliability and performance during operation.

[0167] Fig. 10 is a flowchart showing an example multi-stage catalytic system operation method. For example, a method 1000 may be performed by the SCRS 500 as described with reference to FIG. 5B. In step 1002, the method 1000 begins when a toxic or flammable gas is received. For example, the SCRS 500 may receive the TFG 108 from the battery enclosure 102.

[0168] In step 1004, a flow control unit is activated. For example, the SCRS 500 may activate the active or passive air entrainment system 132 (e.g., a fan, pressure-driven mechanism, other flowinducing component) to generate the make-up airflow 134 through the SCRS 500 reaction stages.

[0169] In step 1006, a first-stage heater is activated. For example, the SCRS 500 may energize an electrically assisted heater (e.g., the first stage heat source 130, the active heater 208) within the first reaction stage 502 to raise the temperature of a catalytic material to a light-off temperature of the first reaction stage 502.

[0170] At a decision point 1008, it is determined whether a next reaction stage is available. For example, a presence of the downstream stages 504 may receive effluent from the preceding stage. If no additional stage is available, a safe treated gas is output in step 1010, and the method 1000 ends.Docket No. 1036-07WO / USFor example, the SCRS 520 may discharge the STEG 112 back into the battery enclosure 102 to maintain a safe environment.

[0171] If a next stage is available, at a decision point 1012, it is determined whether a combined temperature of the effluent and an incoming make-up air (e.g., the make-up airflow 134) exceed a light-off temperature of the next stage. If the combined temperature does not exceed the light-off temperature, in step 1014, a make-up airflow to the next stage is reduced, and the decision point 1012 is repeated. For example, the active or passive air entrainment system 132 may reduce a quantity of the make-up airflow 134 to the next stage.

[0172] If the combined effluent and make-up air temperature exceeds the light-off temperature, in step 1016, the effluent is processed at the next stage. For example, the effluent may be directed through a downstream catalytic chamber.

[0173] Fig. 11 is a flowchart showing an example multi-stage catalytic system configuration method. For example, a method 1100 may be performed by an engineer designing the MSCS 110. In some implementations, the total number of stages (N) and general system architecture may be predetermined before initiating the method 1100.

[0174] In step 1102, characteristics and boundary conditions of a first reaction stage are determined. For example, an engineer may define a processing capacity and boundary conditions (e.g., chamber volume, nozzle diameters, and allowable pressure drop) of a first reaction stage (e.g., the first stage catalytic stage 114 of the MSCS 110). The boundary conditions may, for example, be determined based on an expected gas composition, anticipated flow rate, and targeted output concentration of the STEG 112.

[0175] In step 1104, an output temperature of an effluent of the first reaction stage is calculated based on the processing capacity. For example, the engineer may calculate the expected effluent temperature resulting from a catalytic reaction within the first stage catalytic stage 114. The output temperature may be derived from energy balance equations incorporating exothermic heat release and flow conditions of the TFG 108 received from the battery enclosure 102.

[0176] In step 1106, the amount of make-up air or bypass air is determined such that a temperature of an air mixture of the effluent and the make-up air is larger than a light-off temperature. For example, the make-up airflow 134 may be generated by the active or passive air entrainment system 132.

[0177] In step 1108, a volume of catalytic material and corresponding reactor geometry are determined for the next stage based on the predicted mixture flow rate and desired conversion efficiency. For example, the subsequent stage may be larger or smaller in volume than a precedingDocket No. 1036-07WO / US stage. For example, the final stage of the SCRS 500 may be smaller based on a target quality of STEG 112.

[0178] In step 1110, a flow model predicts the proper make-up air and battery gas distribution across the series of stages. For example, the flow model may determine a temperature and / or gas components of effluent at each stage. At decision point 1112, it is determined whether the predicted battery-gas neutralization meets the desired level (e.g., a predetermined safety threshold). If the predicted battery-gas neutralization does not meet the desired level, the boundary conditions are adjusted in step 1114. For example, the geometry, flow restrictions, or catalytic material of the MSCS 110 may be adjusted. If the predicted battery -gas neutralization meets the desired level, the method 1100 ends.

[0179] Design variables, such as input and outlet nozzle diameters, may be specified. Such variables may, for example, improve flow distribution and pressure conditions across the reaction stages. Iterative optimization programs may be utilized to balance flow rates and heating efficiency. This configuration may, for example, provide means to reduce overall energy usage while maintaining desired temperature gradients. Space efficiency may also be enhanced through compact integration of thermally coupled stages.

[0180] Some embodiments may, for example, provide adaptability based on the chemical composition of incoming gases and the desired reaction outcomes. For example, catalyst selection, stage sizing, or bypass logic thresholds may be adjusted according to reactive species, flow rate, or safety requirements. Applications of this system may include scenarios requiring efficient energy utilization, adaptable reaction management, and improved operational reliability. Compact configuration and primarily passive operation may be advantageous for portable, enclosed, or low- maintenance systems.

[0181] Accordingly, various embodiments may advantageously provide a modular framework for designing thermally self-propagating catalytic systems that achieve efficient neutralization of toxic or flammable gases while reducing dependence on external power and complex controls.

[0182] For example, some systems may include a computer(s) device having a processor(s) operably coupled to memory and storage. The storage may include a program(s) of instructions implementing one or more embodiments of the method 1100. The processor(s) may, for example, execute the program of instructions. Accordingly, the method 1100 may, for example, automatically generate a data structure defining a plurality of stages and associated parameters, such as disclosed at least with reference to Fig. 11.

[0183] Although various embodiments are shown and described, other embodiments are contemplated.Docket No. 1036-07WO / US

[0184] For example, some embodiments may be configured for a variety of use cases, including medical, industrial, residential, commercial, retail, foodservice, transportation, and military applications.

[0185] Some embodiments may, for example, encompass a range of supporting components, including display technologies, chip technologies, interface technologies, power-supply and powerstorage systems, server architectures, personal device architectures, portable computing devices, and / or software architectures.

[0186] For example, processor(s) may include central processing units (CPUs). CPUs may, for example, serve as the ‘brain’ of computer systems, such as by executing instructions and / or processing data, for example. A processor may, for example, include an arithmetic logic unit (ALU), a control unit, and / or numerous registers. Processor(s) may, for example, include graphics processing units (GPUs). GPUs may, for example, be configured to render images, videos, and / or animations. GPUs may, for example, advantageously provide greater speed for parallel processing tasks. Accordingly, GPUs may, for example, be advantageously used for tasks requiring intensive graphical computations.

[0187] Some embodiments may, for example, include application-specific integrated circuits (ASICs). ASICs may, for example, be custom-designed circuits (e.g., chips) tailored for specific applications. ASICs may, for example, provide high performance and efficiency.

[0188] Some embodiments may, for example, include field-programmable gate arrays (FPGAs). FPGAs may be configured, for example, as reconfigurable chips that can be programmed to perform various functions. FPGAs may, for example, advantageously be used in prototyping and / or specialized computing tasks.

[0189] Microprocessors may, for example be configured as general -purpose chips. Microprocessors may, for example, execute instructions from software applications. As such, microprocessors may advantageously be utilized, for example, in a wide range of devices, from desktop computers to embedded systems.

[0190] Memory modules, may, for example, include volatile memory (RAM) and / or non-volatile memory (ROM). RAM may, for example, be used for temporary data storage. ROM may, for example, store firmware and / or system-level software.

[0191] Storage devices may include, for example, hard disk drives (HDDs), solid-state drives (SSDs), and / or optical drives. Storage devices may, by way of example and not limitation, store a device operating system(s), applications, and / or user data.

[0192] Input / output (VO) interfaces may include, by way of example and not limitation, data ports, graphics ports, and / or audio ports. Data ports may include, for example, USB ports (e.g., USB-A,Docket No. 1036-07WO / USUSB-C, USB-Mini, USB-Micro), Ethernet (e.g., RJ45), SATA ports, serial and / or parallel ports. Graphics ports may include, for example, HDMI ports, VGA ports, and / or Display Port ports. Some ports may, for example, be multi-purpose (e.g., USB-C may carry audio, graphics, and / or other data). Audio ports may include, for example, audio jacks. VO interfaces may, for example, facilitate communication between the computer and peripheral devices.

[0193] Various embodiments may include one or more power supply and / or storage technologies. For example, power supplies may convert electrical power from an outlet into usable power for a device’s components. A power supply may, for example, include one or more transformers, rectifiers, and / or regulators. Batteries may, for example, advantageously provide portable power for devices such as laptops, smartphones, and tablets. Batteries of one or more chemistries may be used, including, by way of example and not limitation, lithium-ion and / or nickel-metal hydride.

[0194] In some embodiments, devices disclosed herein may be configured as and / or connected in a server architecture. A server architecture may, for example, be configured to advantageously provide scalable computing resources, such as in enterprise environments, for example. Some embodiments may, for example, include blade servers. Blade servers may, for example, be configured as modular servers that fit into a chassis, which may advantageously allow for high- density computing and / or optimize space and / or power efficiency in data centers. Rack servers may, for example, be configured to be mounted in standardized racks. Rack servers may, for example, advantageously provide scalable computing resources. Cloud servers may, for example, include virtualized servers, which may be hosted in data centers. Cloud servers may, for example, advantageously offer flexible and / or scalable resources to users over the internet.

[0195] In some embodiments, devices disclosed herein may be configured as and / or connected to a personal device architecture, for example. Personal device architectures may include, for example, desktop computers. A desktop computer may, for example, include a tower, monitor, keyboard, and mouse, and may be used, for example, for a wide range of applications, from office work to gaming. Laptops may, for example, be configured as portable computers. The portable computers may, for example, integrate a display, keyboard, and position input (e.g., track pad) into a single unit. Laptops may, for example, be used for mobile computing and may, for example perform many of the same tasks as desktops. Portable personal computing devices may, by way of example and not limitation, include smartphones. Smartphones may be configured, for example, as compact devices that combine computing capabilities with telecommunication functions. These devices may include, by way of example and not limitation, touchscreens, cameras, and / or various sensors. Portable personal computing devices may include, for example, smartwatches. Smartwatches may, for example, be configured as wearable devices. Smartwatches may, for example, provide notifications,Docket No. 1036-07WO / US fitness tracking, and / or other functionalities. Smartwatches may, for example, be configured to pair with smartphones and / or other computer(s) for extended capabilities. Portable personal computing devices may, for example, include tablets. Tablets may, for example, be configured as portable devices with touchscreens larger than smartphones. Tablets may, for example, advantageously be used for tasks such as web browsing, media consumption, and / or productivity applications.

[0196] Engines and / or modules disclosed herein may be configured in one or more software architectures. Software architectures may, for example, include operating systems. Operating systems may, for example, manage hardware resources and / or provide a platform for running applications.

[0197] Software architectures may, for example, include application software. Application software may include, for example, programs designed for specific tasks.

[0198] Software architectures may, for example, include middleware. Middleware may, for example, be configured to provide services to software applications beyond those offered by the operating system. Middleware may, for example, include components such as web servers, database management systems, and / or message brokers.

[0199] Software architectures may include, for example, firmware. Firmware may, for example, be configured as low-level software embedded in hardware devices. Firmware may, for example, controls functions of the hardware devices. Firmware may, by way of example and not limitation, be stored in ROM and / or flash memory.

[0200] Software architectures may, for example, include virtualization technology. Virtualization technology may, for example, be configured to allow multiple virtual machines to run on a single physical machine. Virtualization technology may, for example, advantageously enable efficient resource utilization and / or isolation.

[0201] Various embodiments may, for example, include connection and / or communication technologies. Such technologies may, by way of example and not limitation, be configured to facilitate the exchange of data across various distances and / or environments. Long-range communication technologies may, by way of example and no t limitation, include cellular networks, satellite communications, and / or broadband internet connections. Cellular networks, such as 4G LTE and 5G, may advantageously provide wireless connectivity over large areas. Cellular networks may, for example, enable devices (e.g., mobile devices) to access the internet, make calls, and / or otherwise transmit data. Satellite communications may, for example, advantageously provide global coverage, which may be particularly useful in remote and / or underserved regions where terrestrial infrastructure is limited. Broadband internet connections may include, by way of example and not limitation, fiber-optic, DSL, and / or cable. Broadband may, for example, advantageously provideDocket No. 1036-07WO / US high-speed internet access to devices such as for activities including streaming, online gaming, and / or remote work.

[0202] Local communication technologies may, for example, encompass methods for connecting devices within a limited area, such as a home, office, and / or campus. Local communication technologies include, for example, Wi-Fi. Wi-Fi may, for example, connect device(s) to a wireless local area network (WLAN) and / or access the internet and / or share resources (e.g., printers, storage). Wired communication technology, such as Ethernet, may, for example, advantageously provide reliable and / or high-speed connections between devices in a local network, such as, by way of example and not limitation, desktops, servers, and / or network switches. Power-line communication (PLC) may, for example, enable data transmission over existing electrical wiring. PLC may, for example, advantageously provide an alternative for connecting devices in locations where Wi-Fi signals may be weak or unreliable.

[0203] As an illustrative example, a multistage catalytic system may include a first stage. The first stage may have a reaction chamber containing a catalytic material. An electrically assisted heater may initiate a toxic gas neutralization reaction. A fan may drive airflow into the reaction chamber of the first stage. Several downstream stages may be arranged in series with the first stage. Each downstream stage may have a catalytic reaction chamber. The chamber may receive effluent from a preceding stage. For example, each downstream stage may include a reaction chamber configured to at least partially neutralize toxic gas in the effluent. The distribution may be based on differential pressure. The downstream stages may activate sequentially. This sequence may depend on a predetermined attribute of the effluent. For example, a flammable gas mixture in the effluent may be neutralized.

[0204] The electrically assisted heater may include an electrical resistance heater. The heater may reach a temperature sufficient to activate the catalytic material.

[0205] Each downstream stage may be thermally connected to its preceding stage. This connection may help sustain exothermic propagation without further active heating.

[0206] The volume of each subsequent stage may be greater than the volume of the preceding stage between a first stage and a last stage, for example. For example, the subsequent stage may be activated by the heat of the effluent from the preceding stage.

[0207] The catalytic material may include a precious-metal catalyst located on a high-surface-area substrate.

[0208] A housing may be included that has a modular stack. This stack may hold the first stage and the downstream stages.Docket No. 1036-07WO / US

[0209] The system may operate in a closed loop. The output gas concentration may be maintained below a certain threshold within the housing.

[0210] As an illustrative example, a multistage catalytic system may include multiple reaction stages connected in series. Each stage may have a catalytic reaction chamber containing catalytic material. It may receive gas flow from an upstream stage and deliver effluent to a downstream stage. A first stage may include a heat source. This heat source may start a catalytic reaction. Subsequent downstream stages may activate passively. This activation may occur when the effluent from the preceding stage is above a certain threshold.

[0211] The heat source may be either an electrical heater or a chemical heater.

[0212] Airflow through the series of reaction stages may be provided by a passive pressure differential between adjacent stages.

[0213] The volume of each subsequent stage may be greater than the volume of the preceding stage between a first stage and a last stage. This allows the subsequent stage to activate through the heat of the effluent from the preceding stage.

[0214] The first stage may include an electrically assisted heater. This heater may start a neutralization reaction. A fan may drive airflow into the catalytic reaction chamber of the first stage.

[0215] The electrically assisted heater may be an electrical resistance heater. It may reach a temperature sufficient to activate the catalytic material of the first stage.

[0216] Each downstream stage may be thermally connected to its preceding stage. This connection may help sustain exothermic propagation without further active heating.

[0217] The catalytic material may include a precious-metal catalyst on a substrate.

[0218] The catalytic material of each stage may feature a metal -oxide catalyst located on a substrate.

[0219] A housing may be included. A modular stack may be used to mount the response stages.

[0220] The system may operate in a closed loop. The output gas concentration may be kept below a certain threshold inside the housing.

[0221] In some examples, a method for designing a multistage catalytic system may include defining multiple reaction stages connected in series. Each stage may chemically neutralize a toxic or flammable gas mixture. The stages may generate thermal energy to sustain downstream activation. The volume of each downstream stage may be at least equal to or greater than an upstream stage between a first stage and a last stage.

[0222] Boundary conditions of the first stage may include chamber volume and target processing volume. An output temperature may be calculated based on those conditions. Next, conditions forDocket No. 1036-07WO / US the downstream stage may include a larger volume. A light-off temperature may be determined based on those conditions. Verification may occur to see if the light-off temperature is less than the output temperature of the preceding stage. This way, the downstream stage may activate passively. This process may be repeated until the desired gas-neutralization efficiency is reached. The stages may be configured for activation without additional external heating.

[0223] The boundary conditions may be adaptively adjusted to balance flow, time, and thermal coupling between stages. Airflow activation between stages may be based on pressure differential generated by the effluent of the preceding stage.

[0224] As used in the claims, comprising and consisting are used in the United States open-ended and closed-ended sense, respectively.

[0225] It will be understood that various modifications can be made within the scope of this disclosure. Embodiments depict illustrative combinations of disclosed features, components, and / or steps. Any combination of disclosed features is expressly contemplated unless specifically excluded or required by the context. For example, one or more advantageously results may be achieved if components are removed, added, multiplied, scaled, and / or rearranged, and / or if steps in a method are omitted, added, repeated, and / or performed in a different order. Therefore, other implementations are contemplated within the scope of the following claims.

Claims

1. Docket No. 1036-07WO / USClaims1. A multistage catalytic battery off-gas neutralization system, comprising: a first stage comprising a reaction chamber containing a catalytic material and an electrically assisted heater configured to initiate a toxic gas neutralization reaction; a plurality of downstream stages arranged in series with the first stage; a fan configured to drive airflow into the reaction chamber of the first stage and the plurality of downstream stages; wherein each the plurality of downstream stages comprises: a catalytic reaction chamber configured to receive effluent from a preceding stage; and a reaction chamber configured to at least partially neutralize toxic gas in the effluent; wherein the plurality of downstream stages are configured to achieve sequential activation based on a predetermined attribute of the effluent, such that a flammable gas mixture in the effluent is neutralized.

2. The multistage catalytic battery off-gas neutralization system of claim 1, wherein the electrically assisted heater comprises an electrical resistance heater configured to reach a light- off temperature sufficient to activate the catalytic material.

3. The multistage catalytic battery off-gas neutralization system of any one of claims 1-2, wherein each of the plurality of downstream stages is thermally coupled to its preceding stage to sustain exothermic propagation without additional active heating.

4. The multistage catalytic battery off-gas neutralization system of any one of claims 1-3, wherein, between a first stage and a last stage, a volume of each subsequent stage is greater than a volume of a preceding stage, wherein the subsequent stage is configured to be activated by a heat of the effluent received from the preceding stage.

5. The multistage catalytic battery off-gas neutralization system of any one of claims 1-4, wherein the catalytic material comprises a precious-metal catalyst disposed on a high-surface-area substrate.

6. The multistage catalytic battery off-gas neutralization system of any one of claims 1-5, further comprising a housing, wherein the housing comprises a modular stack configured to mount the first stage and the plurality of downstream stages.Docket No. 1036-07WO / US7. The multistage catalytic battery off-gas neutralization system of claim 6, wherein the multistage catalytic system is configured to operate in a closed loop, such that an output gas concentration within the housing is maintained below a predetermined threshold.

8. A multistage catalytic system comprising: a plurality of reaction stages connected in series, each stage comprising a catalytic reaction chamber comprising a catalytic material, and configured to receive a gas flow from an upstream stage and deliver effluent to a downstream stage, wherein: a first stage of the plurality of reaction stages comprises a heat source configured to initiate a catalytic reaction, and each subsequent downstream stage is configured to be passively activated when the effluent received from the immediately preceding stage possesses an attribute above a predetermined threshold.

9. The multistage catalytic system of claim 8, wherein the system is configured as a battery off-gas neutralization system.

10. The multistage catalytic system of any one of claims 8-9, wherein an intake port feeding the first stage is fluidly coupled to receive a fluid stream from a container containing batteries.

11. The multistage catalytic system of claim 10, wherein a discharge port from a last of the downstream stages is fluidly coupled to discharge into the container.

12. The multistage catalytic system of any one of claims 8-11, wherein the heat source comprises an electrical heater and / or a chemical heater.

13. The multistage catalytic system of any one of claims 8-12, wherein airflow through the series of reaction stages is provided by a passive pressure differential between adjacent reaction stages.

14. The multistage catalytic system of any one of claims 8-13, wherein: between a first stage and a last stage, a volume of each subsequent stage is greater than a volume of a preceding stage, and the subsequent stage is configured to be activated by a heat of the effluent received from the preceding stage.

15. The multistage catalytic system of any one of claims 8-14, wherein the first stage comprises: an electrically assisted heater configured to initiate a neutralization reaction; and a fan configured to drive airflow into the catalytic reaction chamber of the first stage.Docket No. 1036-07WO / US16. The multistage catalytic system of claim 15, wherein the electrically assisted heater comprises an electrical resistance heater configured to reach a light-off temperature sufficient to activate the catalytic material of the first stage.

17. The multistage catalytic system of any one of claims 8-16, wherein each downstream stage of the plurality of reaction stages is thermally coupled to its preceding stage such that exothermic propagation is sustained without additional active heating.

18. The multistage catalytic system of any one of claims 8-17, wherein the catalytic material comprises a precious-metal catalyst disposed on substrate.

19. The multistage catalytic system of any one of claims 8-18, wherein the catalytic material of each stage comprises a metal-oxide catalyst disposed on substrate.

0. The multistage catalytic system of any one of claims 8-19, further comprising a housing, wherein the housing comprises a modular stack configured to mount the plurality of reaction stages.

1. The multistage catalytic system of claim 20, wherein the multistage catalytic system is configured to operate in a closed loop, such that an output gas concentration within the housing is maintained below a predetermined threshold.Docket No. 1036-07WO / US22. A method of configuring a multistage catalytic system, comprising: defining a plurality of reaction stages connected in series, wherein: each reaction stage is configured to chemically neutralize a toxic or flammable gas mixture and to generate thermal energy sufficient to sustain activation of a downstream stage, and between a first stage and a last stage, a volume of each downstream stage is at least equal to or greater than a volume of an upstream stage; determining boundary conditions of a first reaction stage comprising chamber volume and a target gas processing volume; calculating an output temperature of an effluent of the first reaction stage based on the boundary conditions; determining next boundary conditions of a next reaction stage downstream, wherein the next reaction stage has a larger volume than a preceding stage; determining a light-off temperature of the next reaction stage based on the next boundary conditions; verifying that the light-off temperature of the next reaction stage is less than a target output temperature of the preceding stage so that the next reaction stage is passively activated by the effluent of the preceding stage; and repeating the determining and verifying steps for subsequent downstream stages until a desired gas-neutralization efficiency is achieved, such that the plurality of reaction stages are configured for sequential, self-propagating activation without additional external heating.

3. The method of claim 22, wherein the boundary conditions are iteratively adjusted to balance flow distribution, residence time, and thermal coupling between adjacent stages, and wherein airflow between the reaction stages is configured to be activated based on differential pressure generated by the effluent of the preceding stage.

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