A123 Systems LLC

Jonathan Hostler

Mujeeb Ismael Ijaz

Shazad Mahmood Butt

Brian D Rutkowski

Chad Allison

Brian Moorhead

Jason Davis

Whanjin Roh

Mujeeb Ijaz

David Allen

Shazad Butt

Yang Chen

Benjamin J Sinsheimer

Dylan Propst

Peter Won

Allan Alimario

Antoine Jourdan

Myoungshin Hong

Brian Rutkowski

Methods and systems are provided for a battery encapsulant. In one example, a method may include a battery encapsulant surrounding one or more battery cells of a vehicle battery, where the encapsulant comprises a Young Modulus between 0.05 to 0.15 GPa after being cured.

Structural potting material used to increase crush resistance

Disclosed herein, is a battery module that comprises an encapsulant material exhibiting improved thermal transfer and heat dissipation characteristics. In one example embodiment, the battery module comprises a 'stack' of cells, wherein at least some of the cells, and optionally each cell, is not separated by a metal plate or tab-shaped heat sink layer, and instead, the cells are substantially surrounded by an encapsulant material and stacked directly upon one another.

Battery module with heat dissipating encapsulant material and methods therefor

A battery pack includes at least one voltaic cell module. A substrate is mechanically coupled to the module and configured to receive excess heat therefrom. A section of an electrically insulating thermal gap pad is arranged between the module and the substrate. The pad includes a dielectric sheet supporting a deformable layer.

Thermal gap pad for a prismatic battery pack

A battery system comprises a battery cell having a cell body and a voltage terminal extending out of the cell body and having first and second terminal edges; a busbar to which an upper end of the voltage terminal is electrically connected; and a zipper fuse formed in a portion of the terminal between the cell body and the busbar, wherein the zipper fuse comprises an array of perforations through the voltage terminal and extending across the voltage terminal from the first edge to the second edge.

Fuse for battery cells

A battery system comprises a plurality of battery subunits arranged in a stack, wherein each battery subunit among the plurality of battery subunits comprises a first battery cell, a heatsink, a second battery cell, and a compliant pad in that order with the heatsink between and in thermal contact with the first and second battery cells and with the compliant pad abutting the second battery cell.

Structure of prismatic battery modules with scalable architecture

A battery system comprises a plurality of battery subunits, each subunit comprising a heatsink and at least one battery cell with a positive terminal and a negative terminal; where each heatsink has a respective busbar support mounted to it, and each busbar support includes first and second slots through which, respectively, a positive and a negative terminal of the at least one battery cell for that subunit passes, wherein a first busbar is located above and held at least in part by the first busbar support and is electrically connected to the negative terminal passing through the first slot in the first busbar support; and a second busbar is located above and held at least in part by the first busbar support and electrically connected to the positive terminal passing through the second slot in the first busbar support.

Busbar supports and methods of their use for battery systems

Exemplary embodiments of the present invention provide flexible, multi-voltage battery modules having multiple cells that are nested together. The cells can be, for example, cylindrical lithium ion cells. To increase cell package density, the cells can be disposed in a nested configuration so that adjacent cell centers form equilateral triangles. The cells can be placed in a housing or case with interlocking tabs that allow multiple modules to be connected together. Within a module, the cells can be connected in different configurations by buss bars at the top and the bottom of the battery cells. The different configurations may provide different voltages for the module.

Flexible voltage nested battery module design

A battery system including: a plurality of subunits each of which has a heatsink and a battery cell and two voltage terminals symmetrically positioned with respect to a centerline of that battery cell, wherein all of the battery cells are arranged so that their voltage terminals are aligned along two rows; a plurality of identical busbar supports equal in number to the plurality of subunits, each having two slots and mounted on a corresponding different one of the subunits with each of the terminals of the battery cell extending up through the two slots; and a plurality of bimetallic busbars, each one supported by a different corresponding subset of the busbar supports and electrically connected directly to either a first or second terminal of each of the battery cells of each of the modules on which those busbar supports are mounted.

Prismatic battery module with scalable architecture

A battery comprises a battery cell having two voltage terminals and a flexible sidewall; a wall structure against which the battery cell is located, the wall structure including a sidewall that is adjacent to the sidewall of the battery cell; and a tooth structure that extends away from the sidewall of the wall structure and towards the sidewall of the battery cell, wherein the tooth structure includes a distal end sufficiently sharp to puncture the flexible sidewall of the battery cell when the flexible sidewall of the battery cell is forced up against the tooth structure due to a build up of excess pressure inside the battery cell.

Growing community of inventors

Canton, MI, United States of America

Jonathan Hostler