Patents Assigned to Robert Bosch Battery Systems, LLC
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Patent number: 11638948Abstract: A forming device is configured to form metal laminated sheet material into a tray-shaped case half while allowing the material to form pleats in the corners of the recess during the forming process while preventing formation of pleats along the flange. The device forms the flange so that excess material in the corners of the case halves is arranged in an undulating shape. As a result, the flange has a waved or ruffled configuration at each corner. Two such case halves are sealed together along the flange to form a reliably sealed package. A method of forming pouch cell is also described.Type: GrantFiled: November 22, 2017Date of Patent: May 2, 2023Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Mark Kotik, Eugene Levin, David Sarazin
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Patent number: 11588183Abstract: An electrochemical cell includes a cell housing and an electrode assembly disposed in the cell housing. The electrode assembly includes an electrode pair that is arranged to form a winding having a polygonal spiral wound shape in which a radius of the corner portions of each turn of the winding is constant, regardless of the number of turns. In addition, a length of the linear portions of one turn of the winding is different than a length of the linear portions of another turn of the winding. Since each turn of the winding includes the corner portions having a desired radius, the volumetric efficiency of the electrode assembly including the winding within a cell housing is improved relative to some cells that use conventional windings. An apparatus and method of forming a polygonal spiral wound winding are disclosed.Type: GrantFiled: December 20, 2018Date of Patent: February 21, 2023Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Mehul Botadra, Eugene Levin, Mark Kotik, Paul Frick
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Patent number: 11424501Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.Type: GrantFiled: August 8, 2020Date of Patent: August 23, 2022Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Robert Schoenherr, Mehul Botadra
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Patent number: 11152670Abstract: A battery system includes a pair of current collectors that are configured to provide a parallel electrical connection between electrochemical cells of a cell array. The pair of current collectors includes a first current collector plate that provides an electrical connection between the ends of the respective cells, and a second current collector plate that includes openings that receive the cells therein, and provide an electrical connection between the sidewalls of the respective cells. The current collectors are each on the same end of the cells and the opposed end of the cell can be protected or electrically isolated for a multitude of functions, such as cell cooling.Type: GrantFiled: December 6, 2018Date of Patent: October 19, 2021Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Mark Kotik
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Patent number: 11139541Abstract: A battery system includes a first battery cell that is electrically connected to a second battery cell via directed contact between compliant terminals of the first and second battery cells. The compliant terminals include a first end that is electrically connected an electrode assembly disposed within the cell, a second end disposed outside the cell, and an elastically compliant portion disposed between the second end and a cell housing.Type: GrantFiled: September 28, 2016Date of Patent: October 5, 2021Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Robert Schoenherr
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Patent number: 11046017Abstract: The sealing device includes a heatable base plate that cooperates with a heatable split plate to simultaneously form three intersecting seal lines. The split plate includes an alpha plate and a beta plate. The alpha plate and the beta plate each include a first heated surface that cooperate with the base heated surface to form a pair of co-linear seal lines. In addition, the alpha plate and the beta plate each include a second heated surface that cooperate together to form a third seal line that extends in a direction perpendicular to the co-linear seal lines and intersects the co-linear seal lines. A method of forming a complex seal joint is also described.Type: GrantFiled: October 31, 2017Date of Patent: June 29, 2021Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: David Naughton
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Patent number: 11050103Abstract: An electrochemical cell includes a housing, and an electrode assembly disposed in the housing. The electrode assembly comprises a positive electrode, a negative electrode and a separator disposed between the positive electrode and the negative electrode. The housing is formed of a first case half and a second case half. Each case half is formed of a metal foil laminate material and includes a wedge-shaped central recess that is surrounded by a flange. The flange of the first case half is joined to the flange of the second case half along a seal line that surrounds the respective central recesses. The central recesses cooperate to define an interior space of the housing that contains the electrode assembly, and the interior space has the shape of a rectangular prism. The seal line extends along a diagonal of a side of the rectangular prism. A method of forming the housing is described.Type: GrantFiled: July 9, 2019Date of Patent: June 29, 2021Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Eugene Levin
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Patent number: 10992005Abstract: An electrochemical pouch cell includes a pouch cell housing and an electrode assembly disposed in the housing. The housing is formed of a single blank that is progressively drawn to form first and second recesses in the sheet, where the first recess coincides with a portion of the second recess. The blank is then folded so that the recesses are aligned and open facing each other. The electrode assembly is disposed in the space defined within and between the recesses, and flange portions of the material surrounding the recesses are sealed together to form a sealed electrochemical cell in which one side of the cell is free of the flange. The progressive drawing process along with the configuration of the recesses allows the cell housing to have an increased depth relative to some conventional pouch cell housings.Type: GrantFiled: December 6, 2018Date of Patent: April 27, 2021Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Eugene Levin
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Patent number: 10991990Abstract: An electrochemical cell has a flexible low-profile sensor device that includes a solid state device or series of solid state devices on a common carrying material that enable the device(s) to sense battery cell conditions and actively perform cell control functions. At least a portion of the sensor device resides outside the cell. When arranged in a stack, cells including the sensor automatically form a communication network.Type: GrantFiled: April 10, 2017Date of Patent: April 27, 2021Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Mark Kotik
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Patent number: 10797272Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and an elastic restraint that surrounds a plate stack of the electrode assembly.Type: GrantFiled: September 28, 2016Date of Patent: October 6, 2020Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Robert Schoenherr
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Patent number: 10777784Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.Type: GrantFiled: September 28, 2016Date of Patent: September 15, 2020Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Dan Schneider, Mehul Botadra, Robert Schoenherr
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Patent number: 10770730Abstract: A pouch cell (20A, 20) includes a generally rectangular cell housing (20, 21) formed of a metal laminated film, an electrode assembly (60) that is sealed within the cell housing (20, 21), and a current collector device disposed in the cell housing (20, 21). The electrode assembly (60) includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis (66). The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing (20, 21) via an opening (28, 428) formed in the cell housing (20, 21). The opening (28, 428) is formed in a side (22, 24) wall of the cell housing (20, 21) at a location spaced apart from the sealed joint (40) that closes the cell housing (20, 21) and at a location facing the stack axis (66).Type: GrantFiled: December 6, 2016Date of Patent: September 8, 2020Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Adam Bisaro, Mark Kotik, Robert Schoenherr
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Patent number: 10734618Abstract: A battery module incorporates features of both prismatic housings and metal foil laminate pouch housings, and is configured to receive and support electrochemical cells. The battery module housing includes a rigid tubular frame and flexible cover elements that are joined to the frame and close the open ends of the frame. The frame has an inner surface that faces the cells, an outer surface that is opposed to the inner surface, a first edge that joins the inner surface to the outer surface at one open end of the frame, and a second edge that joins the inner surface to the outer surface at the opposed open end of the frame. The first cover element overlies and closes the one open end of the frame and the second cover element overlies and closes the other open end of the frame.Type: GrantFiled: December 5, 2017Date of Patent: August 4, 2020Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventor: Christopher Millon
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Patent number: 10698033Abstract: A method for current sensor fault detection in a battery system comprises receiving a sequence of battery voltage samples from a voltage sensor configured to measure a battery voltage of a battery and a sequence of battery current samples from a current sensor configured to measure a battery current of the battery; determining a change in the battery voltage samples over a predetermined number of samples and a change in the battery current samples over the predetermined number of samples; checking whether a ratio of the change in the battery voltage samples and the change in the battery current samples is within an expected range for one of (i) a resistance of the battery and (ii) a conductance of the battery; and detecting a fault in the current sensor based on whether the ratio is within the expected range.Type: GrantFiled: December 21, 2017Date of Patent: June 30, 2020Assignees: Robert Bosch Battery Systems, LLC, Robert Bosch GmbHInventors: Blake Joseph Riley, Carlton Brown
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Patent number: 10476049Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and a current collector device disposed in the cell housing. The electrode assembly includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis. The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing via an opening formed in the cell housing. The opening is formed in a side wall of the cell housing at a location spaced apart from the sealed joint that closes the cell housing and at a location facing the stack axis.Type: GrantFiled: July 17, 2017Date of Patent: November 12, 2019Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Robert Schoenherr, Mark Kotik
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Patent number: 10446803Abstract: An electrochemical pouch cell includes a stacked or rolled arrangement of electrode plates disposed in a cell housing, and a lead tab that protrudes through the cell housing. The lead tab forms an electrical connection with the electrode plates within the cell and permits transfer of current out of the cell via an opening in a seal joint of the pouch cell housing. The lead tab has a configuration that improves reliability of the seal between the lead tab and the opening.Type: GrantFiled: August 29, 2017Date of Patent: October 15, 2019Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Jeffrey Buckholz, Nick Karditsas, Adam Bisaro, Robert Schoenherr
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Patent number: 10374210Abstract: An electrochemical cell includes a prismatic cell housing including a lid plate that closes one end of the housing. The cell also includes a terminal assembly having a simple structure that is supported on the lid plate. The terminal assembly includes the lid plate, a terminal and an adhesive layer that is disposed between and secures the terminal to the lid plate. The terminal assembly includes features that allow the adhesive layer to flow in a controlled and reproducible manner over the entirety of a predetermined area without flowing beyond the predetermined area. The features result from forming a stop line in the predetermined area by applying a surface treatment to the predetermined area. The stop line delineates a desired adhesive later outer boundary and engages the adhesive so as to maintain the adhesive within the predetermined area.Type: GrantFiled: October 27, 2017Date of Patent: August 6, 2019Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Andreas Ringk, Florian Postler, Martin Busche, Anton Ringel, Jeffrey Buckholz
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Patent number: 10312547Abstract: A electrode assembly includes an electrode pair having a positive electrode and a negative electrode that are arranged crosswise and each z-folded while being cross-woven together in a continuous manner. The electrode assembly includes an electrode stack in which portions of the positive electrode are stacked along a stack axis so as to alternate with portions of the negative electrode.Type: GrantFiled: November 25, 2015Date of Patent: June 4, 2019Assignees: Robert Bosch Battery Systems LLC, Robert Bosch GmbHInventors: Yunlu Zhu, Mehul Botadra
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Patent number: 10109831Abstract: A pressure relief device attached to an outer surface of a battery pack includes an adhesive arranged around an opening in the outer surface of the battery pack and a hat portion arranged over the opening. The hat portion includes an outer ring portion attached to the outer surface of the battery pack via the adhesive and an inner portion that is recessed from the outer surface of the battery pack to form a gap between the opening and the inner portion. A diameter of the inner portion is greater than a diameter of the opening, and a diameter of the gap is greater than the diameter of the opening.Type: GrantFiled: September 9, 2013Date of Patent: October 23, 2018Assignees: Robert Bosch Battery Systems, LLC, Robert Bosch GmbHInventor: Mark M. Kotik
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Patent number: 10008707Abstract: There is disclosed a battery module that includes a housing. At least one terminal is melt joined with the bus member of the housing sealing the terminal relative to the bus member and providing a conductive path to an interior of the battery module. The terminal may be melt joined in an ultrasonic joining operation or in a thermal insertion operation. A plurality of cells are disposed in the housing with each of the cells electrically coupled via bus bars integrated into a bus member. Each of the cells includes a plurality of positive and negative electrodes that are spaced by a separator. The negative electrode includes a substrate having tab meeting at a flange that is connected to an active material portion of the electrode. The positive electrode includes a substrate having a tab meeting at a flange that is connected to an active material portion of the electrode.Type: GrantFiled: January 18, 2012Date of Patent: June 26, 2018Assignees: Robert Bosch Battery Systems, LLC, Robert Bosch GmbHInventor: John V. Hellmann