Tiveni Mergeco, Inc.

Audi Ag

Inevit LLC

American Battery Solutions, Inc.

Tiveni Mergedco, Inc.

Ralf Maisch

Heiner Fees

Martin F Eberhard

Michael Hinterberger

Alexander Eichhorn

Andreas Track

Jörg Damaske

Jörg Schmidt

Valentin Brokop

Claus Gerald Pflüger

Michael John Miskovsky

Hans-Joachim Pflüger

David Vergossen

Torsten Kärcher

Ricky Hudi

Bardo Lang

An embodiment is directed to a hybrid contact plate arrangement in a battery module that includes a plurality of contact plates configured to be arranged on a given side of a set of battery cells in the battery module, at least one insulation layer configured to provide insulation between each of the plurality of contact plates, wherein the set of battery cells includes a plurality of groups of battery cells, and wherein the plurality of contact plates each include a set of bonding connectors, the sets of bonding connectors being configured to connect to the positive and negative terminals of the plurality of groups of battery cells so as to connect battery cells in each of the plurality of groups of battery cells in parallel with each other, and to connect the plurality of groups of battery cells in series with each other.

Multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module

Embodiments are directed to establishing a direct electrical bond between a bonding connector of a contact plate and a battery cell in a battery module. In a first embodiment, an oscillating laser is used to weld the bonding connector to a battery cell terminal over a target area over which the bonding connector makes non-flush contact. In a second embodiment, the bonding connector is flattened to reduce a gap between the bonding connector and the target area on the battery cell terminal, and then laser-welded (e.g., using an oscillating or non-oscillating laser). In a third embodiment, at least one hold-down mechanism is applied over the bonding connector to secure the bonding connector to the battery cell terminal, after which the bonding connector is laser-welded to the battery cell terminal.

Methods of welding a bonding connector of a contact plate to a battery cell terminal

In an embodiment, a battery module is configured for insertion into a battery module compartment of an energy storage system. The battery module includes a first exterior plate configured with a male joining section, a second exterior plate that is adjacent to the first exterior plate and configured with a female joining section, wherein the first and second exterior plates are joined together via the male and female joining sections without welding. In an example, by joining the first and second exterior plates (e.g., and optionally, other exterior plates of the battery module as well) without welding, problems associated with heat from a welding process as well as spatters and dirt accumulation at battery cells of the battery module can be reduced or avoided.

Non-welding joinder of exterior plates of a battery module

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.

Multi-layer contact plate and method thereof

An embodiment is directed to a contact plate configured to establish electrical bonds between battery cells in a battery module, including at least one primary conductive layer, and a set of bonding connectors that are configured to provide direct electrical bonds between the contact plate and terminals of a group of battery cells, the set of bonding connectors being configured to connect the group of battery cells in parallel with each other, wherein at least one bonding connector in the set of bonding connectors is configured with a higher fuse rating than each other bonding connector in the set of bonding connectors so as to contain arcs among the set of bonding connectors to the at least one bonding connector.

Bonding connector with fuse section and battery module with insulative P-group separator

An embodiment is directed to a battery module, including a plurality of battery cell groups that are connected in series with each other, each of the plurality of battery cell groups including a plurality of battery cells that are connected to each other in parallel, a first terminal component at a first terminal of the battery module, the first terminal corresponding to either a positive terminal of the battery module or a negative terminal of the battery module, and a first heat pipe positioned in proximity to the first terminal component and configured to transfer heat away from the first terminal component.

Battery module including cooling component thermally coupled to module connector and battery module including bi-metallic contact plate

An embodiment is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module. The multi-layer contact plate includes two or more primary conductive layers (e.g., Al, Cu, etc.), and a cell terminal connection layer (e.g., steel, Al, Cu, etc.) that is joined with, and sandwiched by, the two or more primary conductive layers. A portion of the cell terminal connection layer is configured to form a set of bonding connectors (e.g., bonding ribbons) to provide a direct electrical bond between the multi-layer contact plate and terminals (e.g., positive terminals, negative terminals, or a combination thereof) of at least one group of battery cells (e.g., a single group of battery cells, two groups of battery cells that are connected in series, etc.).

Embodiments are directed to contact plates configured to establish electrical bonds between battery cells in a battery module. In a first embodiment, the contact plate includes at least one primary conductive layer including a hole that is aligned with two or more terminals of two or more battery cells in a group of battery cells that are configured to be connected in parallel with each other, and a bonding connector configured to provide direct electrical bonds between the contact plate and the two or more terminals of the two or more battery cells. In a second embodiment, a contact plate includes at least one primary conductive layer and a set of bonding connectors made from at least one material that is selected to match at least one material used for the terminals of the at least one group of battery cells.

Contact plate including at least one bonding connector configured to establish electrical bonds to terminals of at least one group of battery cells in a battery module

In an embodiment, a clamping bar holder component configured to be secured to an endplate of a battery module includes a plurality of clamping bar holders configured to hold a respective plurality of clamping bars and to facilitate transitions of each of the plurality of clamping bars between a parked state and an unparked state. In the parked state, each clamping bar is secured by a respective clamping bar holder inside of a respective clearance threshold so as to permit the battery module to be inserted into a battery module compartment and/or to be removed from the battery module compartment. In the unparked state, each clamping bar extends out of the clamping bar holder past the clearance threshold so as to block removal of the battery module from the battery module compartment.

Clamping bar holder component for a battery module and method thereof

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.

Battery module with cell fixation brackets

A connection assembly with at least one receiving module for receiving a securing element. The at least one receiving module has a chamber for receiving the respective securing element, the chamber being delimited by an inner wall, and has a first opening as well as a second opening. The two openings delimit a passage channel within the chamber, and the inner wall has at least one latching module to which the securing element is to be latched within the chamber at least temporarily after guiding the securing element along a longitudinal direction of the passage channel into the chamber through the first opening. The latched securing element is to be received completely within the chamber.

Connection assembly

In an embodiment, an energy storage system includes a battery module mounting area with a plurality of battery module compartments, each of the battery module compartments configured to house a respective battery module, and a venting arrangement configured to define a set of air channels that permits pressure equalization between the plurality of battery module compartments and an external environment. The venting arrangement is configured with an air-permeable, liquid-tight seal at least between (i) the plurality of battery module compartments and (ii) the external environment.

Pressure equalization between battery module compartments of an energy storage system and external environment

In an embodiment, an expansion component (e.g., expanding foam element, inflatable pad, a pneumatic or hydraulic mechanism, etc.) is arranged inside of a battery module compartment (e.g., on a bottom interior surface of the battery module compartment). A battery module is inserted into the battery module component and is fixated, or secured, within the battery module compartment at least in part based upon the expanding component which starts to expand or continues to expand after the insertion. In a further embodiment, the battery module may be removed from the battery module compartment after a contraction function (e.g., collapse of the foam element, deflation of the inflatable pad, etc.) of the expansion component is initiated.

Growing community of inventors

Abstatt, Germany

Ralf Maisch