That battery module patent is really clever, I take my hat off to the patent lawyers who wrote that, it describes everything, while being opaque about what the real innovations are.
What I think it is describing is a new way to manufacture cells, a module at a time.
1. The cell casing for a group of modules is created as a single unit. [ cheaper, faster, no waste material ]
2. Those cells are filled with electrolyte in parallel. [ faster ]
3. Instead of an end cap, the collector plate(s) are used to seal the cell. [ cheaper ]
4. The collector plate(s) are used connect to the anode and cathode, and contain the circuitry to connect them in parallel. [ cheaper, more robust ]
5. Modules (collector plates) have overlaps, which allows them to be connected together in series. [ cheaper ]
6. Protection systems which where on a per cell basis are now on a per module basis. [ fewer redundant systems, cheaper ]
7. Optimisation of battery, module and cell at the same time. [ cheaper, faster, better energy density ]
8. Better more consistent cooling. [ longer lasting, higher power ]
9. Dry electrode cells (Maxwell) eliminate drying ovens, which may make this scheme possible.
10. "This system-level design may be performed such that all the discrete, high precision, high-part-count operations occur in the same part of the manufacturing process, whereby reducing complexity and improving net cell to system yield."
This was filed in March so given time for drafting, this is the state of Tesla's thinking about 9 (Edit: now 12) months ago. I'm not sure how solid state electrolyte fits in with this.
