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: 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 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 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: 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: 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: 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 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: 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 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: 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: 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 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 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: 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 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: 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: A vehicle battery packaging for accommodating a plurality of longitudinal battery cells, wherein the battery cells are arranged in a frame in parallel with respect to their longitudinal axes, and wherein each battery cell has a first end and an opposite second end with respect to the longitudinal axis, the battery packaging including: a conductor plate adapted to electrically couple to the second ends of the battery cells; a cooling plate thermally coupled to the conductor plate; and a gap filler layer sandwiched between the conductor plate and the cooling plate.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control the rate of cooling experienced by each successive additive layer. Accordingly, the system may be used to heat treat the various additive layers.

Abstract: A battery system is provided in which the batteries are mounted between a pair of substrates, the system further including at least one cooling tube mounted next to the batteries, the cooling tube used to withdraw heat from the batteries via a circulating liquid coolant.