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 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: 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, a battery module includes a first layer of battery cells, and a first set of brackets that are each configured to fix at least one battery cell of the first layer of battery cells into a defined position.

Abstract: An embodiment is directed to a contact plate arrangement for a battery module. In an aspect, the contact plate arrangement includes a busbar configured to transport current between first and second parallel groups of battery cells (P-Groups) in series, and a bonding connector attached to a sidewall of the busbar and configured to form an electrical connection with a cell terminal of a battery cell from a respective one of the first and second P-Groups.

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: 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 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: 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 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 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 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: An embodiment is directed to a cylindrical battery cell, comprising a cell can, a jelly roll area of anode electrode, separator, and cathode electrode foils arranged in a middle section of the cell can. The anode electrode foils, the cathode electrode foils, or both extend out of the jelly roll area into an electrolyte area of the cell can. In one embodiment, some of the extended electrode foils are in direct contact with an end (e.g., top or bottom) of the cell can. In another embodiment, the extended electrode foils contact a plurality of connection taps that are thermally and electrically connected to an end (e.g., top or bottom) of the cell can. In another embodiment, the extended electrode foils are bent and stacked so as to function as a foil-integrated connection tap that is thermally and electrically connected to an end (e.g., top or bottom) of the cell can.

Abstract: An embodiment is directed to a battery module comprising an external frame that comprises a bottom plate configured to mechanically reinforce the battery module, and a plurality of battery cells enclosed by the external frame, wherein each of the plurality of battery cells is thermally coupled to the bottom plate to facilitate heat being spread between the plurality of battery cells via the bottom plate.

Abstract: An embodiment of the disclosure is directed to a battery module, comprising a plurality of battery cells that each include a cell terminal formed from a first metal, and a contact plate including a conductive plate that is formed from a second metal and a first metallic surface layer (e.g., a surface coating or clad material) arranged on a first side of the conductive plate that is formed from the first metal, wherein part of the contact plate is arranged as a plurality of bonding connectors that form direct electrical connections to the cell terminals of the plurality of battery cells. In some designs, a second metallic surface layer (e.g., a surface coating or clad material) may further be arranged on a second side of the conductive plate and may also be formed from the first metal.

Abstract: In an embodiment, a battery module includes a plurality of battery cells arranged in a plurality of rows and columns, and foil arranged between two or more adjacent battery cells among the plurality of battery cells.

Abstract: In an embodiment, a battery module includes a first layer of battery cells, and a first set of brackets that are each configured to fix at least one battery cell of the first layer of battery cells into a defined position.

Abstract: In an embodiment, a battery module includes a bottom plate, and a set of positioning elements integrated into the bottom plate or attached to the bottom plate, the set of positioning elements arranged defining a cell fixation region where a bottom of a cylindrical battery cell interfaces with a surface of the bottom plate.