Abstract: An embodiment is directed to a module-to-module power connector configured to form connections between battery modules installed in a battery housing of an energy storage system. The module-to-module power connector includes electrical interfaces and busbar(s) configured to form one or more electrical connections terminals of adjacent battery modules. The busbar(s) is flexibly configured to permit a defined range of movement of the electrical interfaces during insertion of the respective battery modules into respective battery module compartments. The module-to-module power connector may further be arranged inside in a tunnel space, whereby holes are defined in a battery module mounting area housing the battery modules that open into the tunnel space.

Abstract: An embodiment is directed to a battery module mounting area of an energy storage system. The battery module mounting area includes a first set of battery module compartments arranged along a first longitudinal side of the battery module mounting area, and a second set of battery module compartments arranged along a second longitudinal side of the battery module mounting area. Each battery module compartment in the first and second sets of battery module compartments includes an insertion-side through which a battery module is configured to be inserted into the battery module compartment and/or removed from the battery module compartment. The insertion-side of each battery module compartment in the first and second sets of battery module compartments is configured to be closed via an insertion-side cover to form a battery housing with a closed compartment profile that is characterized by each battery module compartment being sealed from at least one other battery module compartment in the battery housing.

Abstract: In an embodiment, a clamping bar holder component configured to be secured to an endplate of a battery module includes a plurality of clamping bar holders configured to hold a respective plurality of clamping bars and to facilitate transitions of each of the plurality of clamping bars between a parked state and an unparked state. In the parked state, each clamping bar is secured by a respective clamping bar holder inside of a respective clearance threshold so as to permit the battery module to be inserted into a battery module compartment and/or to be removed from the battery module compartment. In the unparked state, each clamping bar extends out of the clamping bar holder past the clearance threshold so as to block removal of the battery module from the battery module compartment.

Abstract: In an embodiment, an energy storage system includes a battery module mounting area with a plurality of battery module compartments, each of the battery module compartments configured to house a respective battery module, and a venting arrangement configured to define a set of air channels that permits pressure equalization between the plurality of battery module compartments and an external environment. The venting arrangement is configured with an air-permeable, liquid-tight seal at least between (i) the plurality of battery module compartments and (ii) the external environment.

Abstract: An embodiment is directed to a module-to-module power connector configured to form connections between battery modules installed in a battery housing of an energy storage system. The module-to-module power connector includes electrical interfaces and busbar(s) configured to form one or more electrical connections terminals of adjacent battery modules. The busbar(s) is flexibly configured to permit a defined range of movement of the electrical interfaces during insertion of the respective battery modules into respective battery module compartments. The module-to-module power connector may further be arranged inside in a tunnel space, whereby holes are defined in a battery module mounting area housing the battery modules that open into the tunnel space.

Abstract: In an embodiment, a battery module arrangement is configured for deployment with respect to a battery module compartment within a battery module mounting area of an energy storage system. The battery module arrangement includes a battery module configured to be inserted into and/or removed from an interior space of the battery module compartment via an insertion-side of the battery module compartment, and a clamp-based insertion-side cover configured to be closed over the insertion-side of the battery module compartment. The clamp-based insertion-side cover includes an endplate of the battery module, a compartment section of the battery module compartment, and a plurality of endplate-to-compartment clamping arrangements that are integrated as part of the clamp-based insertion-side cover and are configured to secure the battery module inside of the battery module compartment by clamping the endplate to the compartment section.

Abstract: Disclosed are a busbar for cooling battery cells and a battery module using the same. The busbar for cooling battery cells is a busbar configured to cool a plurality of battery cells included in a battery module, and includes: a body portion formed in a strap shape and contacting an electrode lead of each battery cell; and a bent portion integrally formed with the body portion and extending from one end of the body portion to be bent in a thickness direction of the body portion, wherein the bent portion includes: a coupling groove coupled to a coupling protrusion that is prepared on a cooling plate of the battery module or a coupling protrusion that is prepared on a predetermined frame of the battery module, the predetermined frame supporting the busbar; and a thermal contact surface thermally contacting the cooling plate.

Abstract: In an embodiment, a battery housing arrangement integrated into a vehicle floor of an electric vehicle includes a BJB housing including a BJB configured to be electrically coupled to each of a plurality of battery modules in a battery housing upon installation of the plurality of battery modules into the battery housing. The BJB housing is positioned between at least one center structural support bar and one or more vehicle chassis bars, and is configured to protect the plurality of battery modules in the battery housing from crash forces by directing crash forces from the one or more vehicle chassis bars to the at least one center structural support bar.

Abstract: An embodiment is directed to a module-to-module power connector configured to form connections between battery modules installed in a battery housing of an energy storage system. The module-to-module power connector includes electrical interfaces and busbar(s) configured to form one or more electrical connections terminals of adjacent battery modules. The busbar(s) is flexibly configured to permit a defined range of movement of the electrical interfaces during insertion of the respective battery modules into respective battery module compartments. The module-to-module power connector may further be arranged inside in a tunnel space, whereby holes are defined in a battery module mounting area housing the battery modules that open into the tunnel space.

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.

Abstract: In an embodiment, a battery module is configured for insertion into a battery module compartment of an energy storage system. The battery module includes a first exterior plate configured with a male joining section, a second exterior plate that is adjacent to the first exterior plate and configured with a female joining section, wherein the first and second exterior plates are joined together via the male and female joining sections without welding. In an example, by joining the first and second exterior plates (e.g., and optionally, other exterior plates of the battery module as well) without welding, problems associated with heat from a welding process as well as spatters and dirt accumulation at battery cells of the battery module can be reduced or avoided.

Abstract: In an embodiment, a cooling manifold for cooling battery modules in a battery housing of an electric vehicle is configured with a predetermined leak component arranged at a defined section of the cooling manifold that is outside of the battery housing. In response to crash forces, the predetermined leak component is configured to cause the liquid coolant to leak out of the defined section of the cooling manifold (e.g., to avoid flooding of the battery housing). In a further embodiment, a controller determines a pressure differential between inlet and outlet sides of a cooling tube of a battery module. A valve is configured to selectively shut off a flow of liquid coolant through the cooling tube based at least in part on whether the determined differential exceeds the threshold (e.g., indicative of a leak condition inside the battery module).

Abstract: An endplate of a battery module is configured with holes through which an inlet and outlet for a cooling tube are arranged. Cooling interfaces between the inlet and outlet and a cooling manifold are arranged outside of a battery module compartment that houses the battery module. In a first embodiment, sealing components separate from the cooling tube are arranged inside the inlet and outlet holes, with each sealing component defining multiple sealing areas (e.g., ring-shaped sealing areas) for sealing a respective hole. In a second embodiment, the cooling tube includes integrated sealing components (e.g., threaded sections of the cooling tube) inside the inlet and outlet holes, with each integrated sealing component defining a single sealing area (e.g., a ring-shaped sealing area) for sealing a respective hole.

Abstract: In an embodiment, a battery module fixation arrangement includes gaps arranged between fixation recesses and fixation pins. Upon insertion of a battery module into a battery module compartment, each gap is at least partially filled with a curing material that cures after the insertion. In a further embodiment, the fixation recesses may include cartridges that comprise a foam material along with multiple components that mix to form the curing material after the insertion.

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: A battery module includes a cooling plate arranged underneath a set of battery cells. In an embodiment, one or more electrical insulation layers are arranged between a bottom of each battery cell in the set of battery cells and the cooling plate, wherein an overall thickness of the one or more electrical insulation layers is configured to be greater than or equal to a threshold electrical creeping distance. In a further embodiment, a particular electrical insulation layer is configured with a mixture of thermally-conductive, electrically insulative paste and a set of solid electrically insulative objects (e.g., glass balls). The set of solid electrically insulative objects may be configured to stiffen the first electrical insulation layer so as to resist a weight of the set of battery cells and maintain the overall thickness to be at least equal to the threshold electrical creeping distance.

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: Embodiments are directed to a contact plate configured to establish electrical bonds between battery cells in a battery module. In a first embodiment, the contact plate includes at least one primary conductive layer, wherein the contact plate is configured to exchange current with at least one group of battery cells in the battery module, and wherein a thickness of the at least one primary conductive layer scales with a current expectation at different portions of the contact plate. In a second embodiment, the contact plate includes at least one primary conductive layer, and a set of bonding connectors that is configured to provide direct electrical bonds between the contact plate and terminals of at least one group of battery cells, wherein the set of bonding connectors is pre-assembled with the contact plate before the contact plate is installed into the battery module.

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.