# US 12,224,417 B1 · Intercellular support structure of a battery system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,224,417 B1 - Document ID: US12224417B1 - Status: Granted - Kind: B1 - Application number: 18/438,814 - Filed: 2024-02-12 - Granted: 2025-02-11 - Earliest claimed: 2024-02-12 - Assignees: Rivian IP Holdings, LLC - Applicants: Rivian IP Holdings, LLC - Inventors: Tyler Jacobs; Jonathan Christopher Wilson - Web page: https://patentgrep.com/patent/US12224417B1 ## CPC - H01M 10/6557: arranged between the cells - H01M 10/482: {for several batteries or cells simultaneously or sequentially} - H01M 10/613: Cooling or keeping cold - H01M 10/625: Vehicles - H01M 10/643: Cylindrical cells - H01M 50/204: Racks, modules or packs for multiple batteries or multiple cells - H01M 50/213: adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence) - H01M 50/227: Organic material - H01M 50/293: characterised by the material - H01M 2010/4271: {Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing} - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract An intercellular support structure of a battery system is provided. The battery system includes cells arranged in an array and a first support structure with a first material to hold a first portion of a first group of cells with a first spacing between the first group of cells. The battery system includes a second support structure, adjacent to the first support structure, which can include a second material to hold, and can provide a second spacing between, a second portion of the first group of cells and a first portion of a second group of cells. The battery system can include a third support structure, adjacent to the second support structure and opposite to the first support structure, which can include the first material to hold a second portion of the second group of cells with the first spacing between the second portion of the second group of cells. ## Claims ### Claim 1 A battery system, comprising: a plurality of cells arranged in an array; a first support structure comprising a first material to hold, in a first parallel configuration, a first portion of a first group of cells of the plurality of cells, the first support structure further comprising a first spacing within the first portion of the first group of cells, wherein the first parallel configuration distributes current load across the first group of cells; a second support structure, adjacent to the first support structure, comprising a second material to hold, in a second parallel configuration, a second portion of the first group of cells and a first portion of a second group of cells of the plurality of cells, the second support structure further comprising a second spacing between the second portion of the first group of cells and the first portion of the second group of cells, wherein the second spacing is greater than the first spacing, and wherein the second parallel configuration distributes current load across the second group of cells; and a third support structure, adjacent to the second support structure and opposite to the first support structure, comprising the first material to hold a second portion of the second group of cells of the plurality of cells, the third support structure further comprising the first spacing within the second portion of the second group of cells. ### Claim 2 (depends on 1) The battery system of claim 1, wherein at least one of the first material or the second material comprises foam. ### Claim 3 (depends on 1) The battery system of claim 1, wherein at least one of the first material or the second material comprises expanded polypropylene or modified polyphenylene ether, or a combination thereof. ### Claim 4 (depends on 1) The battery system of claim 1, wherein at least one of the first material or the second material facilitates thermal management for the plurality of cells. ### Claim 5 (depends on 1) The battery system of claim 1, wherein the first support structure comprises a thermal component within the material to carry a fluid to dissipate heat generated from the first portion of the first group of cells. ### Claim 6 (depends on 1) The battery system of claim 1, comprising: a first block formed from the first support structure and the first portion of the first group of cells; and a second block formed from the second support structure and the second portion of the first group of cells, the second block assembled with the first block to establish the array of the plurality of cells. ### Claim 7 (depends on 1) The battery system of claim 1, wherein the first support structure comprises a thickness of at least 2 millimeters. ### Claim 8 (depends on 1) The battery system of claim 1, wherein the second material of the second support structure is in contact with one or more cells of the first group of cells and one or more cells of the second group of cells. ### Claim 9 (depends on 1) The battery system of claim 1, wherein the first support structure, second support structure, and third support structure are configured such that each structure fills in the gaps of the adjacent structure. ### Claim 10 (depends on 1) The battery system of claim 1, wherein the first support structure, second support structure, and third support structure are configured to be in contact with at least 10% of the outer surface of each cell. ### Claim 11 (depends on 1) The battery system of claim 1, wherein the battery system further comprises: a current collector assembly placed on a top surface of the plurality of cells comprising a conductor layer configured to provide an electrically conductive path for electricity to and from the plurality of cells. ### Claim 12 (depends on 11) The battery system of claim 11, wherein the battery system further comprises: a series busbar configured to maintain electrical current distribution and provide a low-impedance path for the current to flow to ground, protecting the components of the current collector assembly. ### Claim 13 (depends on 12) The battery system of claim 12, wherein the battery system further comprises: a balancing voltage and temperature module at one end, wherein the BVT module is configured to: measure at least one a temperature or a state of charge of at least one of the first group or second group of cells of the plurality of cells, sense and control voltage flows through the at least one of the first group or second group of cells of the plurality of cells, and providing real-time feedback of temperature and voltage flows of the at least one of the first group or second group of cells of the plurality of cells. ### Claim 14 A method, comprising: providing a battery system comprising a plurality of cells arranged in an array, wherein the battery system comprises: a first support structure comprising a first material to hold, in a first parallel configuration, a first portion of a first group of cells of the plurality of cells, the first support structure further comprising a first spacing within the first portion of the first group of cells, wherein the first parallel configuration distributes current load across the first group of cells; a second support structure, adjacent to the first support structure, comprising a second material to hold, in a second parallel configuration, a second portion of the first group of cells and a first portion of a second group of cells of the plurality of cells, the second support structure further comprising a second spacing between the second portion of the first group of cells and the first portion of the second group of cells, wherein the second spacing is greater than the first spacing, and wherein the second parallel configuration distributes current load across the second group of cells; and a third support structure, adjacent to the second support structure and opposite to the first support structure, comprising the first material to hold a second portion of the second group of cells of the plurality of cells, the third support structure further comprising the first spacing within the second portion of the second group of cells. ### Claim 15 (depends on 14) The method of claim 14, wherein at least one of the first material or the second material comprises foam. ### Claim 16 (depends on 15) The method of claim 15, wherein the foam is configured into shapes that conform to the contours of the cells. ### Claim 17 (depends on 14) The method of claim 14, wherein at least one of the first material or the second material comprises expanded polypropylene or modified polyphenylene ether, or a combination thereof. ### Claim 18 The method of 14, wherein the first support structure comprises a thermal component within the material to carry a fluid to dissipate heat generated from the first portion of the first group of cells. ### Claim 19 (depends on 14) The method of claim 14, comprising: assembling a first block formed from the first support structure and the first portion of the first group of cells with a second block formed from the second support structure and the second portion of the first group of cells. ### Claim 20 An electric vehicle, comprising: a plurality of cells arranged in an array; a first support structure comprising a first material to hold, in a first parallel configuration, a first portion of a first group of cells of the plurality of cells with a first spacing within the first portion of the first group of cells, wherein the first parallel configuration distributes current load across the first group of cells; a second support structure, adjacent to the first support structure, comprising a second material to hold, in a second parallel configuration, a second portion of the first group of cells and a first portion of a second group of cells of the plurality of cells with a second spacing between the second portion of the first group of cells and the first portion of the second group of cells, wherein the second spacing is greater than the first spacing, and wherein the second parallel configuration distributes current load across the second group of cells; and a third support structure, adjacent to the second support structure and opposite to the first support structure, comprising the first material to hold a second portion of the second group of cells of the plurality of cells with the first spacing within the second portion of the second group of cells. ### Claim 21 (depends on 20) The electric vehicle of claim 20, wherein at least one of the first material or the second material comprises foam.