Nio Usa, Inc.

Tesla, Inc.

Nio Nextev Limited

Nio Technology (anhui) Co., Ltd.

Nextev Usa, Inc.

Austin Lawrence Newman

Alexander Jeffrey Smith

Adam H Ing

Rick Rajaie

Yadunandana Yellambalase

Joshua Smith

David Wheeler

Chris McCarthy

Dennis Polischuk

Jacob Warman

John Hughes

Thomas P Jensen

Miaosen Shen

Christopher Eckert

Batuhan Yildirim

Leon Kaunitz

Chris Mccarthy

Methods and systems are provided for managing multi-battery systems, such as those utilized in an electric vehicle. Multi-battery systems comprise batteries providing power in parallel, thereby making each battery available to the vehicle and avoiding the weight of transporting a backup battery. The methods and systems provided allow for a fault in one battery, in a parallel configuration with at least one other battery, to be detected and managed.

Split battery for autonomous driving

Methods and systems for sequentially laser welding terminal tabs of a battery cell to corresponding terminal tabs of a busbar are described using a single laser position and path. The terminal tabs of a battery cell are aligned in contact with terminal tabs of a busbar. A laser welder, from a first position, generates a laser weld beam at a first diameter welding the first terminal tab of the battery cell to the first terminal tab of the busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without moving the laser welder from the first position, the narrowed laser weld beam burns a hole through the welded first set of terminal tabs, traverses a gap toward a second set of terminal tabs behind the first set and welds the second set together.

Single-position sequential laser welding system

Methods, devices, and systems of a light imaging and ranging system are provided. In particular, the imaging and ranging system includes a LIDAR sensor and a low-profile optics assembly having a reflective element with a continuous and uninterrupted reflective surface surrounding a periphery of a LIDAR sensor in a light path of the LIDAR sensor. The reflective element is positioned at a distance offset from the periphery of the LIDAR sensor and directs light emitted by the LIDAR sensor to a second reflective element that is substantially similar in shape and size as the reflective element. The second reflective element is arranged above and opposite the reflective element directing the light emitted by the LIDAR sensor to a sensing environment outside the imaging and ranging system.

Low-profile imaging system with enhanced viewing angles

A battery module cell cover is provided including a number of features configured to orient, capture, and isolate battery cell interconnections relative to battery cell locations in an array of battery cells. Isolation features may block a negative terminal battery cell interconnect from moving out of an orientation receptacle aligned with a negative terminal of a battery cell and into contact with a positive terminal of the battery cell, or vice versa. The battery module cell cover can include a number of structural connection features protruding from a planar surface into a battery cell containment cavity, between battery cell locations, that provide a number of surfaces for curing to structural adhesive of the battery module. These structural connection features, in conjunction with the structural adhesive, can assist in forming a unified strengthened structure of the battery module.

Battery cell cover including terminal short isolation feature

A battery module for a vehicle is disclosed. The battery module includes a plurality of adjacent battery cells in a module housing, each battery cell including a battery case. The battery module further includes a pressure sensor on one of the battery cells or the module housing. The pressure sensor is configured to produce a signal indicative of a change in pressure associated with any of the battery cells. The battery module further includes an electronic control unit electronically connected to the pressure sensor. The electronic control unit is configured to determine the existence of an abnormal condition based on the signal.

Battery module having a pressure sensor

Methods and systems for welding a terminal of a battery cell to corresponding terminal tab or busbar are described using a magnet that causes the terminal and tab/busbar to be placed in physical contact. The terminal of a battery cell is aligned in contact with the tab/busbar by the force of a magnetic field. A welder, e.g., a laser welder, can then generate a laser weld beam to weld the terminal of the battery cell to the tab/busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without touching the tab/busbar or terminal of the battery (which could affect the welding operation), the magnetic field can cause a force that brings the tab and terminal in contact during welding.

Magnetically coated busbar tabs

A tapered busbar for an energy storage device is provided. The tapered busbar is configured to interconnect with a first row of series-connected energy storage cells in a battery module at a first end of the busbar. As the busbar tapers from a first cross-sectional area at the first end to a larger second cross-sectional area at a second opposite end, the busbar is configured to interconnect with sequentially additional electrically-parallel rows of series-connected energy storage cells. The tapered cross-sectional area of the busbar provides a substantially uniform current density at any point along the length of the busbar regardless of the number of rows of energy storage cells connected before or after the point.

Uniform current density tapered busbar

Systems and methods of detecting leakage and other issues with electrical battery housings are provided. By using an air compressor to alter the air pressure within a battery housing, a processor may detect an abnormal rate of change in the air pressure within the battery housing as compared to a rate of change of an ideal battery housing.

Systems and methods for diagnosing seal integrity in a battery

A battery including supporting material is disclosed. The battery comprises a plurality of modules, each of which further comprises a plurality of battery cells that store and discharge electrical energy. To support the battery modules, a supporting material such as foam is inserted in the space between the battery modules. To support the cells within the modules, a supporting material such as foam is also inserted in between the battery cells in each of the modules.

Battery module structural integration

A multiple-zone thermocouple battery module temperature monitoring system is provided configured to determine a plurality of temperatures along a depth of the battery module at different locations. The system may include a number of temperature probes each including a first temperature sensor oriented at a base of a group of cells in the module and a second temperature sensor oriented at an upper portion of the group of cells in the module. Providing upper and lower battery cell temperature sensors in each probe of the system allows a battery management system to detect and record a temperature gradient of the battery cells in the module at a number of different locations. These recordings can determine a gradient and temperature difference between the upper and lower battery cell portions over an operable threshold difference, and command a thermal management system to return the battery module to limits within the operable threshold.

Multiple-zone thermocouple battery module temperature monitoring system

An energy storage device and structurally enhanced packaging for energy storage cells is provided. The energy storage device includes a number of energy storage cells spaced apart from one another and contained in a lightweight carrier. The energy storage cells and carrier are mechanically coupled together with a structural adhesive forming a unified structure and framework where each connection point acts as a node in a force distribution structure. The structural adhesive can be injected into the volume between the energy storage cells while in a fluid, or semi-fluid, state. While in this state, a retaining form or gasket inside the carrier can prevent the structural adhesive from leaking out of the energy storage device. When in a cured, or hardened, non-fluid state the structural adhesive may adhere to the various components of the energy storage device to mechanically join the component together into a structurally safe package.

Unified battery module with integrated battery cell structural support

Devices, methods, and systems for interconnecting all of the battery cells in a battery module from a single side of the battery cell and module are provided. The cell busbar system comprises a number of thin formed strips arranged to interconnect individual battery cells in a row together in series and each row in parallel along a length of the battery module. In particular, the cell busbar system may include two high voltage, or edge, strips and a number of cell-to-cell, or internal, strips electrically interconnected to the edge strips. All of the battery cells in the battery module may be oriented such that all of the positive terminals are facing the same direction. The interconnections between series-connected rows of cells, and parallel rows of series-connected rows, may all be made in substantially the same plane on a single side of the battery module.

Single side cell-to-cell battery module interconnection

A system and method for monitoring environmental and geological conditions based upon information is collected by a wide array of sensors already included in modern motor vehicles. Also included is a system for monitoring environmental and geological conditions by aggregating data collected by an array of vehicles.

Using vehicle sensor data to monitor environmental and geologic conditions

A battery module has a lower housing and an upper housing. The lower housing has a plurality of generally vertical sidewalls defining a space for receiving a plurality of battery cells and a generally horizontal bottom wall. The plurality of sidewalls include a first sidewall. The lower housing further has a cooling plate integrally formed with the lower housing. The cooling plate has a support wall extending generally parallel to the bottom wall for supporting the plurality of battery cells, a plurality of generally vertical channel walls including a first channel wall, and a cooling channel for receiving a coolant fluid therein. At least a portion of the cooling channel is defined at sides thereof by the first sidewall and the first channel wall. The upper housing covers a top opening of the lower housing to form an enclosure for the plurality of battery cells.

Growing community of inventors

San Jose, CA, United States of America

Austin Lawrence Newman