Abstract: An embodiment is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module. The multi-layer contact plate includes two or more primary conductive layers (e.g., Al, Cu, etc.), and a cell terminal connection layer (e.g., steel, Al, Cu, etc.) that is joined with, and sandwiched by, the two or more primary conductive layers. A portion of the cell terminal connection layer is configured to form a set of bonding connectors (e.g., bonding ribbons) to provide a direct electrical bond between the multi-layer contact plate and terminals (e.g., positive terminals, negative terminals, or a combination thereof) of at least one group of battery cells (e.g., a single group of battery cells, two groups of battery cells that are connected in series, etc.).

Abstract: A battery module includes: a battery cell assembly having a plurality of battery cells; a top plate configured to cover an upper side of the battery cell assembly; a bottom plate configured to cover a lower side of the battery cell assembly; a sensing assembly disposed to cover a front side and a rear side of the battery cell assembly; a pair of side plates disposed at side surfaces, respectively, of the battery cell assembly; and a pair of compression pads disposed between the pair of side plates and the battery cell assembly, respectively.

Abstract: A battery module includes: a first battery cell assembly having at least one battery cell; a second battery cell assembly spaced apart from the first battery cell assembly by a predetermined distance and having at least one battery cell; a bottom plate configured to integrally support the second battery cell assembly and the first battery cell assembly; and a top plate disposed above the bottom plate to integrally cover the first battery cell assembly and the second battery cell assembly.

Abstract: In an embodiment, an expansion component (e.g., expanding foam element, inflatable pad, a pneumatic or hydraulic mechanism, etc.) is arranged inside of a battery module compartment (e.g., on a bottom interior surface of the battery module compartment). A battery module is inserted into the battery module component and is fixated, or secured, within the battery module compartment at least in part based upon the expanding component which starts to expand or continues to expand after the insertion. In a further embodiment, the battery module may be removed from the battery module compartment after a contraction function (e.g., collapse of the foam element, deflation of the inflatable pad, etc.) of the expansion component is initiated.

Abstract: An embodiment is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module. The multi-layer contact plate includes two or more primary conductive layers (e.g., Al, Cu, etc.), and a cell terminal connection layer (e.g., steel, Al, Cu, etc.) that is joined with, and sandwiched by, the two or more primary conductive layers. A portion of the cell terminal connection layer is configured to form a set of bonding connectors (e.g., bonding ribbons) to provide a direct electrical bond between the multi-layer contact plate and terminals (e.g., positive terminals, negative terminals, or a combination thereof) of at least one group of battery cells (e.g., a single group of battery cells, two groups of battery cells that are connected in series, etc.).

Abstract: An embodiment is directed to a battery module, including a plurality of battery cell groups that are connected in series with each other, each of the plurality of battery cell groups including a plurality of battery cells that are connected to each other in parallel, a first terminal component at a first terminal of the battery module, the first terminal corresponding to either a positive terminal of the battery module or a negative terminal of the battery module, and a first heat pipe positioned in proximity to the first terminal component and configured to transfer heat away from the first terminal component.

Abstract: An embodiment is directed to a method of fabricating a multi-layer contact plate, comprising providing a layer stack with first, second and third conductive layers, inserting brazing material into holes first and/or second conductive layers of a layer stack, and brazing the layer stack after the inserting. Another embodiment is directed to a multi-layer contact plate, comprising a layer stack with first, second and third conductive layers, with at least one inter-layer connection including a brazed area where the second conductive layer is brazed to each of the first and third conductive layers, and where the first and third conductive layers are directly brazed to each other through a hole in the second conductive layer.

Abstract: In an embodiment, a battery module is provided with a cooling tube configured to carry liquid coolant for cooling a set of battery cells inside the battery module. A portion of the cooling tube being arranged beneath the set of battery cells and includes an integrated turbulator component configured to transition a flow of the liquid coolant from a laminar flow to a turbulent flow. In an example, the integrated turbulator component may be formed by integrating a turbulent component into a tube (e.g., a straight tube), and then bending the tube to produce the cooling tube portion.

Abstract: An embodiment is directed to a contact plate configured to establish electrical bonds between battery cells in a battery module, including at least one primary conductive layer, and a set of bonding connectors that are configured to provide direct electrical bonds between the contact plate and terminals of a group of battery cells, the set of bonding connectors being configured to connect the group of battery cells in parallel with each other, wherein at least one bonding connector in the set of bonding connectors is configured with a higher fuse rating than each other bonding connector in the set of bonding connectors so as to contain arcs among the set of bonding connectors to the at least one bonding connector.

Abstract: An embodiment is directed to a contact plate configured to establish electrical bonds between battery cells in a battery module, including at least one primary conductive layer, and a set of bonding connectors that are configured to provide direct electrical bonds between the contact plate and terminals of a group of battery cells, the set of bonding connectors being configured to connect the group of battery cells in parallel with each other, wherein at least one bonding connector in the set of bonding connectors is configured with a higher fuse rating than each other bonding connector in the set of bonding connectors so as to contain arcs among the set of bonding connectors to the at least one bonding connector.

Abstract: A connecting element for at least two energy storage cells, having a metal sheet for the electrical connection of the energy storage cells. The metal sheet has at least two perforations for the uptake in each perforation of at least a part of an energy storage cell. Two lugs provided on the metal sheet project into the perforations.

Abstract: An aspect is directed to a contact plate arrangement for a battery module. The contact plate arrangement comprises a first contact plate connected to first terminals of a first parallel group of battery cells (P-Group) and to second terminals of a second P-Group, a second contact plate that is partially stacked over the first contact plate, the second contact plate connected to first terminals of the second P-Group and to second terminals of a third P-Group, and a third contact plate that is partially stacked over the second contact plate, the third contact plate connected to first terminals of the third P-Group.

Abstract: In an aspect, a battery module is assembly by mounting first and second jig towers (e.g., monolithic or modular/stackable jig towers) on a surface. Battery cell(s) are arranged between the jig towers and fixed in position based in part on battery cell fixation elements arranged in the respective jig towers. At least one magnetic-based supplemental fixation element is used to apply magnetic force (e.g., attractive and/or repulsive magnetic force) so as to direct the battery cell(s) towards the first jig tower and away from the second jig tower (e.g., so that battery cells in respective rows will be flush with each other).

Abstract: In an embodiment, a multi-cell hold-down mechanism is clamped over multiple contact tabs aligned with respective cell terminals (e.g., positive and/or negative cell terminal(s). While clamped, the contact tabs are securely welded to respective cell terminals through respective gaps in the multi-cell hold-down mechanism. In another embodiment, a multi-cell hold-down mechanism is clamped over an electrically conductive part that is coupled to multiple cell rims which are configured as negative cell terminals. A respective negative contact tab is welded to the electrically conductive part through a gap in the multi-cell hold-down mechanism. In another embodiment, three (or more) battery cell terminals (e.g., positive or negative terminals) are coupled to an electrically conductive bar that is welded to a contact tab of a busbar.

Abstract: An embodiment is directed to a battery module, including a plurality of battery cell groups that are connected in series with each other, each of the plurality of battery cell groups including a plurality of battery cells that are connected to each other in parallel, a first terminal component at a first terminal of the battery module, the first terminal corresponding to either a positive terminal of the battery module or a negative terminal of the battery module, and a first heat pipe positioned in proximity to the first terminal component and configured to transfer heat away from the first terminal component.

Abstract: An embodiment of the disclosure is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module, comprising a first plate section configured with a first set of raised dimples on an inner side of the first plate section, a second plate section configured with a second set of raised dimples on an inner side of the second plate section, a cell terminal connection layer sandwiched between the first and second plate sections, wherein a portion of the cell terminal connection layer is configured to form a set of bonding connectors to provide a direct electrical bond between the multi-layer contact plate and terminals of at least one group of battery cells, and a set of inter-layer connection points arranged between at least the first and second plate sections, each of the set of inter-layer connection points being arranged where raised dimples on the first and second plate sections are aligned with each other.

Abstract: A battery module includes: a plurality of battery cells; a top plate configured to cover an upper side of the battery cells; a bottom plate configured to cover a lower side of the battery cells; a pair of side plates configured to cover both side surfaces of the battery cells; a bus bar unit configured to cover a front side and a rear side of the battery cells, the bus bar being electrically connected to the battery cells; and a pair of heatsinks each having a coolant injection portion and a coolant discharge portion protruding out of the battery module. The pair of heat sinks are provided at the upper side and the lower side of the battery cells, respectively.

Abstract: An embodiment is directed to a hybrid contact plate arrangement in a battery module that includes a plurality of contact plates configured to be arranged on a given side of a set of battery cells in the battery module, at least one insulation layer configured to provide insulation between each of the plurality of contact plates, wherein the set of battery cells includes a plurality of groups of battery cells, and wherein the plurality of contact plates each include a set of bonding connectors, the sets of bonding connectors being configured to connect to the positive and negative terminals of the plurality of groups of battery cells so as to connect battery cells in each of the plurality of groups of battery cells in parallel with each other, and to connect the plurality of groups of battery cells in series with each other.

Abstract: A battery pack includes: a pack tray; a first x bar provided on the pack tray; a plurality of battery modules provided on the pack tray; a lateral plate for covering a lateral side of at least one of the battery modules; and a second x bar provided on the first x bar, overlapping the first x bar, and disposed in parallel to the first x bar, wherein the lateral plate forms a protrusions and depressions structure with at least one of the first x bar and the second x bar such that the lateral plate is combined with the at least one of the first x bar and the second x bar.

Abstract: Disclosed is a battery module, which includes a battery cell assembly having at least one battery cell, a module case configured to accommodate the battery cell assembly, and a module connector mounted at the module case, wherein the module connector includes a connector pin electrically connected to the battery cell assembly at the inside of the module case so as to be connected to an external connector at the outside of the module case, a connector housing mounted to an outer surface of the module case to surround the connector pin, and a sealing member provided between the connector housing and the module case.