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: 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 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 battery module compartment chamber is configured for deployment with one or more other battery module compartment chambers within a battery module mounting area of an energy storage system. The battery module compartment chamber includes exterior walls and at least one interior firewall that define multiple battery module compartments into which battery modules may be inserted and/or removed. Each battery module compartment includes an insertion-side configured to be closed via a respective insertion-side cover to seal the respective battery module compartment. In a further embodiment, the battery module compartment may be stacked longitudinally with one or more other battery module compartment chambers to form a battery module mounting area. A type of the battery module compartment chamber and/or a number of longitudinally stacked battery module compartment chambers may be selected to satisfy a size requirement for the battery module mounting area.

Abstract: In an embodiment, a module-side optical transceiver is configured to exchange optical signals with a battery module controller (BMC)-side optical transceiver coupled to a BMC. The optical signals are transported inside of a tunnel space between the BMC and the battery module. In one embodiment, the optical signals are transported via a light tube, a deflection element such as a mirror, or a combination thereof. In another embodiment, the optical signals are transported via a cable harness coupled to a plurality of BMC-side optical transceivers in the tunnel space and configured to support optical line of sight (LoS) links to various module-side optical transceivers.

Abstract: Embodiments are directed to establishing a direct electrical bond between a bonding connector of a contact plate and a battery cell in a battery module. In a first embodiment, an oscillating laser is used to weld the bonding connector to a battery cell terminal over a target area over which the bonding connector makes non-flush contact. In a second embodiment, the bonding connector is flattened to reduce a gap between the bonding connector and the target area on the battery cell terminal, and then laser-welded (e.g., using an oscillating or non-oscillating laser). In a third embodiment, at least one hold-down mechanism is applied over the bonding connector to secure the bonding connector to the battery cell terminal, after which the bonding connector is laser-welded to the battery cell terminal.

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: Embodiments are directed to a center contact plate configured to establish electrical bonds between battery cells in a battery module. In an embodiment, the center contact plate includes at least one primary conductive layer including a first set of holes formed within the at least one primary conductive layer that are aligned with positive terminals of a first group of battery cells that are configured to be connected in parallel with each other, and a second set of holes formed within the at least one primary conductive layer that are aligned with negative terminals of a second group of battery cells that are configured to be connected in parallel with each other, wherein the first and second sets of holes are each clustered together on different sides of the at least one primary conductive layer.

Abstract: Embodiments are directed to contact plates 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 including a hole that is aligned with two or more terminals of two or more battery cells in a group of battery cells that are configured to be connected in parallel with each other, and a bonding connector configured to provide direct electrical bonds between the contact plate and the two or more terminals of the two or more battery cells. In a second embodiment, a contact plate includes at least one primary conductive layer and a set of bonding connectors made from at least one material that is selected to match at least one material used for the terminals of the at least one group of battery cells.

Abstract: An embodiment is directed to a cylindrical battery cell with a multi-terminal cell side that includes an inner cell head and an outer cell rim, with an insulative ring arranged in a recessed area between the outer cell rim and the inner cell head. Another embodiment is directed to a cylindrical battery cell configured with one or more insulation layers integrated into (e.g., wrapped around) a shaft of the cylindrical battery cell. Another embodiment is directed to a battery module including a set of cylindrical battery cells including shaft-integrated insulation, with exposed non-insulated sections of the set of cylindrical battery cells upon insertion into a battery housing being overlapped by one or more insulative housing ribs of the battery housing.

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 compartment is configured for deployment with one or more other battery module compartments within a battery module mounting area of an energy storage system. The battery module compartment includes aa plurality of walls defining an interior space configured to fit a battery module, and an insertion-side through which the battery module is configured to be inserted or removed. The insertion-side is configured to be closed via an insertion-side cover to form part of a battery housing with a closed compartment profile that is characterized by the battery module compartment being sealed from at least one other battery module compartment in the battery housing.

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: The invention relates to a battery (10) for a vehicle. Said battery comprises a plurality of battery cells (12), which are arranged in a housing (16, 18, 20) of the battery (10), and also a cooling device (22, 24) for dissipating heat from the battery cells (12). A material (32), which takes up a first volume in a basic state and takes up a volume which is greater than the first volume in an expanded state, is introduced between the housing (20) and the cooling device (22, 24). The cooling device (22, 24) is pressed against the battery cells (12) by the material (32) which has changed over to its expanded state. The invention also relates to a method for producing a battery (10) of this kind.

Abstract: The invention relates to a method for manufacturing a battery (10) in which at least one battery module (12) having a plurality of battery cells (14) is provided. A cooling device (26) is selected depending on whether liquid cooling or cooling by a gaseous medium is intended for the at least one battery module (12). Depending on the selection, at least one first heat sink (26), through which a cooling liquid can flow, or at least one second heat sink, through which a gaseous medium can flow, is arranged on the at least one battery module (12) as the cooling device. The invention further relates to a battery arrangement and a modular system for producing a battery (10).

Abstract: The invention relates to a method for manufacturing a battery (10) in which at least one battery module (12) having a plurality of battery cells (14) is provided. A cooling device (26) is selected depending on whether liquid cooling or cooling by a gaseous medium is intended for the at least one battery module (12). Depending on the selection, at least one first heat sink (26), through which a cooling liquid can flow, or at least one second heat sink, through which a gaseous medium can flow, is arranged on the at least one battery module (12) as the cooling device. The invention further relates to a battery arrangement and a modular system for producing a battery (10).

Abstract: The invention relates to a battery (10) for a vehicle. Said battery comprises a plurality of battery cells (12), which are arranged in a housing (16, 18, 20) of the battery (10), and also a cooling device (22, 24) for dissipating heat from the battery cells (12). A material (32), which takes up a first volume in a basic state and takes up a volume which is greater than the first volume in an expanded state, is introduced between the housing (20) and the cooling device (22, 24). The cooling device (22, 24) is pressed against the battery cells (12) by the material (32) which has changed over to its expanded state. The invention also relates to a method for producing a battery (10) of this kind.