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.

A battery pack assembly includes an array of individual electrochemical cells electrically connected to one another. The array of individual electrochemical cells is embedded and encapsulated by a matrix of conformable material and the matrix of conformable material provides a protective outer shell. A sensor is electrically connected to the array.

The present disclosure provides energy storage systems that can be manufactured with lower cost. The energy storage system may comprise a plurality of electrochemical cells, a rack placed in an enclosure to support the plurality of electrochemical cells, one or more panels between the rack and the enclosure to form one or more insulation sections, and insulation material disposed in the one or more insulation sections.

A battery module having a battery cell assembly that is free from module banding is provided. The assembly includes an expandable battery cell having a first and second face. The assembly further includes a growth plate having a first and second face. The first face of the battery cell contacts the second face of the growth plate. The battery cell assembly further includes a first cell frame securing the growth plate on at least two sides and a second cell frame that contacts the second face of the battery cell. The first face of the growth plate includes a plurality of spacing features disposed along the first face of the growth plate that offset the first face of the growth plate from the first cell frame, which creates a cavity between the growth plate and the first cell frame. The cavity decreases when the battery cell expands.

Disclosed is a double-sided adhesive tape (30) that is disposed between an outer surface of a mono frame (12) of a battery module (10) and a mica sheet (17) to maintain a strong adhesive state while exhibiting an effect of blocking heat caused by thermal runaway generated from inner battery cells (11) and simultaneously effectively suppressing swelling that causes deformation and explosion. That is, the double-sided adhesive tape (30) is melt and ruptured in a predetermined temperature range to provide a passage through which at least one of a gas and a flame, which are generated and accumulated due to thermal runaway, is discharged to the outside in cooperation with a tear-off hole forming part (A) of the mica sheet (17), which is ruptured when the thermal runaway occurs, thereby effectively suppressing increase of an inner pressure and an inner temperature of the battery module (10). The double-sided adhesive tape (30) includes a laminated structure in which a first adhesive layer (31) having a composition in which a photocuring agent is added to an acrylic-based polymer, a flexible base layer (35) having a composition in which black carbon is added to a polyurethane resin, and a second adhesive layer (32) having a composition in which a photocuring agent is added to an acrylic-based polymer are sequentially laminated.

Disclosed is a double-sided adhesive tape (30) that is disposed between an outer surface of a mono frame (12) of a battery module (10) and a mica sheet (17) to maintain a strong adhesive state while exhibiting an effect of blocking heat caused by thermal runaway generated from inner battery cells (11) and simultaneously effectively suppressing swelling that causes deformation and explosion. That is, the double-sided adhesive tape (30) is melt and ruptured in a predetermined temperature range to provide a passage through which at least one of a gas and a flame, which are generated and accumulated due to thermal runaway, is discharged to the outside in cooperation with a tear-off hole forming part (A) of the mica sheet (17), which is ruptured when the thermal runaway occurs, thereby effectively suppressing increase of an inner pressure and an inner temperature of the battery module (10). The double-sided adhesive tape (30) includes a laminated structure in which a first adhesive layer (31) having a composition in which a photocuring agent is added to an acrylic-based polymer, a flexible base layer (35) having a composition in which black carbon is added to a polyurethane resin, and a second adhesive layer (32) having a composition in which a photocuring agent is added to an acrylic-based polymer are sequentially laminated.

An L-shape design of battery blocks (100) is described. Within each pair of the battery blocks (100), one L-shape battery block (100-1) may be placed at an angle of 180° to another battery block (100-2). A sufficient non-linear gap may be left within each pair of battery blocks (100) for natural cooling through movement of air. A bus-bar (200) developed by twisting of multiple pure copper wires may be used for connecting the battery blocks (100) with nuts and bolts. A fuse wire is used to connect at least one of the terminals of the cells (102) to the bus-bar (200). The battery blocks (100) may be placed in trays (300) having transparent walls (302) made of plexiglass. The battery blocks (100) may be packed together using a Velcro® and/or tension wrapped with wire before being placed in the trays (300).

Disclosed are designs for batter assemblies. In some embodiments, a battery assembly includes: a battery housing is made from a first material; a battery structure disposed in the battery housing and is made from a second material different from the first material; and a battery comprising a plurality of battery cells disposed on the battery structure; and wherein the battery housing is sealed.

Disclosed are designs for batter assemblies. In some embodiments, a battery assembly includes: a battery housing is made from a first material; a battery structure disposed in the battery housing and is made from a second material different from the first material; and a battery comprising a plurality of battery cells disposed on the battery structure; and wherein the battery housing is sealed.

An electric aircraft with a battery pack for failure safety is provided. The battery pack may be disposed within a fuselage of the electric aircraft. The battery pack may include a crush zone having energy absorbing material configured to compress as a function of a crash force.