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.

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.

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.

Embodiments are directed to a contact plate 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, wherein the contact plate is configured to exchange current with at least one group of battery cells in the battery module, and wherein a thickness of the at least one primary conductive layer scales with a current expectation at different portions of the contact plate. In a second embodiment, the contact plate includes at least one primary conductive layer, and a set of bonding connectors that is configured to provide direct electrical bonds between the contact plate and terminals of at least one group of battery cells, wherein the set of bonding connectors is pre-assembled with the contact plate before the contact plate is installed into the battery module.

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.

Embodiments are directed to a center contact plate configured to establish electrical bonds between battery cells in a battery module. In an embodiment, the center contact plate includes at least one primary conductive layer including a first set of holes formed within the at least one primary conductive layer that are aligned with positive terminals of a first group of battery cells that are configured to be connected in parallel with each other, and a second set of holes formed within the at least one primary conductive layer that are aligned with negative terminals of a second group of battery cells that are configured to be connected in parallel with each other, wherein the first and second sets of holes are each clustered together on different sides of the at least one primary conductive layer.

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.

An embodiment is directed to a cylindrical battery cell with a multi-terminal cell side that includes an inner cell head and an outer cell rim, with an insulative ring arranged in a recessed area between the outer cell rim and the inner cell head. Another embodiment is directed to a cylindrical battery cell configured with one or more insulation layers integrated into (e.g., wrapped around) a shaft of the cylindrical battery cell. Another embodiment is directed to a battery module including a set of cylindrical battery cells including shaft-integrated insulation, with exposed non-insulated sections of the set of cylindrical battery cells upon insertion into a battery housing being overlapped by one or more insulative housing ribs of the battery housing.

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.

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.