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.

A vehicle power module assembly including an array of stacked switch unit assemblies, a front cover, first and second side rails, and an end cover is provided. Each of the assemblies may include a power stage frame having a mid-cutout located at a substantially central side frame region such that a mid-cutout region is defined along each side of the array. The front cover may be disposed at a first end of the array. The first and second side rails may each extend from the front cover and each may be disposed within one of the mid-cutout regions such that an outer surface of each side rail is substantially flush with an outer surface of a respective power stage frame. The end cover may be arranged with the front cover to retain the assemblies therebetween. The assembly may further include a clamping plate and a spring element.

A pickup truck includes a box side inner panel, a box side outer panel, a first compartment defined between the box side inner panel and the box side outer panel and a battery cooling pack held in the first compartment. A storage space customization feature may also be provided in the first compartment.

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.

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.

A modular battery system for use with a material handling vehicle, the modular battery system comprises a battery assembly and a counterweight assembly. The battery assembly can include a power source and a battery base, and the counterweight assembly can include a counterweight base configured to slidably receive the battery base and be removably secured thereto.

An electrical vehicle including a vehicle body, a passenger compartment, a chassis supporting the passenger compartment, a plurality of wheels and at least one electrical motor for driving the wheels. A battery compartment of the vehicle is configured to removably mount therein a plurality of more than two rechargeable batteries which are movable into position in the battery compartment by a battery conveyor system which has a battery access opening through which batteries are installed or removed, one by one, to and from the battery compartment. In the battery compartment, a connection mechanism effects the needed mechanical and electrical connections. An overall control system controls the conveyor system and the connection mechanism to enable rapid replacement of the removable batteries, whereby an electrical vehicle can be instantly driven, even after its batteries have been discharged by a replacement of the discharged batteries and the installation of freshly charged batteries.

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.