In an embodiment, a battery module compartment is configured for deployment with one or more other battery module compartments within a battery module mounting area of an energy storage system. The battery module compartment includes aa plurality of walls defining an interior space configured to fit a battery module, and an insertion-side through which the battery module is configured to be inserted or removed. The insertion-side is configured to be closed via an insertion-side cover to form part of a battery housing with a closed compartment profile that is characterized by the battery module compartment being sealed from at least one other battery module compartment in the battery housing. In another embodiment

An embodiment is directed to a module-to-module power connector configured to form connections between battery modules installed in a battery housing of an energy storage system. The module-to-module power connector includes electrical interfaces and busbar(s) configured to form one or more electrical connections terminals of adjacent battery modules. The busbar(s) is flexibly configured to permit a defined range of movement of the electrical interfaces during insertion of the respective battery modules into respective battery module compartments. The module-to-module power connector may further be arranged inside in a tunnel space, whereby holes are defined in a battery module mounting area housing the battery modules that open into the tunnel space.

In an embodiment, a battery housing arrangement integrated into a vehicle floor of an electric vehicle includes a BJB housing including a BJB configured to be electrically coupled to each of a plurality of battery modules in a battery housing upon installation of the plurality of battery modules into the battery housing. The BJB housing is positioned between at least one center structural support bar and one or more vehicle chassis bars, and is configured to protect the plurality of battery modules in the battery housing from crash forces by directing crash forces from the one or more vehicle chassis bars to the at least one center structural support bar.

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.

An embodiment is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module. The multi-layer contact plate includes two or more primary conductive layers (e.g., Al, Cu, etc.), and a cell terminal connection layer (e.g., steel, Al, Cu, etc.) that is joined with, and sandwiched by, the two or more primary conductive layers. A portion of the cell terminal connection layer is configured to form a set of bonding connectors (e.g., bonding ribbons) to provide a direct electrical bond between the multi-layer contact plate and terminals (e.g., positive terminals, negative terminals, or a combination thereof) of at least one group of battery cells (e.g., a single group of battery cells, two groups of battery cells that are connected in series, etc.).

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 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.

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 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.