BATTERY MODULE INCLUDING COATED OR CLAD MATERIAL CONTACT PLATE
An embodiment of the disclosure is directed to a battery module, comprising a plurality of battery cells that each include a cell terminal formed from a first metal, and a contact plate including a conductive plate that is formed from a second metal and a first metallic surface layer (e.g., a surface coating or clad material) arranged on a first side of the conductive plate that is formed from the first metal, wherein part of the contact plate is arranged as a plurality of bonding connectors that form direct electrical connections to the cell terminals of the plurality of battery cells. In some designs, a second metallic surface layer (e.g., a surface coating or clad material) may further be arranged on a second side of the conductive plate and may also be formed from the first metal.
1 . A battery module, comprising:
a plurality of battery cells that each include a cell terminal formed from a first metal; and
a contact plate including a conductive plate that is formed from a second metal and a first metallic surface layer arranged on a first side of the conductive plate that is formed from the first metal,
wherein part of the contact plate is arranged as a plurality of bonding connectors that form direct electrical connections to the cell terminals of the plurality of battery cells.
2 . The battery module of claim 1 , wherein part of the first metallic surface layer is in direct contact with the cell terminals.
3 . The battery module of claim 1 , further comprising:
a second metallic surface layer arranged on a second side of the conductive plate that is formed from the first metal.
4 . The battery module of claim 1 , wherein the first metal comprises steel, coated steel or Hilumin.
5 . The battery module of claim 1 , wherein the second metal comprises Cu, Al or an alloy thereof.
6 . The battery module of claim 1 , further comprising:
another contact plate that includes a bonding connector that forms a direct electrical connection to a cell terminal of one of the plurality of battery cells.
7 . The battery module of claim 6 , wherein the contact plate and the another contact plate are stacked on top of each other above the cell terminal.
8 . The battery module of claim 6 , wherein the contact plate and the another contact plate are not stacked on top of each other above the cell terminal.
9 . The battery module of claim 1 , wherein at least one of the plurality of bonding connectors comprises a fuse area that is configured to break before any other part of the respective bonding connector in response to a temperature of the respective bonding connector exceeding a particular temperature threshold or a current flowing through the respective bonding connector exceeding a particular current threshold.
10 . The battery module of claim 9 ,
wherein the fuse area is thinner than any other part of the respective bonding connector in terms of thickness and/or width, or
wherein the fuse area includes one or more tapered or cutout sections, or
any combination thereof.
11 . The battery module of claim 1 , wherein at least one of the plurality of bonding connectors comprises at least one joint area where the at least one bonding connector is configured to permit flexing.
12 . The battery module of claim 11 , wherein the at least one bonding connector includes a single joint area.
13 . The battery module of claim 11 , wherein the at least one bonding connector includes multiple joint areas that are separate from each other.
14 . The battery module of claim 11 , wherein the at least one joint area corresponds to a respective depressed or crimped section of the at least one bonding connector.
15 . The battery module of claim 1 , wherein at least one of the plurality of bonding connectors comprises at a welding area where a respective direct electrical connection is formed with a respective cell terminal.
16 . The battery module of claim 1 , wherein an average thickness of the conductive plate is in the range from about 0.3 mm to about 3.0 mm.
17 . The battery module of claim 16 , wherein an average thickness of the conductive plate is in the range from about 1.0 mm to about 2.0 mm.
18 . The battery module of claim 1 , wherein an average thickness of the first metallic surface layer is in the range from about 0.05 mm to about 1.00 mm.
19 . The battery module of claim 18 , wherein the average thickness of the first metallic surface layer is in the range from about 0.15 mm to about 0.45 mm.
20 . The battery module of claim 1 , wherein at least one of the plurality of bonding connectors is at least partially formed and/or depressed in thickness and/or width.
21 . The battery module of claim 1 , wherein the first metallic surface layer is cladded on the conductive plate.
22 . The battery module of claim 1 , wherein the first metallic surface layer is coated on the conductive plate.
23 . A battery module, comprising:
a plurality of battery cells that each include a cell terminal formed from a first metal; and
a contact plate including a conductive plate that is formed from a second metal, a first metallic surface layer arranged on a first side of the conductive plate that is formed from the first metal, and a second metallic surface layer arranged on a second side of the conductive plate,
wherein part of the contact plate is arranged as a plurality of bonding connectors that form direct electrical connections to the cell terminals of the plurality of battery cells.
24 . The battery module of claim 23 , the second metallic surface layer is also formed from the first metal so as to compensate for thermal expansion of the first metallic surface layer.
25 . The battery module of claim 23 , wherein part of either the first metallic surface layer or the second metallic surface layer is in direct contact with the cell terminals.
26 . The battery module of claim 23 , wherein the first metal comprises steel, coated steel or Hilumin.
27 . The battery module of claim 23 , wherein the second metal comprises Cu, Al or an alloy thereof.
28 . The battery module of claim 23 , wherein at least one of the plurality of bonding connectors comprises a fuse area that is configured to break before any other part of the respective bonding connector in response to a temperature of the respective bonding connector exceeding a particular temperature threshold or a current flowing through the respective bonding connector exceeding a particular current threshold.
29 . The battery module of claim 23 , wherein at least one of the plurality of bonding connectors comprises at least one joint area where the at least one bonding connector is configured to permit flexing.
30 . The battery module of claim 23 , wherein at least one of the plurality of bonding connectors comprises at a welding area where a respective direct electrical connection is formed with a respective cell terminal.