Thunder Power New Energy Vehicle Development Company Limited

Peter Tutzer

Francesco Mastrandrea

A vehicle including a lateral energy absorption system which includes a first side beam that defines a first chamber. The first side beam extends between a front and a rear of the vehicle. A second side beam that defines a second chamber. The second side beam extends between the front and the rear of the vehicle. Further, a first carbon structure within the first chamber, and a second carbon structure within the second chamber, are included. The first and second carbon structures absorb energy from an impact on a side of the vehicle.

Lateral energy absorption system

A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, and a second busbar attached to the lower tray. The battery pack also includes a plurality of battery cells arranged in the upper and lower trays between the first and second busbars, where the first busbar is between the battery cells and the upper tray, and where the second busbar is between the battery cells and the lower tray.

Battery system housing with internal busbar

A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, and a second busbar attached to the lower tray. The battery pack also includes a plurality of battery cells arranged in the upper and lower trays, and a cooling duct contacting the lower and upper trays.

Battery system housing with integrated cooling pipe

A rechargeable battery system, a battery pack, and methods of manufacturing the same are disclosed herein. The rechargeable battery system and/or battery pack can be for an electric vehicle. The rechargeable battery system and/or battery pack can include a plurality of battery cells arranged into one or more rows, a busbar, and a housing. The busbar can extend over the ends of the plurality of battery cells, and can be configured to conduct electrical energy to and from the battery cells. The busbar may also connect to the one or more of the terminals of the plurality of battery cells. The busbar may define a busbar cooling duct having an entrance and an exit. In addition, the busbar cooling duct may be in thermal connection with a plurality of contacts of the busbar.

Cooled busbars and plate

A battery system that includes a battery cell. The battery cell defines a proximal end and a distal end where the proximal end is a positive terminal and the distal end is a negative terminal. A first busbar couples to the proximal end and a second busbar couples to the distal end to complete an electrical circuit. A first energy transfer conduit carries a fluid that cools and/or heats the battery cell. The first busbar or the second busbar couple to the first cooling conduit.

Battery system

A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, a second busbar attached to the lower tray, and a plurality of battery cells arranged in the upper and lower trays between the first and second busbars. The first busbar is between the battery cells and the upper tray, and the second busbar is between the battery cells and the lower tray. The battery pack also includes a first cooling plate, connected with one of at least one of the lower tray and the second busbar, and at least one of the upper tray and the first busbar.

A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, and a second busbar attached to the lower tray. The battery pack also includes a plurality of battery cells arranged in the upper and lower trays, and an armor layer connected with the lower tray.

Battery system housing with underside armor

A lateral energy absorption system includes a first carbon structure. The first carbon structure includes a first plurality of carbon tubes. The first plurality of carbon tubes have a first end with a first width and a second end with a second width. The first plurality of carbon tubes define a first taper between the second end and the first end that facilitates crumpling of the first plurality of carbon tubes during an impact. A first plurality of carbon flanges connects the carbon tubes together.

A battery system that includes a battery cell. The battery cell includes a proximal end and a distal end, where the proximal end is both a positive terminal and a negative terminal. The system also includes a first busbar that electrically couples to the negative terminal or the positive terminal. A second busbar is electrically coupled to the negative terminal or the positive terminal. An energy transfer plate couples to the distal end of the battery cell.

A rechargeable battery system, a battery pack, methods of manufacturing the same, and an electric vehicle are disclosed herein. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, a second busbar attached to the lower tray, and a plurality of battery cells arranged in the upper and lower trays. The rigidity of the combination of the upper tray and the first busbar is provided predominantly by the first busbar.

Battery system housing with busbar grid fixation

A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, and a second busbar attached to the lower tray. The battery pack also includes a plurality of battery cells arranged in the upper and lower trays, and a threaded fastener mechanically connecting the lower tray to the upper tray.

Battery system housing with fastener

A method of manufacturing a battery pack for an electric vehicle is disclosed. The method includes placing a cooling duct between first and second pluralities of battery cells, and applying a first force to the first plurality of battery cells and a second force to the second plurality of batteries. The first and second forces cause the first and second pluralities of battery cells to press against the cooling duct, the first plurality of battery cells is pressed against a first side of the cooling duct, the second plurality of battery cells is pressed against a second side of the cooling duct, and the first side of the cooling duct is opposite the second side of the cooling duct. The method also includes placing the first and second plurality of battery cells in a first tray configured to hold the first and second plurality of battery cells.

Battery system assembly process and battery system assembly

A method of manufacturing a battery pack is disclosed. The method includes placing first and second sets of battery cells in first and second battery cell holders of a battery system assembly press, placing a cooling duct in a gap between the first and second sets of battery cells, and applying a first and second forces to the first and second sets of battery cells to cause the first and second sets of battery cells to respectively press against first and second sides of the cooling duct. The method also includes, while applying the first and second forces, placing the first and second plurality of battery cells in a first tray configured to hold the first and second plurality of battery cells.

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Milan, Italy

Peter Tutzer