Rivian IP Holdings, LLC

Travis Cournoyer

Nathaniel C Wynn

Tyler David Collins

Kyle William Butterfield

Kyle O'Neil

Kyle Butterfield

Tyler Jacobs

Emil Chao

Daniel Adam Beverley

Nicholas West

Daniel Domikaitis

A battery module and a method of assembling the battery module are provided. The battery module includes a cooling surface having a first area and a second area with different cooling capacities, an adhesive including a first component having a first thermal conductivity and a second component having a second thermal conductivity, and a first battery and a second battery. The first battery is secured to the first area by a first portion of the adhesive and the second battery is secured to the second area by a second portion the adhesive. The first portion of the adhesive has a first ratio of the first component to the second component and the second portion of the adhesive has a second ratio of the first component to the second component. The first and second ratios are different and compensate for the different cooling capacities of the first and second areas.

Temperature gradient control with thermal interface material variation

An apparatus includes a component having an edge feature that has a radius of curvature. The apparatus includes an underlayer arranged over the edge feature and configured to increase the radius of curvature of the edge feature. The apparatus includes a powder coating arranged over the component and over the underlayer to form a continuous layer. The underlayer is configured to remain under the powder coating. The underlayer helps the powder coating achieve a more uniform thickness over the edge feature. The apparatus is formed by applying an underlayer to a first region of the component to form an underlaid component. The first region includes the edge feature. A powder coating is applied to the underlaid component. A masking layer may be applied to a region other than the first region, and after powder coating, the masking may be removed to expose a surface of the component.

Systems and methods for managing sharp transitions for powder coating

Systems and methods are disclosed herein for determining the remaining useful life of a battery cell that includes the battery cell's internal resistance and/or shock loading. In one example implementation, the systems and methods disclosed herein monitor acceleration information over time based on information received from an accelerometer integrated in a battery cell and electrical information for at least one electrical parameter of the battery cell over time. The information is stored for determining remaining useful life. In another example implementation, the systems and methods disclosed herein determine a voltage drop across the battery cell and a current output of the battery cell. The systems and methods determine an internal cell resistance of the battery cell based on charge or discharge voltage and current information.

Systems and methods for a battery odometer with active shock andvibration monitoring

Systems and methods are provided herein for disassembling a battery system. Further, systems and methods are provided herein for a battery apparatus configured for disassembly of a battery system. In addition, systems and methods are provided herein for preparing a battery system including a first plurality of members bonded with a first adhesive and a second plurality of members bonded with a second adhesive for disassembly of the battery system.

Systems and methods for disassembling a battery module

A barrier structure, a battery module including the barrier structure, and a method of assembling the battery module are provided. The barrier structure includes a plurality of first sidewalls oriented in a first direction, and a plurality of second sidewalls oriented in a second direction. The plurality of first sidewalls interlock with the plurality of second sidewalls to form a grid structure comprising a plurality of cells, each having an open-ended top and an open-ended bottom and configured to be arranged around a cylindrical section of at least one of a plurality of battery cells. The battery module includes a plurality of cylindrical battery cells arranged in a predetermined pattern and a barrier structure for separating the battery cells.

Cell module barrier sheets for thermal propagation resistance

A battery support beam and battery module including the battery support beam are provided. The battery support beam includes a first end, a second end opposite the first end, and a battery support section between the first end and the second end. The battery support section includes a plurality of cylindrical sleeves arranged in a predetermined pattern, each having a cylindrical sidewall having an open-ended top and an open-ended bottom. Each of the cylindrical sidewalls is configured to be arranged around a cylindrical middle section of one of a plurality of cylindrical battery cells. The battery module includes a plurality of cylindrical battery cells including a plurality of groups of battery cells arranged in the predetermined pattern. The battery module further includes a battery support section for each of the plurality of groups of battery cells.

Battery module support beam

Methods and systems for welding contacts of a plurality of battery cells are provided. A method includes using a detector to perform a scan of the cell electrode contact area for each of the plurality of battery cells. Based upon the scan of each cell electrode contact area, a determination is made of whether one or more possible weld sites for each electrode contact area are viable for welding. In response to determining that one or more weld sites are viable, one or more of the viable weld sites are selected and a welder is used to weld at least one of the selected weld sites.

Systems and methods of battery cell manufacture

A battery module and a method of assembling the battery module are provided. The battery module includes a cooling plate having a cooling surface, an adhesive standoff disposed on a first portion of the cooling surface, and a securing adhesive disposed on a second portion of the first cooling surface. The securing adhesive is disposed on the cooling surface after the adhesive standoff is substantially cured. The battery module further includes a plurality of battery cells. A first end of each of the plurality of battery cells is secured to the cooling surface by the securing adhesive. The adhesive standoff maintains the first end of each of the plurality of battery cells a distance away from the cooling surface while the securing adhesive cures.

Adhesive bond setting with pre-cured adhesive standoffs

A fluid-affected fuse includes a structural housing, a pair of electric terminals, one or more fuse elements, and a fluid arranged in an internal volume of the structure. The structure provides rigidity to the fuse. The terminals are coupled to the structural housing and are configured to be coupled to an electric power circuit of a battery circuit. The one or more fuse elements are electrically connected in series to the pair of electric terminals and are arranged in the internal volume. The fluid is configured to affect a temperature of the fuse element. A fluid-filled fuse is filled with fluid, optionally sealed, and operated with the increased heat capacity of the fluid to affect temperature of the fuse. A fluid-cooled fuse is filled with the fluid, undergoing a stream of the fluid thus allowing control of fuse temperature. A control system controls the fluid stream and fuse operation.

Systems and methods for providing fluid-affected fuses

A method for making a battery system includes applying fast-cure and slow-cure adhesives to interfaces between components. The fast-cure adhesive allows manipulation of the assembly during manufacturing while the slow-cure adhesive cures. The slow-cure adhesive provides desired strength and toughness as needed during use of the final assembly. The fast-cure adhesive and slow-cure adhesive have respective curing schedules. The fast-cure adhesive includes a moisture-curing adhesive or any other suitable adhesive curing on the order of seconds such as UV-activated or cyanoacrylate adhesives. The slow cure adhesive includes any suitable structural adhesive such as a two-part mix-cure epoxy or acrylic. The components adhered using the fast-cure adhesive and slow-cure adhesive include side wall sections, battery cells, mounting bracket, bus bars, or any other suitable components. The fast-cure and slow-cure adhesives are applied in any suitable pattern such as, for example, beads, dots, paths, non-intersecting paths, or any other suitable application shape.

Systems and methods for managing adhesive joints

A battery system includes battery cells arranged and adhered to a carrier. One or more side walls are bonded with adhesive to the battery cells to provide support, and a current collector assembly is also adhered on one axial side of the battery cells. One or more dividers may be included to maintain electrically isolation between the parallel connected battery cell groups. The other axial side of the battery cells is adhered to a cooling plate. A similar structure is bonded with adhesive to the other side of the cooling plate to form a compact battery system. Shear walls, busbars, terminal busbars, and an isolation bracket with a mounted Electronic Control Unit are bonded with adhesive to the assembly to form the battery system. Each adhesive, or type of adhesive, may exhibit specified criteria and requirements such as strength, thermal conductivity, electronic conductivity, curing requirements, or a combination thereof.

Fastener-free battery modules

A battery module and a method of assembling a battery module are provided. The method includes selectively applying a light-cure adhesive to recesses in a first side of a carrier layer and inserting battery cells into respective recesses. The method further includes exposing the first side of the carrier layer to light to at least partially cure the light-cure adhesive with the carrier layer in a first orientation, moving the carrier layer into a second orientation, and exposing a second opposite side of the carrier layer to light to fully cure the light-cure adhesive. The recesses may include a sidewall having crush points spaced apart along the sidewall and a bottom portion having an opening between a pair of crush points, where adhesive is not disposed between the pair of crush points.

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Redondo Beach, CA, United States of America

Travis Cournoyer