Rivian IP Holdings, LLC

Ehsan Baseri

Kyle William Butterfield

Nathaniel C Wynn

Tyler David Collins

Kyle O'Neil

Vignesh Sekar

Akshay Kishor Murkute

Jonathan Verghese

Luke Rayment Morrow

Kyle Butterfield

Todd Putnam

Anish Shah

Casey Taylor Dunn

Jagannathan Shankar Mahadevan

Herbert J Collick

A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

High voltage laminated power distribution system with integrated fuses

A battery system for an electric vehicle includes a fixed cover, and a removable cover arranged over battery modules and a high voltage distribution system. The battery system includes a busbar arranged at least partially over a region of the battery modules and under the removable cover. The busbar includes a fixed section and a movable section, or a hinge, such that the busbar can be repositioned out of the way. The support tray includes a link between the fixed and movable sections. Floating fasteners, allowing at least one of radial float and axial float are used to secure the link to the support tray, thereby avoiding safety hazards and reducing the potential for short circuits in high voltage distribution systems or conductors thereof. The floating fasteners include a head, a neck, an engagement section, and a washer, which prevent removal from a component once installed.

Systems and methods for servicing high voltage components of a battery system

A battery enclosure is provided having unswitched positive and negative terminals that are physically separated. The unswitched positive and negative terminals may be connected to circuit protection components, such as contactors and fuses. The contactors are set to an opened or closed state via a contactor control module. The battery enclosure includes external terminals that electrically couple the battery and circuit protection devices to external components, such as charging ports and electrical loads.

Distribution system for unswitched high voltage power

Efficiency of a battery module is achieved using an actively cooled high power electrical interface. The battery module comprises a plurality of battery cells, at least one busbar coupled to the battery cells, a connector electrically coupled to the at least one busbar, and at least one cooling component that is thermally coupled to the first connector. The battery cells may be arranged in two layers, each layer containing a plurality of battery cells connected by a busbar. The connector comprises a contact through which the battery module may be coupled to an external circuit. The at least one cooling component provided cooling for the battery cells and the connectors and may be placed on the surface of the battery module or between layers of battery cells.

Battery module with actively cooled high power electrical interface

Fasteners and assemblies for servicing high voltage components of a battery system

A laminated busbar assembly includes one or more busbars that are configured to be electrically coupled to a plurality of battery cells, one or more insulative layers arranged adjacent to the one or more busbars, and a steel layer arranged between the one or more busbars and the plurality of battery cells. The steel layer is configured to shield the one or more busbars from a thermal event associated with one or more battery cells of the plurality of battery cells. The thermal event may include a debris, hot gas, sparks, embers, or other emanations. Each of the battery cells each include a respective venting end, where electrical terminals are located, that face the steel layer. The laminated busbar is a stack of layers that can include two busbars that form a DC bus, with insulation arranged between the busbars and between the steel layer and the proximal busbar.

Laminated busbar having a shield layer for battery systems

An electric vehicle battery pack with a thermal shield that protects internal components from, for example, battery ventilation, and in particular allows battery pack electrical components to be placed above venting ends of batteries. The thermal shield is positioned above the venting ends of one or more batteries, and various battery pack electrical components may be placed above the thermal shield. Gases and particulate matter from battery venting are thus intercepted and deflected by the thermal shield, instead of damaging battery pack electrical components. In this manner, various battery pack electrical components may be placed above battery venting ends without risk of damage. This allows for a more compact and versatile arrangement of battery pack components.

Thermal shield for protection of electrical components in electric vehicle battery pack

Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.

Modular electric vehicle battery pack frame having extruded aluminum structural members

Various disclosed embodiments include cover assemblies for an electrical busbar connection, busbar connector assemblies, and battery systems. In an illustrative embodiment, a cover assembly for an electrical busbar connection includes an electrically insulative busbar cover configured to receive therein an end of an electrical busbar. Electrically insulative fastener receptacles extend from the busbar cover, each fastener receptacle being sized to receive therein a fastener assembly, each fastener receptacle defining therein a first opening at a first end distal the busbar cover and a second opening at a second end proximal the busbar cover, the first opening being sized to permit insertion therethrough of a tool to turn a fastener assembly, the first opening being further sized to prevent insertion therethrough of a finger of a human. Electrically insulative retaining tabs extend into an interior of each of the fastener receptacles intermediate the first opening and the second opening.

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Irvine, CA, United States of America

Ehsan Baseri