US 12,456,777 B2
Integrated energy storage system
Andrew Pires, San Francisco, CA (US); Robert David Sumpf, Jr., San Francisco, CA (US); William B. Stockton, San Francisco, CA (US); Cole Spooner, Palo Alto, CA (US); Cole Prodan, Mountain View, CA (US); Jayesh Bharat Gorasia, San Francisco, CA (US); Kenton Harris, Palo Alto, CA (US); Dan Burke, Palo Alto, CA (US); Dafna Gabriela Szafer, Palo Alto, CA (US); Krupal Patel, Palo Alto, CA (US); Benjamin Parker, Palo Alto, CA (US); and David Elias Hegeman, San Jose, CA (US)
Assigned to Tesla, Inc., Austin, TX (US)
Filed by Tesla, Inc., Austin, TX (US)
Filed on Apr. 12, 2024, as Appl. No. 18/634,689.
Application 18/634,689 is a continuation of application No. 17/100,700, filed on Nov. 20, 2020, granted, now 11,962,030.
Claims priority of provisional application 63/081,253, filed on Sep. 21, 2020.
Claims priority of provisional application 62/938,646, filed on Nov. 21, 2019.
Prior Publication US 2024/0372200 A1, Nov. 7, 2024
Int. Cl. H01M 50/249 (2021.01); B60L 50/64 (2019.01); H01M 10/613 (2014.01); H01M 10/625 (2014.01); H01M 10/643 (2014.01); H01M 10/6556 (2014.01); H01M 10/658 (2014.01); H01M 50/213 (2021.01); H01M 50/271 (2021.01)
CPC H01M 50/249 (2021.01) [B60L 50/64 (2019.02); H01M 10/613 (2015.04); H01M 10/625 (2015.04); H01M 10/643 (2015.04); H01M 10/6556 (2015.04); H01M 10/658 (2015.04); H01M 50/213 (2021.01); H01M 50/271 (2021.01); H01M 2220/20 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A unitary battery component comprising:
a plurality of cell arrays, wherein individual cell arrays include a plurality of cylindrical-shaped cells arranged in a common orientation such that the plurality of cylindrical-shaped cells form one or more lines of cylindrical-shaped cells;
a cooling channel formed by one or more thermal components in proximity to the plurality of cell arrays, the one or more thermal components configured to cool the plurality of cell arrays;
a potting material formed of a resin compound, the potting material encompassing the plurality of cell arrays and providing structural support and thermal protection for the unitary battery component;
one or more foil sheets providing electrical connectivity to individual cylindrical-shaped cells of the plurality of cell arrays, wherein the one or more foil sheets are laser-welded to the plurality of cell arrays, and wherein the one or more foil sheets comprise a plurality of perforations configured to allow the potting material formed of the resin compound to fill in to encompass the plurality of cell arrays;
a bottom surface for supporting the plurality of cell arrays; and
a top surface for supporting the plurality of cell arrays, the top surface at least partially forming a structural component associated with a floor of a vehicle.