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Li-ion maker Boston-Power launches module system for EV and ESS applications; no-weld integration (updated with graphic)

Li-ion battery maker Boston-Power Inc. (earlier post) recently launched its Ensemble Module System; a “kit” of standard components that provides OEMs and pack assemblers with a simple, cost-effective way to assemble large format battery pack solutions for electric vehicle (EV) and energy storage system (ESS) applications. Available in 155 Wh and 116 Wh increments, module designs can be created to meet a wide variety of voltage and capacity requirements.

Key to the Ensemble solution is its novel pressure-connect approach to module assembly which completely eliminates the need for costly and time-consuming cell welding. Fully tested to automotive quality standards, the result is a mechanically robust module that can be assembled and disassembled in a fraction of the time of conventional methods.

Boston-Power’s Ensemble system. Click to enlarge.

By utilizing Boston-Power’s Swing Cell products, customers can realize the ease of assembly benefits of large format modules while retaining the benefits of packing density, reliability and thermal performance that come with using Boston-Power’s small form-factor battery cells.

Sample, prototype and production volumes are currently available.

Boston-Power’s battery technology platform is based on a flat, oval-shaped prismatic cell design with external dimensions equivalent to two conventional 18650 lithium-ion cells.

The Swing 5300 cell is targeted at a wide range of applications including Battery Electric Vehicles (BEVs), Plug-in Hybrid Electric Vehicles (PHEV), Light Commercial Vehicles (LCV), Neighborhood Electric Vehicles (NEV), and Stationary Energy Storage.

Gravimetric energy density for the 5300 mAh, 19.3 Wh cell is 207 Wh/kg; volumetric density is 490 Wh/L.

Companies in need of large format battery packs typically are faced with spending significant time and expense in designing, qualifying and fabricating custom solutions to meet their requirements, Bosston-Power said. The Ensemble Module System provides a semi-custom cell-to-module approach for the quick and easy integration of Boston-Power’s cells into high energy density battery modules, the company said.

For OEMs and pack assemblers, the Ensemble Module System accelerates time to proof-of-concept, prototype and market while reducing upfront capital investment, program risk, BOM complexity, labor cost, production yield and operational complexity.

The flexibility of the Ensemble system allows customers to design, build and test a prototype pack in a fraction of the time it would typically take for a fully custom solution. Next, the production quality components used in the initial prototypes greatly reduce the pack qualification effort needed to launch into mass production. Finally, the same highly-reliable standard components used in the prototype and development stages support a cost-effective launch of low, medium and high volume packs without the need for expensive tooling or a complex assembly line. Ensemble provides clear value from project inception through high volume pack production.

—Darren Bischoff, Director of Business Development and Marketing for Boston-Power

Boston-Power has R&D centers in Westborough, Massachusetts, and Beijing, China, and mass manufacturing operations based in Asia. The company is funded by top-tier venture capital firms GSR Ventures, Foundation Asset Management and Oak Investment Partners.



Li-ion maker Boston-Power launches module system for EV and ESS applications; no-weld integration

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