Method of controlling battery pack humidity utilizing an active reactivation system

1. A method of controlling battery pack humidity, the method comprising the steps of:

providing a first air passageway between a battery pack enclosure and a desiccant enclosure, wherein said battery pack enclosure is configured to hold a plurality of batteries and said desiccant enclosure is configured to contain a volume of desiccant;

providing a second air passageway between said desiccant enclosure and a volume of air external to said battery pack enclosure and external to said desiccant enclosure;

removing water vapor from said battery pack enclosure, wherein said water vapor is absorbed and adsorbed by said volume of desiccant;

determining if said volume of desiccant has lost absorption/adsorption efficacy;

outputting a first heater control signal when it is determined that said volume of desiccant has lost absorption/adsorption efficacy;

closing said first air passageway and opening said second air passageway after receipt of said first heater control signal;

heating said volume of desiccant in situ within said desiccant enclosure upon receipt of said first heater control signal, wherein said step of heating said volume of desiccant further comprises the step of reactivating said volume of desiccant;

outputting a second heater control signal after a preset period of time has passed since initiation of said step of heating said volume of desiccant;

opening said first air passageway and closing said second air passageway after receipt of said second heater control signal; and

terminating said heating step upon receipt of said second heater control signal.

2. The method of claim 1 , the method further comprising the step of actively circulating air through said first air passageway and between said battery pack enclosure and said desiccant enclosure while performing said steps of removing said water vapor from said battery pack enclosure and absorbing and adsorbing said water vapor by said volume of desiccant.

3. The method of claim 1 , the method further comprising the step of actively circulating air through said second air passageway and between said desiccant enclosure and said volume of air while performing said steps of heating said volume of desiccant and reactivating said volume of desiccant.

4. The method of claim 1 , the method further comprising the step of opening said first air passageway and closing said second air passageway prior to receipt of said first heater control signal and upon receipt of a system initialization signal.

5. The method of claim 1 , wherein said step of opening said second air passageway is delayed for a predetermined period of time after receipt of said first heater control signal.

6. The method of claim 1 , wherein said step of determining if said volume of desiccant has lost absorption/adsorption efficacy further comprises the steps of:

determining elapsed time since receipt of a system initialization signal;

comparing said elapsed time to a preset time period; and

outputting said first heater control signal when said elapsed time exceeds said preset time period.

7. The method of claim 6 , wherein after performing said step of outputting said first heater control signal, said method further comprises the step of recording a new system initialization signal.

8. The method of claim 6 , wherein after performing said step of outputting said second heater control signal, said method further comprises the step of recording a new system initialization signal.

9. The method of claim 1 , wherein said step of determining if said volume of desiccant has lost absorption/adsorption efficacy further comprises the steps of:

monitoring humidity within said battery pack enclosure;

comparing said humidity to a preset humidity level; and

outputting said first heater control signal when said humidity exceeds said preset humidity level.

10. The method of claim 1 , wherein said step of determining if said volume of desiccant has lost absorption/adsorption efficacy further comprises the steps of:

monitoring humidity within said desiccant enclosure;

comparing said humidity to a preset humidity level; and

outputting said first heater control signal when said humidity exceeds said preset humidity level.

11. The method of claim 1 , wherein after said step of outputting said first heater control signal and prior to performing said step of heating said volume of desiccant the method further comprises the steps of:

determining if an electric vehicle containing said battery pack is in-service or out-of-service;

performing said step of heating said volume of desiccant if said electric vehicle is out-of-service; and

delaying said step of heating said volume of desiccant if said electric vehicle is in-service, wherein said delaying step is performed until said electric vehicle is out-of-service.

12. The method of claim 11 , further comprising the step of determining if said electric vehicle is parked, wherein said electric vehicle is out-of-service if said electric vehicle is parked.

13. The method of claim 11 , further comprising the step of determining if said battery pack is coupled to a charging system and a charging source, wherein said electric vehicle is out-of-service if said battery pack is coupled to said charging system and said charging source.

14. The method of claim 11 , further comprising the steps of determining a time of day and determining if said time of day is within a preset time range, wherein said electric vehicle is out-of-service if said time of day is within said preset time range.

15. The method of claim 1 , wherein said step of heating said volume of desiccant in situ within said desiccant enclosure further comprises the steps of:

activating a heating element located in an air heating chamber within said desiccant enclosure, wherein said heating chamber is separate from a desiccant chamber containing said volume of desiccant; and

circulating heated air from said air heating chamber through said desiccant chamber.

16. The method of claim 15 , further comprising the step of positioning a plurality of thermally conductive structures throughout said desiccant chamber, wherein said step of heating said volume of desiccant in situ further comprises the steps of heating said plurality of thermally conductive structures with said heating element, wherein said plurality of thermally conductive structures transfer heat from said heating element to said volume of desiccant.

17. The method of claim 1 , wherein said step of heating said volume of desiccant in situ within said desiccant enclosure further comprises the step of activating a heating element located within said volume of desiccant within said desiccant enclosure.

18. The method of claim 17 , wherein said step of heating said volume of desiccant further comprises the step of circulating air throughout said desiccant enclosure.

19. The method of claim 17 , further comprising the step of positioning a plurality of thermally conductive structures throughout said desiccant chamber, wherein said step of heating said volume of desiccant in situ further comprises the steps of heating said plurality of thermally conductive structures with said heating element, wherein said plurality of thermally conductive structures transfer heat from said heating element to said volume of desiccant.

20. The method of claim 1 , wherein said step of heating said volume of desiccant in situ within said desiccant enclosure further comprises the steps of:

activating a heating element located in an air heating chamber separate and remote from said desiccant enclosure; and

circulating heated air from said air heating chamber through said desiccant enclosure.