Aspects of the present disclosure involve various battery can designs. In general, the battery can design includes two fitted surfaces oriented opposite each other and seam welded together to form an enclosure in which a battery stack is located. To form the enclosure, the two fitted surfaces are welded together along the large perimeter. Other swelling-resisting advantages may also be achieved utilizing the battery can design described herein including, but not limited to, the ability to modify one or more can wall thicknesses to control a pressure applied to the battery stack by the can, overall reduction in wall thickness of the can through the use of stronger materials for the can surfaces, additional supports structures included within the can design, and/or bossing or other localized thinning of surfaces of the can.

A method for filling a thermal paste into a battery module. The battery module includes a module housing with at least one cooling wall, at which a cooling plate can be arranged outside the module housing. At least one stack is formed by a plurality of uniformly stacked pouch cells. The at least one stack is arranged at the at least one cooling wall in the module housing. In proximity to at least one opening, a fold of at least one pouch cell is folded over toward the surface of pouch cell and glued, thereby forming a first flow channel between a stack cooling side and the cooling wall. The thermal paste is filled in through the opening and the thermal paste spreads homogeneously in the first flow channel.

A method for filling a thermal paste into a battery module. The battery module includes a module housing with at least one cooling wall, at which a cooling plate can be arranged outside the module housing. At least one stack is formed by a plurality of uniformly stacked pouch cells. The at least one stack is arranged at the at least one cooling wall in the module housing. In proximity to at least one opening, a fold of at least one pouch cell is folded over toward the surface of pouch cell and glued, thereby forming a first flow channel between a stack cooling side and the cooling wall. The thermal paste is filled in through the opening and the thermal paste spreads homogeneously in the first flow channel.

Systems and techniques for measuring process characteristics including electrolyte distribution in a battery cell. A non-destructive method for analyzing a battery cell includes determining acoustic features at two or more locations of the battery cell, the acoustic features based on one or more of acoustic signals travelling through at least one or more portions of the battery cell during one or more points in time or responses to the acoustic signals obtained during one or more points in time, wherein the one or more points in time correspond to one or more stages of electrolyte distribution in the battery cell. One or more characteristics of the battery cell are determined based on the acoustic features at the two or more locations of the battery cell.

Battery systems, methods of in-situ grid-scale battery construction, and in-situ battery regeneration methods are disclosed. The battery system features controllable capacity regeneration for grid-scale energy storage. The battery system includes a battery comprising a plurality of cells. Each cell includes a cathode comprising cathode electrode materials disposed on a first current collector, an anode comprising anode electrode materials disposed on a second current collector, a separator or spacer disposed between the cathode and the anode an electrolyte to fill the battery in the spaces between electrodes. The battery system includes a battery system controller, wherein the battery system controller is configured to selectively charge and discharge the battery at a normal cutoff voltage and wherein the battery system controller is further configured to selectively charge and discharge the battery at a capacity regeneration voltage as part of a healing reaction to generate active electrode materials.

Battery systems, methods of in-situ grid-scale battery construction, and in-situ battery regeneration methods are disclosed. The battery system features controllable capacity regeneration for grid-scale energy storage. The battery system includes a battery comprising a plurality of cells. Each cell includes a cathode comprising cathode electrode materials disposed on a first current collector, an anode comprising anode electrode materials disposed on a second current collector, a separator or spacer disposed between the cathode and the anode an electrolyte to fill the battery in the spaces between electrodes. The battery system includes a battery system controller, wherein the battery system controller is configured to selectively charge and discharge the battery at a normal cutoff voltage and wherein the battery system controller is further configured to selectively charge and discharge the battery at a capacity regeneration voltage as part of a healing reaction to generate active electrode materials.

A holding device for battery cells forming a high-voltage module that can be used for electrically driven motor vehicles includes an insulation plate provided with a pattern of recesses for each of the battery cells, the pattern of recesses includes positioning supports for the battery cell and flow grooves for an electrically insulating adhesive mass to be introduced.

An electrolyte is introduced into an electrochemical device, passed, via a first corrugation feature, through a first electrode of the electrochemical device, passed through an ion permeable separator, and contacted with a second electrode. The first or second electrode comprises a second corrugation feature in fluid communication with the first corrugation feature to contact the electrolyte across a portion of an active surface of the first or second electrode.

An electrolyte is introduced into an electrochemical device, passed, via a first corrugation feature, through a first electrode of the electrochemical device, passed through an ion permeable separator, and contacted with a second electrode. The first or second electrode comprises a second corrugation feature in fluid communication with the first corrugation feature to contact the electrolyte across a portion of an active surface of the first or second electrode.

The flat-shaped battery of the present invention comprises a battery container provided with an outer can and a sealing plate, and a positive electrode, a negative electrode, a separator, and an electrolyte solution are enclosed in the battery container. The positive electrode is housed in the outer can, and a porous electrolyte solution absorber is inserted between the positive electrode and an inner bottom surface of the outer can. Also, the method for manufacturing a flat-shaped battery, including: disposing an electrolyte solution absorber on an inner bottom surface of the outer can; disposing the positive electrode on the electrolyte solution absorber; and injecting the electrolyte solution into the outer can after disposing the electrolyte solution absorber, before or after disposing the positive electrode. A porous body having a porosity of 40 to 90% is used as the electrolyte solution absorber.