Battery cell interconnection architecture for mitigating short circuits

Abstract

An electrical interconnection architecture for electrically connecting stacked square battery modules in various combinations of parallel and series configurations distributes heat sources (e.g., heat conduction through busbars, and internal resistance heating from short circuits) to multiple battery cells, rather than a single adjacent battery cell, reducing thermal skew propagation. Examples of the interconnection architecture include various combinations of interleaved bus and bypass bus configurations. A dual parallel module configuration can have two series submodules, with battery cells connected in an interleaved interconnection pattern. A bus connection pattern can allow negative inlet and positive outlet to be on the same end of the battery module. Battery cells can be interconnected such that parallel battery cells are not adjacent battery cells. Various combinations of resistors and fuses can also be used to reduce overheating from short circuits.

Description

Technical Field

[0001] This disclosure relates to various square cell interconnect architectures for battery electric or hybrid electric vehicles and other battery-powered applications, which can passively resist inter-cell short circuits that could cause overheating of adjacent cells. Background Technology

[0002] Rechargeable energy storage systems (RESS) used in electric vehicles (EVs) achieve desired performance by electrically connecting several battery cells using a combination of series and parallel connections. In a single series string, each interconnected cell adds its individual voltage potential to achieve the desired total terminal voltage of the single series string. Parallel interconnections, on the other hand, produce a higher total energy capacity by adding the ampere-hour (Ah) coulombic capacities of multiple series-connected battery cells.

[0003] For example, a battery module with four individual cells can be electrically connected as one parallel group and four series groups (i.e., a "1P4S" battery architecture). A second example of a battery module with eight individual cells can be electrically connected as two parallel groups and four series groups (i.e., a "2P4S" battery architecture).

[0004] The battery pack design can be configured to optimize overall thermal performance under both normal and thermal offset conditions. This thermal optimization can also increase the overall energy density of the battery pack while reducing the overall battery pack space dedicated to using thermal barriers (which can be placed between adjacent cells). Short circuits in the interconnecting cell circuitry can cause internal resistance heating, which rapidly increases the cell temperature during thermal offset events. Under nominal operating conditions, "surge" or short-circuit currents can exceed the maximum discharge current by up to 70%. Such high short-circuit currents and heat conduction through the electrical bus can introduce excessive heat into adjacent cells, subsequently causing the cell temperature to rise beyond its normal design limits. Summary of the Invention

[0005] This disclosure teaches various electrical interconnect architectures for prismatic battery modules stacked in various combinations of electrical connections in parallel and series configurations. These interconnect architectures distribute heat sources (e.g., heat conduction through the bus and heating from internal resistance caused by short circuits) across multiple battery cells, rather than a single adjacent battery cell, thereby reducing heat offset propagation. Examples of interconnect architectures include various combinations of overlapping bus and bypass bus configurations. A dual-parallel module configuration can have two series sub-modules where battery cells are connected in an interleaved interconnect pattern. The bus connection pattern can allow the negative inlet and positive outlet to be located at the same end of the battery module. Battery cells can be interconnected such that parallel battery cells are not adjacent battery cells. Various combinations of resistors and fuses can also be used to reduce overheating caused by short circuits.

[0006] In a first embodiment, the battery module includes at least eight stacked square battery cells, each having positive and negative terminals arranged in various alternating patterns (architectures).

[0007] In the relevant embodiments, odd-numbered battery cells 1, 3, 5, etc., have a negative to positive polarity direction pointing from left to right, while even-numbered battery cells 2, 4, 6, etc., have a negative to positive polarity direction pointing in the opposite direction, i.e., from right to left. This "alternating single-cell" pattern, i.e., - / + / - / +..., repeats along the left side of the battery module. A similar but opposite pattern repeats along the right side of the module.

[0008] In another related embodiment, the first pair of adjacent battery cells each have a negative-to-positive polarity direction pointing from left to right, while the next pair of adjacent battery cells each have a negative-to-positive polarity direction pointing from right to left. This "alternating dual-cell" pattern, i.e., -- / ++ / -- / ++..., repeats along the left side of the battery module. A similar but reversed pattern repeats along the right side of the module.

[0009] In another related embodiment, the first group of four adjacent battery cells has a positive polarity direction from left to right, while the next group of four adjacent battery cells all have a negative polarity direction from right to left. This "alternating four-cell" pattern, i.e., ---- / ++++ / ---- / ++++..., repeats along the left side of the battery module. A similar but reversed pattern repeats along the right side of the module.

[0010] In the relevant embodiment, there are two adjacent battery cell segments, namely segment A and adjacent segment B. In segment A, odd-numbered battery cells 1 and 3 have a negative-to-positive polarity direction pointing positively from left to right, while even-numbered battery cells 2 and 4 have a negative-to-positive polarity direction pointing negatively from right to left. Adjacent segment B reverses this pattern, where odd-numbered battery cells 5 and 7 now have a negative-to-positive polarity direction pointing negatively from right to left, while even-numbered battery cells 6 and 8 have a negative-to-positive polarity direction pointing positively from left to right. This “alternating A / B” pattern, i.e., - / + / - / + / + / - / + / -..., repeats along the left side of the battery module. A similar but opposite pattern repeats along the right side of the module.

[0011] In one embodiment, the battery cells in the battery module are arranged in an "alternating alternating single cell" pattern - / + / - / +. A first C-shaped electrical "overlapping" bus interconnects the first negative battery terminal to the third positive terminal, a second interleaved C-shaped electrical "overlapping" bus interconnects the second negative battery terminal to the fourth positive terminal, and so on along the left side of the battery module. A similar but reversed interleaved C-shaped overlapping bus interconnection configuration is used on the right side of the module.

[0012] In one embodiment, the more negative inlet of the battery module is located at the proximal end of the module, while the more positive outlet is located at the distal end of the module.

[0013] In another embodiment, the more negative inlet of the battery module is located at the proximal end of the module, while the more positive outlet is also located at the proximal end of the module (i.e., the same end).

[0014] In one embodiment, the total number N of battery cells in the battery module is an even number.

[0015] In another embodiment, the total number N of battery cells in the battery module is an odd number.

[0016] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern - / + / - / +. A first C-shaped electrical "overlapping" bus interconnects the first negative battery terminal with the third positive terminal; a second interleaved C-shaped electrical "overlapping" bus interconnects the second negative battery terminal with the fourth positive terminal, and so on along the left side of the battery module. A similar but reversed set of interleaved C-shaped overlapping buses is used along the right side of the module.

[0017] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern - / + / - / +. A four-way "overlapping" bus electrically interconnects the second positive terminal with the fourth positive terminal, the fifth negative terminal, and the seventh negative terminal; this repeats in an alternating manner along the left side of the battery module. On the right side of the module, a first vertical bus interconnects the first positive terminal with the second negative terminal, the third positive terminal, and the fourth negative terminal. This vertical bus pattern repeats along the right side of the battery module.

[0018] In one embodiment, the battery cells in the battery module are arranged in an "alternating dual-cell" pattern ++ / -- / ++ / --. A first C-shaped "bypass" bus electrically interconnects the first positive terminal and the fourth negative terminal. A first vertical bus interconnects the second positive terminal and the third negative terminal. These patterns are repeated along the module. A first resistor may be connected between the first and second positive terminals. A second resistor may be connected between the third and fourth negative terminals. This pattern of interconnecting resistors is repeated along the module.

[0019] In one embodiment, the battery cells in the battery module are arranged in an "alternating dual-cell" pattern ++ / -- / ++ / --. A first vertical bus electrically interconnects the first positive terminal to the second positive terminal, the third negative terminal, and the fourth negative terminal. These patterns are repeated along the module. This interconnection architecture is an example of a "2P4S" pattern. A first fuse may be connected between the first and second positive terminals. A second fuse may be connected between the third and fourth negative terminals. This interconnection fuse pattern is repeated along the module.

[0020] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern: - / + / - / +. On the left side of the module, a first four-way C-shaped overlapping bus interconnects the second positive terminal with the fourth positive terminal, the fifth negative terminal, and the seventh negative terminal. On the right side of the module is a first vertical bus that interconnects the first positive terminal with the second negative terminal, the third positive terminal, and the fourth negative terminal. These patterns are repeated along the module.

[0021] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern: - / + / - / +. A first C-shaped overlapping bus interconnects the first negative terminal with the third negative terminal. A second interleaved C-shaped overlapping bus interconnects the second positive terminal with the fourth positive terminal. A first diagonal bus interconnects the fourth positive terminal with the adjacent fifth negative terminal. These patterns are repeated along the module.

[0022] In one embodiment, the battery cells are arranged in an "alternating four-cell" pattern: ---- / ++++ / ---- / ++++. On the left, a first four-pronged, non-uniformly spaced C-shaped overlapping bus interconnects the second negative terminal with the fourth negative terminal, the fifth positive terminal, and the seventh positive terminal. On the right, a second four-pronged, uniformly spaced C-shaped overlapping bus interconnects the first positive terminal with the third positive terminal, the fifth negative terminal, and the seventh negative terminal. These patterns are repeated along the module.

[0023] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern: - / + / - / +. On the left side, a first four-pronged, evenly spaced C-shaped overlapping bus interconnects the fifth positive terminal with the seventh positive terminal, the ninth negative terminal, and the eleventh negative terminal. On the right side, a second four-pronged, evenly spaced C-shaped overlapping bus interconnects the first positive terminal with the third positive terminal, the fifth negative terminal, and the seventh negative terminal. These patterns are repeated along the module.

[0024] In one embodiment, the electric vehicle includes: a body; wheels rotatably attached to the body; an electric traction drive motor rotatably attached to the wheels; a battery tray attached to the body; and a battery module attached to the battery tray, the battery module being electrically connected to the electric traction drive motor. The battery module includes at least a first set of four stacked prismatic battery cells and a second set of four additional stacked prismatic battery cells, wherein a first overlapping bus electrically connects a first positive terminal to a third negative terminal; a second bus electrically connects a second positive terminal to a fourth negative terminal; a third overlapping bus electrically connects the third positive terminal to a fifth negative terminal; a fourth overlapping bus electrically connects the fourth positive terminal to a sixth negative terminal; a fifth overlapping bus electrically connects the fifth positive terminal to a seventh negative terminal; a sixth overlapping bus electrically connects the sixth positive terminal to an eighth negative terminal; a seventh inline bus electrically connects the first positive terminal to the second positive terminal; and an eighth bus electrically connects the seventh negative terminal to the eighth negative terminal. In this embodiment, the battery module has a first side and an opposing second side. The third, fourth, seventh, and eighth positive terminals are located on the first side of the battery module. Furthermore, the first, second, fifth, and sixth positive terminals are located on the opposite second side of the battery module. Additionally, the first, second, fifth, and sixth negative terminals are located on the first side of the battery module, and finally, the third, fourth, seventh, and eighth negative terminals are located on the opposite second side of the battery module.

[0025] This invention provides the following technical solutions:

[0026] 1. A battery module, comprising:

[0027] The first square repeating battery sub-unit includes:

[0028] Four adjacent positions, including position #1, position #2, position #3 and position #4, are confined within the first square repeating sub-unit and stacked in ascending order from position #1 to position #2 to position #3 to position #4;

[0029] The first square battery cell located at position #1 includes a first positive terminal and a first negative terminal;

[0030] The second square battery cell located at position #2 includes a second positive terminal and a second negative terminal;

[0031] The third-shaped battery cell located at position #3 includes a third positive terminal and a third negative terminal;

[0032] The fourth square battery cell located at position #4 includes a fourth positive terminal and a fourth negative terminal; and

[0033] The second square repeatable battery sub-cell, located adjacent to the first square repeatable battery sub-cell, includes:

[0034] Four additional adjacent positions, including positions #5, #6, #7 and #8, are confined within the second square repeating battery sub-cell and stacked in ascending order from position #5 to position #6 to position #7 to position #8.

[0035] The fifth square battery cell located at position #5 includes the fifth positive terminal and the fifth negative terminal;

[0036] The sixth square battery cell located at position #6 includes the sixth positive terminal and the sixth negative terminal;

[0037] The seventh square battery cell, located at position #7, includes the seventh positive terminal and the seventh negative terminal; and

[0038] The eighth square battery cell, located at position #8, includes the eighth positive terminal and the eighth negative terminal.

[0039] 2. The battery module according to Scheme 1,

[0040] The battery module has a first side and an opposite second side;

[0041] Among them, the first, second, fifth and sixth positive terminals are located on the opposite second side of the battery module;

[0042] Among them, the third, fourth, seventh and eighth positive terminals are located on the first side of the battery module;

[0043] The first, second, fifth, and sixth negative terminals are located on the first side of the battery module; and

[0044] The third, fourth, seventh, and eighth negative terminals are located on the opposite second side of the battery module.

[0045] 3. The battery module according to Scheme 2 further includes:

[0046] The first bus electrically connects the first negative terminal to the third positive terminal;

[0047] The second bus electrically connects the second negative terminal to the fourth positive terminal;

[0048] The third bus connects the third negative terminal to the fifth positive terminal;

[0049] The fourth bus connects the fourth negative terminal to the sixth positive terminal.

[0050] The fifth bus connects the fifth negative terminal to the seventh positive terminal.

[0051] The sixth bus connects the sixth negative terminal to the eighth positive terminal.

[0052] The seventh bus electrically connects the first positive terminal to the second positive terminal; and

[0053] The eighth bus connects the seventh negative terminal to the eighth negative terminal.

[0054] 4. The battery module according to Scheme 3,

[0055] Among them, the first, second, third, fourth, fifth and sixth buses are all C-shaped;

[0056] The first bus and the second bus are intertwined;

[0057] The third and fourth buses are intertwined;

[0058] The fifth and sixth buses are intertwined.

[0059] The seventh bus is an inline bus; and

[0060] The eighth bus is an inline bus.

[0061] 5. The battery module according to Scheme 2 further includes:

[0062] The third square repeating battery sub-unit includes:

[0063] The ninth position #9 is confined within the third-shaped repeating battery sub-cell and stacked adjacent to the position #8 of the second square repeating battery sub-cell; and

[0064] The ninth square battery cell, located at position #9 of the ninth stack, includes the ninth positive terminal and the ninth negative terminal; and

[0065] The first bus electrically connects the second positive terminal to the fourth negative terminal;

[0066] The second bus connects the fourth positive terminal to the sixth negative terminal;

[0067] The third bus connects the sixth positive terminal to the eighth negative terminal;

[0068] The fourth bus connects the first negative terminal to the third positive terminal.

[0069] The fifth bus connects the third negative terminal to the fifth positive terminal.

[0070] The sixth bus connects the fifth negative terminal to the seventh positive terminal;

[0071] The seventh bus connects the seventh negative terminal to the ninth positive terminal.

[0072] The eighth bus connects the eighth positive terminal to the ninth negative terminal.

[0073] A more negative input bus connected to the second negative terminal; and

[0074] The corrected output bus is connected to the first positive terminal.

[0075] 6. The battery module according to Scheme 5,

[0076] Among them, the first, second, third, fourth, fifth and sixth buses are all C-shaped;

[0077] The first bus and the fifth bus are intertwined;

[0078] The second bus and the sixth bus are intertwined;

[0079] The third and seventh buses are intertwined; and

[0080] The eighth bus is an inline bus.

[0081] 7. The battery module according to Scheme 2 further includes:

[0082] The first bus electrically connects the first positive terminal to the second positive terminal, the third negative terminal, and the fourth negative terminal;

[0083] The second bus electrically connects the fifth positive terminal to the sixth positive terminal, the seventh negative terminal, and the eighth negative terminal;

[0084] The third bus connects the first negative terminal to the second negative terminal;

[0085] The fourth bus electrically connects the third positive terminal to the fourth positive terminal, the fifth negative terminal, and the sixth negative terminal; and

[0086] The fifth bus connects the seventh positive terminal to the eighth positive terminal.

[0087] 8. The battery module according to claim 7 further includes:

[0088] The first fuse is disposed between the first positive terminal and the second positive terminal;

[0089] A second fuse is provided between the third and fourth negative terminals;

[0090] A third fuse is located between the fifth and sixth positive terminals;

[0091] A fourth fuse is located between the seventh and eighth negative terminals;

[0092] The fifth fuse is located between the first negative terminal and the second negative terminal;

[0093] A sixth fuse is located between the third and fourth positive terminals;

[0094] The seventh fuse is located between the fifth and sixth negative terminals; and

[0095] The eighth fuse is located between the seventh positive terminal and the eighth positive terminal.

[0096] 9. The battery module according to claim 2, further comprising:

[0097] A first resistor is disposed between the first positive terminal and the second positive terminal;

[0098] A second resistor is disposed between the third negative terminal and the fourth negative terminal;

[0099] A third resistor is positioned between the fifth and sixth positive terminals;

[0100] A fourth resistor is positioned between the seventh and eighth negative terminals;

[0101] A fifth resistor positioned between the third and fourth positive terminals; and

[0102] A sixth resistor is positioned between the fifth and sixth negative terminals.

[0103] 10. The battery module according to claim 2 further includes:

[0104] The first bus electrically connects the first positive terminal to the fourth negative terminal;

[0105] The second bus electrically connects the second positive terminal to the third negative terminal;

[0106] The third bus connects the fifth positive terminal to the eighth negative terminal;

[0107] The fourth bus connects the sixth positive terminal to the seventh negative terminal.

[0108] The fifth bus connects the first negative terminal to the second negative terminal.

[0109] The sixth bus connects the third positive terminal to the sixth negative terminal.

[0110] The seventh bus connects the fourth positive terminal to the fifth negative terminal; and

[0111] The eighth bus connects the seventh positive terminal to the eighth positive terminal; and

[0112] The first fuse is disposed between the first positive terminal and the second positive terminal;

[0113] A second fuse is provided between the third and fourth negative terminals;

[0114] A third fuse is located between the fifth and sixth positive terminals;

[0115] A fourth fuse is located between the seventh and eighth negative terminals;

[0116] The fifth fuse is positioned between the third and fourth positive terminals; and

[0117] The sixth fuse is located between the fifth and sixth negative terminals.

[0118] 11. The battery module according to Scheme 1,

[0119] The battery module has a first side and an opposite second side;

[0120] Among them, the second, fourth, sixth and eighth positive terminals are located on the first side of the battery module;

[0121] Among them, the first, third, fifth and seventh positive terminals are located on the opposite second side of the battery module;

[0122] The second, fourth, sixth, and eighth negative terminals are located on opposite second sides of the battery module; and

[0123] The first, third, fifth, and seventh negative terminals are located on the first side of the battery module.

[0124] 12. The battery module according to claim 11 further includes:

[0125] The first bus electrically connects the first negative terminal to the third negative terminal;

[0126] The second bus electrically connects the second positive terminal to the fourth positive terminal, the fifth negative terminal, and the seventh negative terminal;

[0127] The third bus electrically connects the first positive terminal to the second negative terminal, the third positive terminal, and the fourth negative terminal;

[0128] The fourth bus connects the fifth positive terminal to the sixth, seventh, and eighth negative terminals;

[0129] The fifth bus connects the sixth positive terminal to the eighth positive terminal.

[0130] 13. The battery module according to Scheme 12,

[0131] The first bus is C-shaped;

[0132] The second bus includes four intersecting forks;

[0133] The third bus includes the first vertical electrical bus; and

[0134] The fourth bus includes the second inline electrical bus.

[0135] 14. The battery module according to claim 11 further includes:

[0136] The first bus electrically connects the first negative terminal to the third negative terminal;

[0137] The second bus electrically connects the second positive terminal to the fourth positive terminal;

[0138] The third bus connects the fifth negative terminal to the seventh negative terminal;

[0139] The fourth bus connects the sixth positive terminal to the eighth positive terminal.

[0140] The fifth bus connects the first positive terminal to the third positive terminal.

[0141] The sixth bus connects the second negative terminal to the fourth negative terminal.

[0142] The seventh bus connects the fifth positive terminal to the seventh positive terminal.

[0143] The eighth bus connects the sixth negative terminal to the eighth negative terminal.

[0144] The ninth bus connects the second negative terminal to the third positive terminal.

[0145] The tenth bus connects the fourth positive terminal to the fifth negative terminal; and

[0146] The eleventh bus connects the sixth negative terminal to the seventh positive terminal.

[0147] 15. The battery module according to Scheme 1,

[0148] The battery module has a first side and an opposite second side;

[0149] Among them, the first, second, third and fourth negative terminals are located on the first side of the battery module;

[0150] Among them, the first, second, third and fourth positive terminals are located on the opposite second side of the battery module;

[0151] The fifth, sixth, seventh, and eighth positive terminals are located on the first side of the battery module; and

[0152] Among them, the fifth, sixth, seventh and eighth negative terminals are located on the opposite second side of the battery module.

[0153] 16. The battery module according to claim 15 further includes:

[0154] The first bus electrically connects the first negative terminal to the third negative terminal;

[0155] The second bus electrically connects the second negative terminal to the fourth negative terminal, the fifth positive terminal, and the seventh positive terminal;

[0156] The third bus electrically connects the first positive terminal to the third positive terminal, the fifth negative terminal, and the seventh negative terminal; and

[0157] The fourth bus connects the second positive terminal to the fourth positive terminal, the sixth negative terminal, and the eighth negative terminal.

[0158] 17. The battery module according to Scheme 1,

[0159] The battery module has a first side and an opposite second side;

[0160] Among them, the first, third, sixth and eighth negative terminals are located on the first side of the battery module;

[0161] Among them, the first, third, sixth and eighth positive terminals are located on the opposite second side of the battery module;

[0162] The second, fourth, fifth, and seventh positive terminals are located on the first side of the battery module; and

[0163] The second, fourth, fifth, and seventh negative terminals are located on the opposite second side of the battery module.

[0164] 18. The battery module according to claim 17 further includes:

[0165] The first bus electrically connects the first negative terminal to the third negative terminal;

[0166] The second bus electrically connects the second positive terminal to the fourth positive terminal;

[0167] The third bus electrically connects the first positive terminal to the third positive terminal, the fifth negative terminal, and the seventh negative terminal; and

[0168] The fourth bus connects the second negative terminal to the fourth negative terminal, the sixth positive terminal, and the eighth positive terminal.

[0169] 19. A battery module, comprising:

[0170] The first square repeating battery sub-unit includes:

[0171] Four adjacent positions, including position #1, position #2, position #3 and position #4, are confined within the first square repeating battery sub-cell and stacked in ascending order from position #1 to position #2 to position #3 to position #4.

[0172] The first square battery cell located at position #1 includes a first positive terminal and a first negative terminal;

[0173] The second square battery cell located at position #2 includes a second positive terminal and a second negative terminal;

[0174] The third-shaped battery cell located at position #3 includes a third positive terminal and a third negative terminal;

[0175] The fourth square battery cell located at position #4 includes a fourth positive terminal and a fourth negative terminal; and

[0176] The second square repeatable battery sub-cell, located adjacent to the first square repeatable battery sub-cell, includes:

[0177] Four additional adjacent positions, including positions #5, #6, #7 and #8, are confined within the second adjacent square repeating battery sub-cell and stacked in ascending order from position #5 to position #6 to position #7 to position #8.

[0178] The fifth square battery cell located at position #5 includes the fifth positive terminal and the fifth negative terminal;

[0179] The sixth square battery cell located at position #6 includes the sixth positive terminal and the sixth negative terminal;

[0180] The seventh square battery cell, located at position #7, includes the seventh positive terminal and the seventh negative terminal; and

[0181] The eighth square battery cell, located at position #8, includes the eighth positive terminal and the eighth negative terminal; and

[0182] The first bus electrically connects the second positive terminal to the fourth positive terminal, the fifth negative terminal, and the seventh negative terminal;

[0183] The second bus connects the sixth positive terminal to the eighth positive terminal, the ninth negative terminal, and the eleventh negative terminal.

[0184] The third bus electrically connects the first positive terminal to the second negative terminal, the third positive terminal, and the fourth negative terminal; and

[0185] The fourth bus connects the fifth positive terminal to the sixth, seventh, and eighth negative terminals.

[0186] The battery module has a first side and an opposite second side;

[0187] Among them, the second, fourth, sixth and eighth positive terminals are located on the first side of the battery module;

[0188] Among them, the first, third, fifth and seventh positive terminals are located on the opposite second side of the battery module;

[0189] The second, fourth, sixth, and eighth negative terminals are located on opposite second sides of the battery module; and

[0190] The first, third, fifth, and seventh negative terminals are located on the first side of the battery module.

[0191] 20. A vehicle comprising:

[0192] Body;

[0193] Wheels that can be rotatably attached to the vehicle body;

[0194] An electric traction drive motor attached to the wheels;

[0195] Battery tray attached to the vehicle body; and

[0196] A battery module attached to a battery tray and electrically connected to an electric traction drive motor;

[0197] The battery module includes:

[0198] The first square repeating battery sub-unit includes:

[0199] Four adjacent positions, including position #1, position #2, position #3 and position #4, are confined within the first square repeating battery sub-cell and stacked in ascending order from position #1 to position #2 to position #3 to position #4.

[0200] The first square battery cell located at position #1 includes a first positive terminal and a first negative terminal;

[0201] The second square battery cell located at position #2 includes a second positive terminal and a second negative terminal;

[0202] The third-shaped battery cell located at position #3 includes a third positive terminal and a third negative terminal;

[0203] The fourth square battery cell located at position #4 includes a fourth positive terminal and a fourth negative terminal; and

[0204] The second square repeatable battery sub-cell, located adjacent to the first square repeatable battery sub-cell, includes:

[0205] Four additional adjacent positions, including positions #5, #6, #7 and #8, are confined within the second adjacent square repeating battery sub-cell and stacked in ascending order from position #5 to position #6 to position #7 to position #8.

[0206] The fifth square battery cell located at position #5 includes the fifth positive terminal and the fifth negative terminal;

[0207] The sixth square battery cell located at position #6 includes the sixth positive terminal and the sixth negative terminal;

[0208] The seventh square battery cell, located at position #7, includes the seventh positive terminal and the seventh negative terminal; and

[0209] The eighth square battery cell, located at position #8, includes the eighth positive terminal and the eighth negative terminal; and

[0210] The first bus electrically connects the first positive terminal to the third negative terminal;

[0211] The second bus electrically connects the second positive terminal to the fourth negative terminal;

[0212] The third bus connects the third positive terminal to the fifth negative terminal;

[0213] The fourth bus connects the fourth positive terminal to the sixth negative terminal.

[0214] The fifth bus connects the fifth positive terminal to the seventh negative terminal.

[0215] The sixth bus connects the sixth positive terminal to the eighth negative terminal.

[0216] The seventh bus electrically connects the first positive terminal to the second positive terminal; and

[0217] The eighth bus connects the seventh negative terminal to the eighth negative terminal; and

[0218] The battery module has a first side and an opposite second side;

[0219] Among them, the first, second, fifth and sixth positive terminals are located on the opposite second side of the battery module;

[0220] Among them, the third, fourth, seventh and eighth positive terminals are located on the first side of the battery module;

[0221] The first, second, fifth, and sixth negative terminals are located on the first side of the battery module; and

[0222] The third, fourth, seventh, and eighth negative terminals are located on the opposite second side of the battery module. Attached Figure Description

[0223] Figure 1 A perspective view of an example car with a battery tray is shown, which houses a battery pack with multiple interconnected square battery modules, each of which includes multiple stacked square battery cells interconnected in various series and parallel configurations.

[0224] Figure 2 An exploded perspective view shows a schematic example of a battery module with multiple stacked battery cells.

[0225] Figure 3 It shows Figure 2 An exploded side cross-sectional view (section AA) of a schematic example of the battery module shown.

[0226] Figure 4 It shows Figure 2 A schematic example of the battery module shown is presented in a front cross-sectional view (section BB).

[0227] Figure 5 A top view showing a schematic example of a battery module is shown.

[0228] Figure 6 A top view showing a schematic example of a battery module is shown.

[0229] Figure 7 A top view showing a schematic example of a battery module is shown.

[0230] Figure 8 A top view showing a schematic example of a battery pack.

[0231] Figure 9 A top view showing a schematic example of a battery pack.

[0232] Figure 10 A top view shows a schematic example of a battery pack with two interconnected battery modules.

[0233] Figure 11A A top view shows a schematic example of the circuitry of a battery module, where the battery undergoes thermal displacement.

[0234] Figure 11B A top view shows a schematic example of the circuitry of a battery module, where the battery undergoes thermal displacement.

[0235] Figure 12 A top view showing a schematic example of a battery module is shown.

[0236] Figure 13A top view showing a schematic example of a battery module is shown.

[0237] Figure 14A A top view shows a schematic example of a battery module with thermally offset battery cells.

[0238] Figure 14B A top view shows a schematic example of a battery module with thermally offset battery cells.

[0239] Figure 15 A top view showing a schematic example of a battery module is shown.

[0240] Figure 16 A top view showing a schematic example of a battery module is shown.

[0241] Figure 17 A top view showing a schematic example of a battery module is shown.

[0242] Figure 18 A top view showing a schematic example of a battery module is shown.

[0243] Figure 19 A top view showing a schematic example of a type A battery module is shown.

[0244] Figure 20 A top view showing a schematic example of a Type B battery module is shown.

[0245] Figure 21 A top view showing a schematic example of a C-type battery module is shown.

[0246] Figure 22 A top view showing a schematic example of a D-type battery module is shown.

[0247] Figure 23 A top view showing a schematic example of a 1P4S battery architecture for a battery module.

[0248] Figure 24 A top view showing a schematic example of a 2P4S battery architecture for a battery module. Detailed Implementation

[0249] The square battery modules disclosed herein can be used in a variety of different mobile electric or hybrid electric applications, including but not limited to: automobiles, trucks, motorcycles, boats, submarines, aircraft, drones, spacecraft, satellites, trains or other mobile platforms, as well as non-mobile electric systems such as power plants, electrical appliances, and photovoltaic solar cell storage devices. The phrase "vehicle" is broadly defined as a mobile machine, including but not limited to: automobiles, trucks, motorcycles, boats, submarines, aircraft, drones, spacecraft, satellites, trains or other mobile platforms. The term "square" broadly refers to a six-sided object with 90-degree (square) angles, which may have an elongated rectangular or square (cube) shape. The term "battery cell" broadly includes both lithium-ion based battery chemistry and sodium-ion battery chemistry. The terms "bus," "bus connection," and "bus" have the same meaning and are interchangeable. The terms "battery cell" and "cell" have the same meaning and are interchangeable. The terms "connection" and "interconnection" have the same meaning and are interchangeable. The terms "through hole" and "hole" have the same meaning and can be used interchangeably.

[0250] The terms “C-bus,” “C-overlapping bus,” “double-fork bus,” and “double-fork overlapping bus” have the same meaning and are interchangeable. A “C-overlapping bus” may have two or four integral forks, protrusions, or fingers that extend vertically from a common longitudinal bus in a comb-like geometry. The terms “alternating” and “interlacing” have the same meaning and are interchangeable. The term “alternating” also means “every other” (e.g., “every other cell”). The phrase “alternating orientation” also means “facing in opposite directions” or “opposite orientation” (e.g., “opposite-facing C-bus”). The terms “overlapping” and “interlacing” have the same meaning and are interchangeable. The phrase “a pair of interlacing C-overlapping buses” refers to a pair of oppositely facing, offset C-overlapping buses, where each bus has two or four forks (protrusions, fingers) that “interlac” or “overlap” with another oppositely facing C-bus. The modifier "about" indicates that the range (tolerance) of the specified variable does not exceed + / - 10% of the specified value of the variable.

[0251] Figure 1 An example perspective view of a vehicle 1 is shown, which has a body 2, two connected wheels 3 and 3', and a battery pack 5. The battery pack 5 includes a battery tray 7 connected to the body 2. The battery tray 7 houses a square battery module 8, which includes multiple stacked square battery cells 4, 4', etc., which are electrically interconnected with electrical buses 6, 6', etc., in different combinations of parallel and series architectures. The battery cells 4, 4', etc., are electrically connected to a drive traction motor 9, which is rotatably connected to the wheel 3' to drive the wheel 3'.

[0252] Figure 2 An exploded perspective view shows a schematic example of a battery module 10 having multiple stacked battery cells 12, 12', 12" etc. The battery module 10 includes multiple stacked first, second, and third shaped battery cells 12, 12', 12" etc. Each battery cell 12, 12', 12" etc. includes a pair of positive terminals 11, 11', 11" and negative terminals 13, 13', 13"' etc. A first horizontal layer 14 located above the battery cells 12, 12', 12" etc. is a thin vent 14 made of an electrically insulating material (e.g., mica) having multiple pairs of through holes (i.e., holes) 15 and 15' etc., which are respectively disposed above the positive terminal 11 and the negative terminal 13 and vertically aligned with the positive terminal 11 and the negative terminal 13. Next, the second horizontal layer 16 located above the vent 14 is an interconnect board (ICB) 16, which is made of an electrically insulating material (e.g., a polymer or plastic material) and has multiple pairs of through holes (i.e., holes) 17 and 17', etc., which are located above and vertically aligned with the through holes (i.e., holes) 15 and 15' in the vent 14, respectively. Next, the third horizontal layer 25 located above the ICB 16 includes multiple pairs of interleaved (i.e., overlapping) right- and left-facing C-shaped overlapping buses 20 and 20', 22 and 22', etc.

[0253] See also Figure 2 The right-facing C-shaped overlapping bus 20 is electrically connected in an interleaved configuration to both the negative terminal 13 of the first battery cell 12 and the negative battery terminal 13” of the third battery cell 12”. Note: The negative terminal 13 protrudes vertically through vertically aligned holes 15 and 17 and is electrically connected to the C-shaped overlapping bus 20. In this embodiment, the C-shaped overlapping buses 20, 20', 22, 22', etc., have two forks (protrusions) perpendicular to their respective bus extensions (like a "comb"). Finally, the fourth horizontal layer 27 includes a pair of longitudinal cover plates 18 and 18', which are located above the C-shaped overlapping buses 20, 20', 22, 22', etc., included in the third layer 25, and electrically insulate the electrical buses 20, 20', 22, 22', etc., to prevent short circuits. The cover plates 18 and 18' comprise an electrically insulating material (e.g., mica). Ventilation holes 24 are arranged through ICB16 and are appropriately sized to release gas generated when the lower ventilation fin 14 ruptures due to a thermal offset event that puts pressure on the square battery cell 12.

[0254] The diagram below shows additional details of various examples of terminal-to-bus interconnect architectures.

[0255] Figure 3 It showed the previous Figure 2The diagram shows an exploded side cross-sectional view (section AA) of a schematic example of the battery module 10. The ICB 16 has a plurality of through-holes (holes) 17, 17', 17”, etc., arranged vertically through the thickness of the ICB 16. Right-facing C-shaped overlapping buses 20, 22, etc., and left-facing C-shaped overlapping buses 20', 22', etc., are located above the ICB 16 and vertically aligned with the rows of through-holes (holes) 17, 17', 17”, etc. Each pair of C-shaped overlapping buses 20, 20' and 22, 22', etc., is horizontally offset from each other in an interleaved configuration.

[0256] Figure 4 It shows Figure 2 The diagram shows a schematic example of a front cross-sectional view (section BB) of the battery module 10. Each battery cell 12 includes a pair of positive and negative terminals 11 and 13, respectively. A vent 14 is disposed above the battery cell 12 and is thin enough that an increase in gas pressure inside the battery cell 12 due to a thermal offset event causes the vent 14 to rupture and gas to escape upwards through a vent hole 24, thereby preventing overpressure of the battery cell 12 during a thermal offset event. Next, an ICB 16 is disposed above the vent 14 and has a pair of through holes (holes) 15 and 15' through the ICB 16, which are vertically aligned with the battery cell terminals 13 and 11, respectively. Next, a pair of C-shaped overlapping busbars 20 and 20' are disposed above the ICB 16 and vertically aligned (and electrically connected) with the battery terminals 13 and 11 below, respectively. Finally, a pair of electrically insulating covers 18 and 18' are disposed above the pair of C-shaped overlapping busbars 20 and 20', respectively.

[0257] Figure 5 A top view of a schematic example of a battery module 30 is shown. Module 30 includes at least eight square battery cells 12, 12', 12”, 12”', etc., stacked in ascending order of position #1, position #2, etc., up to position #8. The total number of battery cells stacked in module 30 is N, where “N” is an even number. The first battery cell 12 includes a positive terminal 11 on the right and a negative terminal 13 on the left, having a positive polarity direction (i.e., - / + from left to right). Similarly, the adjacent second battery cell 12' includes a positive terminal 11' and a negative terminal 13', which are arranged in the same positive polarity direction as the first battery cell 12 (i.e., - / + from left to right). Compared to the previous pair of battery cells 12, 12', the next pair of battery cells 12” and 12”' both have opposite (reverse) right-to-left polarity directions (i.e., - / + from right to left). This repeating pattern of battery pairs with alternating positive / reverse polarity directions repeats along the length of module 30.

[0258] Still referencing Figure 5The repeating pattern of the positive and negative terminal pairs along the left side of module 30 is "- / - / + / + / - / - / + / +…", and so on along the length of module 30. The repeating pattern of the positive and negative terminal pairs along the right side of module 30 is "+ / + / - / - / + / + / --…", and so on along the length of module 30. Direct current (DC) 43 flows from the negative terminal to the positive terminal of each battery cell. This embodiment is referred to as a "2P" configuration, meaning that a first current 43 flows through a first pair of two alternating (interleaved) battery cells 12 and 12”, while a second current 43' flows through a second pair of two alternating (interleaved) battery cells 12' and 12”', which have opposite polarity directions from left to right, and so on, through the rest of module 30. The two parallel currents 43 and 43' (with similar amplitudes) are combined via an inline outlet bus 28 to produce an outlet current 47. The total number of battery cells = N, where N is equal to an even number of battery cells.

[0259] Still referencing Figure 5 The first right-facing C-shaped overlapping bus 19 electrically connects the negative terminal 13 of the first battery cell 12 to the positive terminal 11" of the third battery cell 12" in an alternating manner. The second left-facing C-shaped overlapping bus 21 electrically connects the negative terminal 13" of the second battery cell 12" to the positive terminal 11"" of the fourth battery cell 12"' in an alternating manner. This pattern is repeated along the length of the module 30. Each individual C-shaped overlapping bus 19, 20, 21, 22, etc., is configured in an alternating (interleaved) manner along the length of the module 30 to electrically connect the negative terminal (e.g., terminal 13) of the first battery cell (e.g., battery cell 12) to the positive terminal (e.g., terminal 11") of an alternating third battery cell (e.g., battery cell 12"'). The two forks of the first right-facing C-shaped overlapping bus 19 intersect (i.e., stagger) with the two forks of the second left-facing C-shaped overlapping bus 21, and so on for each pair of left-facing and right-facing C-shaped overlapping buses 19, 20, 21, 22, etc. Module 30 has a more negative inline input bus 26 for inputting a DC input current 45 at the far end (bottom) end 33 of module 30. Module 30 also has a more positive inline output bus 28 for outputting a DC output current 47 at the near end (top) end 31 of module 30. The more negative inline input bus 26 is electrically connected to a pair of bottom (far end) more negative terminals 23 and 29. The more positive inline output bus 28 is electrically connected to a pair of top (near end) positive terminals 11 and 11'. The overall battery cell interconnect architecture for module 30 in this embodiment is referred to as the "overlapping bus" architecture.

[0260] Figure 6A top view of a schematic example of a battery module 36 is shown. Module 36 includes at least eight square battery cells 12, 12', 12”, 12”', etc., stacked in ascending order of position #1, position #2, etc., up to position #8, and finally up to “N” stacked battery cells, where “N” is an even number. The first battery cell 12 includes a positive terminal 11 on the right and a negative terminal 13 on the left, arranged in a positive polarity direction (i.e., - / + from left to right). Similarly, the adjacent second battery cell 12' includes a positive terminal 11' on the left and a negative terminal 13' on the right, arranged in a polarity direction opposite to (reverse of) the positive polarity direction of the first battery cell 12 (i.e., + / - from left to right). The repeating pattern of alternating positive and negative terminals along the left side of module 36 is represented by “- / + / - / + / - / + / - / - / +…”, and so on along the length of module 36. The repeating pattern of alternating positive and negative terminals along the right side of module 36 is represented by "+ / - / + / - / + / - / + / -…", and so on along the length of module 36.

[0261] Still referencing Figure 6 Direct current 43 (DC) flows from the negative terminals 13, 13', 13" of each battery cell 12, 12', 12" to the positive terminals 11, 11', 11" respectively. The negative terminal 13 of the first battery cell 12 is electrically connected to the negative terminal 13" of the non-adjacent third battery cell 12" via a first left-facing C-shaped overlapping bus 22. The positive terminal 11' of the second battery cell 12' is connected to the positive terminal 11"' of the fourth battery cell 12"' and the negative terminals 300 of the fifth battery cell 400 and the seventh battery cell 404 via a first right-facing four-pronged (i.e., four-finger) C-shaped overlapping bus 34. Sub-module 304. On the right side of module 36, a first vertical bus 32 interconnects the positive terminal 11 of the first battery cell 12 to the negative terminal 13' of the second battery cell 12', the positive terminal 11' of the third battery cell 12'", and the negative terminal 13'' of the fourth battery cell 12''. Similarly, on the right side of module 36, a second vertical bus 32' interconnects the positive terminal 310 of the fifth battery cell 400 to the negative terminal 312 of the sixth battery cell 402, the positive terminal 314 of the seventh battery cell 404, and the negative terminal 316 of the eighth battery cell 406. The total number of battery cells in module 36 is N, where N is an even number.

[0262] Still referencing Figure 6Module 36 has a negative input bus 26 for inputting a DC input current 45 at the near end (top) 31 of module 36, and a positive output bus 28 for outputting a DC output current 47 at the far end (bottom) 33 of module 36. The negative input bus 26 is electrically connected to the negative terminal 13 of the first battery cell 12, and the positive output bus 28 is electrically connected to the positive terminal 500 of the last battery cell 600.

[0263] Figure 7 A top view illustrating a schematic example of battery module 38 is shown. The configuration of battery cells 12, 12', 12”, 12”', etc., is the same as previously shown. Figure 5 The example of battery module 30 shown is the same, except that an additional battery cell 37 (i.e., the ninth battery cell) is added at the distal end 33 of module 38. A DC inlet current 45 enters the proximal end 31 of module 38 via an inlet bus 26, which is electrically connected to the negative terminal 13' of the second battery cell 12'. The ninth battery cell 37 includes a negative terminal 49 and a positive terminal 53. The negative terminal 49 of battery cell 37 is electrically connected to the positive terminal of the eighth battery cell via an electrical bus 51. This allows the DC current 43 to cross from the left to the right side of the ninth battery cell 37 at the distal end 33 of module 38, and then subsequently return to the proximal end 31 of module 38. The outlet DC current 47 exits module 38 via an outlet bus 28, which is electrically connected to the positive terminal 11 of the first battery cell 12. In this embodiment, the total number of battery cells in module 38 is an odd number (= N+1), where N is an even number. Both the inlet current 45 and the outlet current 47 are located at the same proximal (top) end 31 of module 38.

[0264] Figure 8 A top view of a schematic example of a battery pack 42 is shown, comprising eight battery modules labeled A, B, C, D, E, F, G, and H. Each individual module A, B, C, etc., has a more negative input bus 46 and a more positive output bus 48 located at the same end of each module. The eight interconnected modules A, B, C, etc., are electrically connected in a "2P4S" parallel / series configuration, meaning that two modules are connected in parallel and four modules are connected in series. Specifically, the two negative terminals of modules A and E are connected together via the first bus 46. Next, the two positive terminals of modules A and E (along with the two negative terminals of modules B and F) are connected together via the second bus 48. Similarly, the two positive terminals of modules B and F (along with the two negative terminals of modules C and G) are connected via the third bus 48'. Likewise, the two positive terminals of modules C and G (along with the two negative terminals of modules D and H) are connected via the fourth bus 48'. Finally, the two positive terminals of modules D and H are connected via the fifth bus 46'. A DC input current 45 is present in... Figure 8The current flows from left to right through module 42 and flows out together with the outlet current 47.

[0265] Figure 9 A top view of a schematic example of a battery pack 50 is shown, comprising eight battery modules labeled A, B, C, D, E, F, G, and H. Module E has a more negative input bus 60 located diagonally (i.e., along the diagonal) and a more positive output bus 56, etc., and the remaining modules follow the same configuration. The eight interconnected modules A, B, C, etc., are electrically connected in a “1P8S” series configuration, meaning there is one parallel series (i.e., “1P”) and eight series-connected modules A, B, C, etc. (i.e., “8S”) to form a “1P8S” architecture. Specifically, the positive terminal of module E and the negative terminal of module A are connected via a first bus 56. Similarly, the positive terminal of module A and the negative terminal of module B are connected via a second bus 54. Similarly, the positive terminal of module B and the negative terminal of module F are connected via a third bus 58. Similarly, the positive terminal of module F and the negative terminal of module G are connected via a fourth bus 62. Similarly, the positive terminal of module G and the negative terminal of module C are connected via the fifth bus 56'. Likewise, the positive terminal of module C and the negative terminal of module D are connected via the sixth bus 54'. Finally, the positive terminal of module D and the negative terminal of module H are connected together via the seventh bus 58'. The DC inlet current 66 flows into module E through the inlet bus 60 and exits module H as the outlet current 68 through the outlet bus 64.

[0266] Figure 10 A top view of a schematic example of a battery pack 70 is shown, comprising two interconnected battery modules A and B. Each module A and B includes eight stacked square battery cells 12, 12', 12”, 12”', etc., numbered #1, #2, #3, #4, etc. The battery cell interconnection architecture used by each module A and B is referred to as a “bypass bus” architecture. The term “bypass bus” means that battery cell #1 is connected to battery cell #4, bypassing the two battery cells #2 and #3 located between the first and fourth battery cells. In module A, the positive terminal of the first battery cell 12 is electrically connected to the negative terminal of the fourth battery cell 12”' via a left-facing C-shaped bypass bus 72. Similarly, the positive terminal of the third battery cell 12”' is electrically connected to the negative terminal of the sixth battery cell via a right-facing C-shaped bypass bus 73. Furthermore, the positive terminal of the second battery cell 12' is electrically connected to the negative terminal of the third battery cell 12" via the first inline bus 74. Similarly, the positive terminal of the fourth battery cell 12"' is electrically connected to the negative terminal of the fifth battery cell via the second inline bus 79. The interconnection architecture of each independent module A and B is a "2P4S" parallel / series architecture. Finally, module A is connected in series with module B via two parallel electrical buses 76 and 76'.

[0267] Still referencing Figure 10 Module B has the same interconnect architecture as Module A. The DC input current 82 flows into the input bus 78', then through Module B, then through the parallel electrical buses 76 and 76', and finally out through the output bus 78 as the output current 84.

[0268] Still referencing Figure 10 Each module A and B can have six resistors. In module A, resistor 80 is connected between the positive terminal of the first battery cell 12 and the positive terminal of the adjacent second battery cell 12'. Resistor 81 is connected between the negative terminal of the third battery cell 12" and the negative terminal of the adjacent fourth battery cell 12"'. Resistor 80' is connected between the positive terminal of the third battery cell 12" and the positive terminal of the adjacent fourth battery cell 12"'. Resistor 81' is connected between the negative terminal of the fifth battery cell and the negative terminal of the adjacent sixth battery cell. Resistor 83 is connected between the positive terminals of the fifth and sixth battery cells. Resistor 83' is connected between the negative terminal of the seventh battery cell and the negative terminal of the adjacent eighth battery cell. Similarly, module B has six resistors, which are located in similar positions to those in module A.

[0269] Still referencing Figure 10 When considering thermal offset events, the resistance of resistors 80, 80', 81, 81', etc., can be set large enough to limit short-circuit current (and resistor heating) to negligible levels. When considering normal operation, the resistance can be set small enough to allow for cell balancing (e.g., D-state of charge (SOC) and cell balancing criteria).

[0270] Figure 11A A top view of a schematic circuit example of battery module 87 is shown, in which battery cell 88 experiences a thermal offset event and causes a short circuit I. short Battery cell 12 has an internal (inherent) resistance 85, while battery cell 12' has an internal (inherent) resistance 85'. Resistors 86 and 86' are arranged (bridging) between the first battery cell string ABC and the second battery cell string A'-B'-C'. Both resistors 86 and 86' have a resistance of R. p By reducing short-circuit I short The amplitude helps protect the remaining battery cells from short circuits. short This causes the internal resistance to heat up and overheat.

[0271] Still referencing Figure 11A The resistance R of resistors 86 and 86' pThe size can be optimized based on various factors, including: chemical properties, capacity, DC internal resistance (DCIR), electrical parallel-series architecture, etc. When thermal offset events are considered, R... p The value of R can be set large enough to limit the short-circuit current (and resistance heating) to a negligible level. When considering normal operation, R... p The size can be set small enough to allow for cell balancing (e.g., incremental state of charge (SOC) and cell balancing criteria).

[0272] Figure 11B A top view of a schematic circuit example of battery module 90 is shown, in which battery cell 88 experiences a thermal offset event and causes a short circuit I. short Each battery cell 12 has an internal (inherent) resistance 85, and each battery cell 12' has an internal (inherent) resistance 85'. Resistors 86, 86', etc., are arranged (bridging) between the first battery cell string ABCDE and the second battery cell string A'-B'-C'-D'-E'.

[0273] See also Figure 11B It has resistance = R p Resistors such as 86 and 86' help to reduce short-circuit I short The amplitude is used to protect the remaining battery cells from short circuits. short This leads to overheating due to internal resistance heating. When considering thermal offset events, R... p The value of R can be set large enough to limit the short-circuit current (and resistance heating) to a negligible level. When considering normal operation, R... p The size can be set small enough to allow for cell balance (e.g., Δ state of charge (SOC) and cell balance criteria).

[0274] Figure 12A top view of a schematic example of a battery module 92 is shown. Module 92 includes eight stacked square battery cells 12, 12', 12”, 12”', etc., numbered #1, #2, etc., up to #8. The first battery cell 12 includes a positive terminal 11 on the left and a negative terminal 13 on the right. Similarly, the adjacent second battery cell 12' includes a positive terminal 11' on the left and a negative terminal 13' on the right. The third battery cell 12” includes a negative terminal 13' on the left and a positive terminal 11 on the right. Similarly, the adjacent fourth battery cell 12”' includes a negative terminal 13”' on the left and a positive terminal 11”' on the right. The repeating pattern of the alternating pairs of two positive terminals and two negative terminals along the left side of module 92 is represented by "+ / + / - / - / + / + / - / -…", and so on along the length of module 92. The repeating pattern of the alternating pairs of two negative terminals and two positive terminals along the right side of module 92 is represented by "- / - / + / + / - / - / + / +…", and so on along the length of module 92.

[0275] See also Figure 12 The positive terminal 11 of the first battery cell 12 is electrically connected via a first inline bus 94 to the positive terminal 11' of the second battery cell 12', the negative terminal 13' of the third battery cell 12"', and the negative terminal 13"' of the fourth battery cell 12"'. Similarly, the positive terminal 11" of the third battery cell 12" is electrically connected via a second inline bus 96' to the positive terminal 11"' of the fourth battery cell 12"', the negative terminal of the fifth battery cell, and the negative terminal of the sixth battery cell. A direct current 43 flows from the negative terminal of each individual battery cell to the positive terminal of the battery cell. This repeating pattern is called a "2P4S" architecture (two parallel groups and four series groups).

[0276] See also Figure 12 In this embodiment, the first fuse 93 is disposed between the positive terminal 11 of the first battery cell 12 and the positive terminal 11' of the second battery cell 12'. The second fuse 95 is disposed between the negative terminal 13' of the third battery cell 12' and the negative terminal 13'' of the fourth battery cell 12''. The third fuse 97 is disposed between the negative terminal 13 of the first battery cell 12 and the negative terminal 13' of the second battery cell 12'. The fourth fuse 97' is disposed between the positive terminal 11' of the third battery cell 12' and the positive terminal 11'' of the fourth battery cell 12''. The fifth fuse 99 is disposed between the negative terminal of the fifth battery cell and the negative terminal of the sixth battery cell. The sixth fuse 99' is disposed between the positive terminal of the seventh battery cell and the positive terminal of the eighth battery cell.

[0277] Still referencing Figure 12When considering thermal offset events, the strength of each fuse (93, 95, 97, 97', 99, and 99') can be set small enough to limit short-circuit current (and resistance heating) to negligible levels. When considering normal operation, the strength of each fuse (93, 95, 97, 97', 99, and 99') can be large enough to allow for cell balancing (e.g., Δstate of charge (SOC) and inter-cell balancing criteria) and ensure that fuses do not accidentally open.

[0278] Figure 13 A top view of a schematic example of a battery module 100 is shown. Module 100 includes eight stacked square battery cells 12, 12', 12”, 12”', etc., numbered #1, #2, etc., up to #8. The first battery cell 12 includes a positive terminal 11 on the left and a negative terminal 13 on the right. Similarly, the adjacent second battery cell 12' includes a positive terminal 11' on the left and a negative terminal 13' on the right. The third battery cell 12” includes a negative terminal 13” on the left and a positive terminal 11” on the right. Similarly, the adjacent fourth battery cell 12”' includes a negative terminal 13”' on the left and a positive terminal 11” on the right. The repeating pattern of alternating pairs of positive and negative terminals on the left side of module 100 is represented by “+ / + / - / - / + / + / - / -…”, and so on along the length of module 100. The repeating pattern of two alternating negative extreme pairs and two positive extreme pairs on the right side of module 100 is represented by "- / - / + / + / - / - / + / +…", and so on along the length of module 100.

[0279] Still referencing Figure 13 On the left side of module 100, the positive terminal 11 of the first battery cell 12 is electrically connected to the negative terminal 13"' of the fourth battery cell 12"' via a left-facing C-shaped bypass bus 102. The positive terminal 11' of the second battery cell 12"' is electrically connected to the negative terminal 13"' of the third battery cell 12"' via a first vertical bus 104. On the right side of module 100, the negative terminal 13" of the first battery cell 12 is electrically connected to the negative terminal 13' of the second battery cell 12"' via a second vertical bus 106. The positive terminal 11"' of the third battery cell 12"' is electrically connected to the negative terminal of the sixth battery cell via a right-facing C-shaped bypass bus 102'. The positive terminal 11"' of the fourth battery cell 12"' is electrically connected to the negative terminal of the fifth battery cell via a second vertical bus 104'. The battery cell interconnection architecture used in module 100 is referred to as the "bypass bus" architecture. The term "bypass bus" means that battery cell #1 is connected to battery cell #4, bypassing the two battery cells #2 and #3 located between the first and fourth battery cells.

[0280] See also Figure 13 In this embodiment, the first fuse 108 is disposed between the positive terminal 11 of the first battery cell 12 and the positive terminal 11' of the second battery cell 12'. The second fuse 110 is disposed between the negative terminal 13' of the third battery cell 12' and the negative terminal 13'' of the fourth battery cell 12''. The third fuse 108' is disposed between the positive terminal 11' of the third battery cell 12' and the positive terminal 11' of the fourth battery cell 12''. The fourth fuse 110' is disposed between the negative terminal of the fifth battery cell and the negative terminal of the sixth battery cell.

[0281] Still referencing Figure 13 When considering thermal offset events, the strength of each fuse 108, 108', 110, 110' can be set small enough to limit short-circuit current (and resistance heating) to a negligible level. When considering normal operation, the strength of each fuse 108, 108', 110, 110' can be set large enough to allow for cell balancing (e.g., Δstate of charge (SOC) and inter-cell balancing criteria) and ensure that fuses do not trip unexpectedly.

[0282] Figure 14A A top view of a schematic example of the circuitry of battery module 112 is shown, in which battery cell 88 experiences a thermal offset event and causes a short circuit I. short Fuse 114 and 114' are arranged (bridging) between the first battery cell string ABC and the second battery cell string A'-B'-C'. Fuse 114 and 114' reduce short circuit I. short The amplitude helps protect the remaining battery cells from short circuits. short This causes the internal resistance to heat up and overheat.

[0283] Still referencing Figure 14A When considering thermal offset events, the strength of each fuse 114, 114' can be set small enough to limit short-circuit current (and resistance heating) to a negligible level. When considering normal operation, the strength of each fuse can be set large enough to allow for cell balancing (e.g., Δ state of charge (SOC) and cell-to-cell balancing criteria) and ensure that fuses do not trip unexpectedly.

[0284] Figure 14B A top view of a schematic example of the circuitry of battery module 116 is shown, in which battery cell 88 experiences a thermal offset event and causes a short circuit I. short Fuse 114, 114', etc., are arranged across the first battery cell string ABCDE and the second battery cell string A'-B'-C'-D'-E'. Fuse 114, 114', etc., reduce short-circuit I. shortThe amplitude helps protect the remaining battery cells from short circuits. short This causes the internal resistance to heat up and overheat.

[0285] Still referencing Figure 14B When considering thermal offset events, the strength of each fuse 114, 114', etc., can be set small enough to limit short-circuit current (and resistance heating) to negligible levels. When considering normal operation, the strength of each fuse can be set large enough to allow for cell balancing (e.g., Δ state of charge (SOC) and cell-to-cell balancing criteria) and to ensure that fuses do not trip unexpectedly.

[0286] Figure 15 A top view illustrating a schematic example of a battery module 134 is shown. Module 134 comprises sixteen stacked square battery cells 12, 12', 12”, 12”', etc., numbered sequentially from #1, #2 to #16. A first battery cell 12 includes a positive terminal 11 on the right and a negative terminal 13 on the left. Adjacent second battery cells 12' have opposite polarity orientations, including a positive terminal 11' on the left and a negative terminal 13' on the right. The repeating pattern of alternating pairs of positive and negative terminals along the left side of module 134 is represented by “- / + / - / + / - / + / - / +…”, and so on along the length of module 134. The repeating pattern of alternating pairs of positive and negative terminals along the right side of module 134 is represented by “+ / - / + / - / + / - / + / - / + / -…”, and so on along the length of module 134.

[0287] Still referencing Figure 15 On the left side of module 134, the inlet current 142 enters the negative terminal 13 of the first battery cell 12, which is electrically connected to the negative terminal of the third battery cell 12” via the first four-way overlapping bus 138. Next, the positive terminal of the second battery cell 12” is electrically connected to the positive terminal of the fourth battery cell 12”’, the negative terminal of the fifth battery cell, and the negative terminal of the sixth battery cell via the opposing-facing second four-way overlapping bus 140, and so on along the left side of module 134 toward the outlet current 144.

[0288] Still referencing Figure 15 On the right side of module 134, the positive terminal 11 of the first battery cell 12 is electrically connected via a first vertical electrical bus 136 to the negative terminal of the second battery cell 12', the positive terminal of the third battery cell 12"', and the negative terminal of the fourth battery cell 12"', and so on, along the right side of module 134. Similarly, the second vertical bus 136' connects the next four battery cells along the length of module 134, and so on, until the far end of module 134. Figure 15The interconnection architecture shown includes a straight (inline) bus 136, 136', etc., for connecting four adjacent battery cells, and a longer bus 138, 140, 140', 140", 138', etc., for connecting two adjacent battery cells and two alternating battery cells.

[0289] Figure 16 A top view illustrating a schematic example of a battery module 146 is shown. Module 146 comprises sixteen stacked square battery cells 12, 12', 12”, 12”', etc., numbered sequentially from #1, #2 to #16. A first battery cell 12 includes a positive terminal 11 on the right and a negative terminal 13 on the left. Adjacent second battery cells 12' have opposite polarity orientations, including a positive terminal 11' on the left and a negative terminal 13' on the right. The repeating pattern of the alternating pairs of positive and negative terminals along the left side of module 146 is represented by “- / + / - / + / - / + / - / +…”, and so on along the length of module 146. The repeating pattern of the alternating pairs of positive and negative terminals along the right side of module 146 is represented by “+ / - / + / - / + / - / + / - / + / -…”, and so on along the length of module 146.

[0290] Still referencing Figure 16 On the left side of module 146, the inlet current 160 enters the negative terminal 13 of the first battery cell 12, which is electrically connected to the negative terminal of the third battery cell 12” via a first C-shaped overlapping bus 152. Next, the positive terminal of the second battery cell 12” is electrically connected to the positive terminal of the fourth battery cell 12”’ via a second opposing C-shaped overlapping bus 154. A first diagonal bus 158 electrically connects the positive terminal of the fourth battery cell to the negative terminal of the adjacent fifth battery cell. A second diagonal bus 158’ connects the positive terminal of the eighth battery cell to the negative terminal of the adjacent ninth battery cell, and so on along the length of module 146. This left-side repeating pattern of alternating opposing C-shaped overlapping buses 152, 154, 152’, and 154’, and diagonal buses 158, 158’, etc., repeats along the left side of module 146 towards the outlet current 162.

[0291] Still referencing Figure 16On the right side of module 146, the positive terminal 11 of the first battery cell 12 is electrically connected to the positive terminal of the third battery cell via a third C-shaped overlapping bus 148. Next, the negative terminal of the second battery cell is electrically connected to the negative terminal of the fourth battery cell via a fourth opposing C-shaped overlapping bus 150. A third diagonal bus 156 electrically connects the negative terminal of the second battery cell to the positive terminal of the adjacent third battery cell. A fourth diagonal bus 156' electrically connects the negative terminal of the sixth battery cell to the positive terminal of the adjacent seventh battery cell, and so on along the length of module 146. This right-side repeating pattern of alternating opposing C-shaped overlapping buses 148, 150, 148', 150', etc., and diagonal buses 156, 156', etc., repeats along the right side of module 146. Figure 16 The interconnect architecture shown includes a shorter busbar connecting two adjacent battery cells and a longer busbar connecting two alternating (staggered) battery cells.

[0292] Figure 17 A top view of a schematic example of a battery module 164 is shown. Module 164 comprises sixteen stacked square battery cells 12, 12', 12”, 12”', etc., numbered sequentially from #1, #2 to #16. The first battery cell 12 includes a positive terminal 11 on the right and a negative terminal 13 on the left. Similarly, the adjacent second battery cell 12' includes a positive terminal 11' on the right and a negative terminal 13' on the left, and so do the next two adjacent third and fourth battery cells 12”, 12”'. The repeating pattern of alternating groups of four negative terminals, then four positive terminals, etc., along the left side of module 164 is represented by "- / - / - / - / + / + / + / +...", and so on along the length of module 164. The repeating pattern of alternating groups of four positive terminals, then four negative terminals, along the right side of module 164 is represented by "+ / + / + / + / - / - / - / -...", and so on along the length of module 164.

[0293] See also Figure 17On the left side of module 164, the inlet current 174 enters the negative terminal 13 of the first battery cell 12, which is electrically connected to the negative terminal of the third battery cell 12” via a first non-uniformly spaced quad-branch overlapping bus 170. Next, the negative terminal of the second battery cell is electrically connected to the negative terminal of the fourth battery cell via a second alternately facing non-uniformly spaced quad-branch overlapping bus 172, then to the positive terminal of the fifth battery cell, and finally to the positive terminal of the seventh battery cell. Next, the positive terminal of the sixth battery cell is electrically connected to the positive terminal of the eighth battery cell via a third non-uniformly spaced quad-branch overlapping bus 170', then to the negative terminal of the ninth battery cell, and finally to the negative terminal of the eleventh battery cell. This left-side repeating pattern of alternately facing non-uniformly spaced quad-branch buses 172, 170', 172', etc., repeats along the left side of module 164 towards the outlet current 176.

[0294] See also Figure 17 On the right side of module 164, the positive terminal 11 of the first battery cell 12 is electrically connected to the positive terminal of the third battery cell and the negative terminal of the fifth battery cell via a fourth evenly spaced quad-branch overlapping bus 166, and then electrically connected to the negative terminal of the seventh battery cell. Next, the positive terminal of the second battery cell is electrically connected to the positive terminal of the fourth battery cell via a fifth alternating-facing evenly spaced quad-branch overlapping bus 168, then electrically connected to the negative terminal of the sixth battery cell, and finally electrically connected to the negative terminal of the eighth battery cell. This right-side repeating pattern of alternating-facing evenly spaced quad-branch buses 166, 168, 166', 168', etc., repeats along the right side of module 164. Figure 17 The interconnect architecture shown includes a uniformly spaced busbar connecting four alternating (staggered) battery cells, and a non-uniformly spaced busbar connecting two adjacent battery cells and two alternating (staggered) battery cells.

[0295] Figure 18A top view of a schematic example of a battery module 178 is shown. Module 178 includes sixteen stacked square battery cells 12, 12', 12”, 12”', etc., numbered sequentially from #1, #2 to #16. The first battery cell 12 includes a positive terminal 11 on the right and a negative terminal 13 on the left. Similarly, the adjacent second battery cell 12' includes a positive terminal 11' on the left and a negative terminal 13' on the right, with opposite polarity orientations. The repeating pattern of the alternating pairs of positive and negative terminals along the left side of module 178 is represented by "- / + / - / + / - / + / - / +...", and so on along the length of module 178. The repeating pattern of the alternating pairs of positive and negative terminals along the right side of module 178 is represented by "+ / - / + / - / + / - / + / - / + / -...", and so on along the length of module 178.

[0296] Still referencing Figure 18 On the left side of module 178, the inlet current 188 enters the negative terminal 13 of the first battery cell 12, which is electrically connected to the alternating (interleaved) negative terminal of the third battery cell 12” via a first four-pronged, evenly spaced overlapping bus 184. Next, the positive terminal of the second battery cell is electrically connected to the positive terminal of the fourth battery cell via a second alternating, evenly spaced four-pronged overlapping bus 186. Next, the positive terminal of the fifth battery cell is electrically connected to the positive terminal of the seventh battery cell via a third four-pronged, evenly spaced overlapping bus 184', then electrically connected to the negative terminal of the ninth battery cell, and finally electrically connected to the negative terminal of the eleventh battery cell. Next, the sixth battery cell… The negative terminal is electrically connected to the negative terminal of the eighth cell via a fourth alternating, evenly spaced four-pronged overlapping bus 186', then electrically connected to the positive terminal of the tenth cell, and finally electrically connected to the positive terminal of the twelfth cell. This left-side repeating pattern of alternating, evenly spaced four-pronged overlapping buses 184, 186, 184', 186', etc., repeats along the left side of module 178 towards the outlet current 190. At the outlet of module 178, a straight bus 192 interconnects the positive terminal of the thirteenth cell with the negative terminals of the fourteenth, fifteenth, and sixteenth cells, and then exits module 178 via the outlet current 190.

[0297] See also Figure 18On the right side of module 178, the positive terminal 11 of the first battery cell 12 is electrically connected to the positive terminal of the third battery cell and the negative terminal of the fifth battery cell via a fifth evenly spaced quad-branch overlapping bus 180, and then electrically connected to the negative terminal of the seventh battery cell. Next, the negative terminal of the second battery cell is electrically connected to the negative terminal of the fourth battery cell via a sixth alternating-facing, evenly spaced quad-branch overlapping bus 182, then electrically connected to the positive terminal of the sixth battery cell, and finally electrically connected to the positive terminal of the eighth battery cell. This right-side repeating pattern of alternating-facing, evenly spaced quad-branch overlapping buses 180, 182, 180', 182', etc., repeats along the right side of module 178. Figure 18 The interconnect architecture shown includes a quad-overlapping bus with alternating orientations and uniform spacing, which connects four alternating (staggered) battery cells.

[0298] Figure 19 A top view of a schematic example of a type A battery module is shown. Battery module A includes repeating sub-units comprising four stacked square battery cells 200, 202, 204, and 206, numbered #1, #2, #3, and #4 sequentially. The repeating pattern of alternating pairs of two adjacent positive terminals 201 and 203 and two adjacent negative terminals 205 and 207 on the left side of module A is indicated by "+ / + / - / -". The repeating pattern of alternating pairs of two adjacent negative terminals 209 and 211 and two adjacent positive terminals 213 and 215 on the right side of module A is indicated by "- / - / + / +".

[0299] Figure 20 A top view of a schematic example of a Type B battery module is shown. Battery module B includes repeating sub-units comprising four stacked square battery cells 200, 202, 204, and 206, numbered #1, #2, #3, and #4 sequentially. The repeating pattern of alternating negative terminals 217, 221 and positive terminals 219, 223 on the left side of module B is indicated by "- / + / - / +". The repeating pattern of alternating positive terminals 235, 239 and negative terminals 237, 241 on the right side of module B is indicated by "+ / - / + / -".

[0300] Figure 21A top view of a schematic example of a type C battery module is shown. Battery module C includes repeating sub-units comprising eight stacked square battery cells 200, 202, 204, etc., numbered sequentially as #1, #2, #3, etc., up to #8. On the left side of module B, the repeating pattern of alternating strings of four adjacent negative terminals 243, 245, 247, 249 followed by a string of four adjacent positive terminals 251, 253, 255, 257 is indicated by "- / - / - / - / + / + / + / +". On the right side of module B, the repeating pattern of alternating strings of four adjacent positive terminals 259, 261, 263, 265 and four adjacent negative terminals 267, 269, 271, 273 is indicated by "+ / + / + / + / - / - / -".

[0301] Figure 22 A top view of a schematic example of a D-type battery module is shown. Battery module D includes a repeating sub-unit comprising eight stacked square battery cells 200, 202, 204, etc., up to 214, numbered sequentially #1, #2, #3, etc., up to #8. The repeating pattern in this embodiment has two distinct adjacent segments: a first segment 310 and an adjacent second segment 312. In the first segment 310, the alternating (interleaved) pattern of negative terminals 275, 279 and alternating (interleaved) positive terminals 277, 281 on the left side of module D is represented by "- / + / - / +". In the adjacent second segment 312, the reverse pattern of alternating (interleaved) positive terminals 283, 287 and alternating (interleaved) negative terminals 285, 291 on the left side of module D is represented by "+ / - / + / -". Please note that the pair of adjacent positive terminals 281 and 283 at the fourth and fifth battery cells on the left side of module D are on the boundary separating the first segment 310 and the second segment 312.

[0302] Still referencing Figure 22 On the right side of module D, the alternating (interleaved) positive terminals 293, 297 and alternating (interleaved) negative terminals 295, 299 in the first segment 310 are represented by "+ / - / + / -". In the second segment 312, the reversed patterns of the alternating (interleaved) negative terminals 301, 305 and alternating (interleaved) positive terminals 303, 307 on the right side of module D are represented by "- / + / -+". Note that the pair of adjacent negative terminals 299 and 301 at the fourth and fifth battery cells on the right side of module D are on the boundary separating the first segment 310 and the second segment 312.

[0303] Figure 23A top view illustrating a schematic example of a "1P4S" battery module architecture for module 493 is shown. Module 493 includes four stacked square battery cells 400, 402, 404, and 406, with or without thermal barriers between adjacent cells. A first electrical bus 494 is electrically connected to the negative terminal of the first battery cell 400 and brings a DC input current i into module 493. A second electrical bus 495 connects the positive terminal of the first battery cell 400 in series with the negative terminal of the second battery cell 402. Next, a third electrical bus 496 connects the positive terminal of the second battery cell 402 in series with the negative terminal of the third battery cell 404. Next, a fourth electrical bus 497 connects the positive terminal of the third battery cell 404 in series with the negative terminal of the fourth battery cell 406. Finally, a fifth electrical bus 498 takes the DC output current i away from module 493. The interconnect architecture in this embodiment is a "1P4S" architecture, which means that module 493 has one parallel string with four battery cells connected in series. In this embodiment, the total number of battery cells N is an even number (i.e., N = 4).

[0304] Figure 24 A top view illustrating a schematic example of a “2P4S” battery module architecture for module 510 is shown. Module 510 includes eight stacked square battery cells 600, 602, 604, 606, 608, 610, 612, and 614, wherein a thermal barrier (not shown) may or may not be provided between adjacent battery cells. A first inline bus 116 is electrically connected to both the negative terminal of the first battery cell 600 and the negative terminal of the second battery cell 602, and introduces a DC input current i into module 510. A second inline bus 118 electrically connects the positive terminal of the first battery cell 600 to the positive terminal of the second battery cell 602, and then (in series) connects to the negative terminals of the third battery cell 604 and the fourth battery cell 606. A third inline bus 120 electrically connects the positive terminal of the third battery cell 604 to the positive terminal of the fourth battery cell 606, and then (in series) connects to the negative terminals of the fifth battery cell 608 and the sixth battery cell 610. The fourth inline bus 122 electrically connects the positive terminal of the fifth battery cell 608 to the positive terminal of the sixth battery cell 610, and then (in series) connects to the negative terminals of the seventh battery cell 612 and the eighth battery cell 614. Finally, the fifth inline bus 124 electrically connects the positive terminal of the seventh battery cell 612 to the positive terminal of the eighth battery cell 614, and carries away the DC output current i from module 510. The interconnection architecture shown in this embodiment is a "2P4S" architecture, which means that there are two parallel strings for module 510, and each string has four battery cells connected in series. In this embodiment, the total number of battery cells N is an even number (i.e., N = 8).

[0305] In one embodiment, a dual-parallel (2P) battery module configuration may include two series submodules, wherein the battery cells are connected in an alternating (interleaved) pattern.

[0306] In one embodiment, the series-connected submodules may include an “xP” battery module architecture, where x = 1, 2, 3, etc. (i.e., 1P, 2P, 3P, etc.).

[0307] In one embodiment, the negative DC current inlet and the positive DC current outlet can be located on the same side of the battery module.

[0308] In one embodiment, the 2P battery cell group can be connected to every other (i.e., alternately or interleaved) battery cell to isolate the effects of thermal offset inter-cell thermal conduction, bus thermal conduction, and short-circuit resistance heating on different adjacent battery cells.

[0309] In one embodiment, one or more bus dimensions can be optimized to achieve the desired resistance for interconnection between specific cell units.

[0310] In one embodiment, the ICB tray can be extended to be suspended (overhanged) on the crossbeam to achieve sufficiently large creepage clearance and package space efficiency.

[0311] In one embodiment, C-shaped double or quad busbars can be assembled using various methods (e.g., ICB trays, laminated ICBs, blister packs, or other forms) to provide design integration flexibility.

[0312] In one embodiment, the fuse feature can be incorporated into a bus design using “1P” battery strings.

[0313] In one embodiment, the resistor bus (i.e., the Rp bus) can be used to limit short-circuit current within parallel battery cell banks or adjacent battery cell banks. The resistor Rp can be optimized to minimize short-circuit current while allowing for optimal battery cell balance between cells or between parallel series.

[0314] In one embodiment, the resistor bus feature can be incorporated into a "1p" serial bus design.

[0315] In one embodiment, fuse features can be used to reduce the number of voltage sensing lines and reduce the heat generated due to parallel short circuits during thermal offset events.

[0316] In one embodiment, battery cells can be interconnected in an alternating manner, such that parallel battery cells are not adjacent battery cells.

[0317] In one embodiment, different “2P” interconnect architectures can be used to create separation of parallel and adjacent battery cells.

[0318] In one embodiment, the dual-bus variant may include a straight (i.e., "inline") bus connecting four adjacent battery cells and a four-way bus connecting two adjacent battery cells and two alternating (staggered) battery cells.

[0319] In one embodiment, the dual-bus variant may include a shorter bus connecting two adjacent battery cells and a longer bus connecting two alternating (staggered) battery cells.

[0320] In one embodiment, the dual-bus variant may include a bus connecting four alternating battery cells and another bus connecting two adjacent battery cells and two alternating (interleaved) battery cells.

[0321] In one embodiment, a single bus variant can connect four alternating (staggered) battery cells together.

[0322] In one embodiment, thermal offset propagation events can be reduced by distributing multiple heat sources caused by thermal offset events among several adjacent battery cells, rather than concentrating multiple heat sources into a single directly adjacent battery cell.

[0323] In one embodiment, thermal offset propagation events can be reduced by redistributing conductive heat from the bus to one or more non-adjacent cell units.

[0324] In one embodiment, the reliance on thermal barriers and / or active cooling capabilities between adjacent cell cells can be reduced or eliminated by redistributing heat conduction from the bus to one or more non-adjacent cell cells.

[0325] In a first embodiment, the battery module includes at least eight stacked square battery cells, each having positive and negative terminals arranged in various alternating patterns (architectures).

[0326] In the relevant embodiments, odd-numbered battery cells 1, 3, 5, etc., have a negative-to-positive polarity direction pointing from left to right, while even-numbered battery cells 2, 4, 6, etc., have a negative-to-positive polarity direction pointing in the opposite direction, i.e., from right to left. This "alternating single-cell" pattern, i.e., - / + / - / +... repeats along the left side of the battery module. A similar but opposite pattern repeats along the right side of the module.

[0327] In another related embodiment, the first pair of adjacent battery cells each have a negative-to-positive polarity direction pointing from left to right, while the next pair of adjacent battery cells each have a negative-to-positive polarity direction pointing from right to left. This "alternating dual-cell" pattern, i.e., -- / ++ / -- / ++..., repeats along the left side of the battery module. A similar but reversed pattern repeats along the right side of the module.

[0328] In another related embodiment, the first group of four adjacent battery cells has a positive polarity direction from left to right, while the next group of four adjacent battery cells all have a negative polarity direction from right to left. This "alternating four-cell" pattern, i.e., ---- / ++++ / ---- / ++++..., repeats along the left side of the battery module. A similar but reversed pattern repeats along the right side of the module.

[0329] In a related embodiment, there are two adjacent battery cell segments, namely segment A and adjacent segment B. In segment A, odd-numbered battery cells 1 and 3 have a negative-to-positive polarity direction pointing positively from left to right, while even-numbered battery cells 2 and 4 have a negative-to-positive polarity direction pointing negatively from right to left. Adjacent segment B reverses this pattern, where odd-numbered battery cells 5 and 7 now have a negative-to-positive polarity direction pointing negatively from right to left, while even-numbered battery cells 6 and 8 have a negative-to-positive polarity direction pointing positively from left to right. This “alternating A / B” pattern, i.e., - / + / - / + / + / - / + / -..., repeats along the left side of the battery module. A similar but opposite pattern repeats along the right side of the module.

[0330] In one embodiment, the battery cells in the battery module are arranged in an "alternating alternating single cell" pattern - / + / - / +. A first C-shaped electrical "overlapping" bus interconnects the first negative battery terminal to the third positive terminal, a second interleaved C-shaped electrical "overlapping" bus interconnects the second negative battery terminal to the fourth positive terminal, and so on along the left side of the battery module. A similar but reversed interleaved C-shaped overlapping bus interconnection configuration is used on the right side of the module.

[0331] In one embodiment, the more negative inlet of the battery module is located at the proximal end of the module, while the more positive outlet is located at the distal end of the module.

[0332] In another embodiment, the more negative inlet of the battery module is located at the proximal end of the module, while the more positive outlet is also located at the proximal (i.e., the same) end of the module.

[0333] In one embodiment, the total number N of battery cells in the battery module is an even number.

[0334] In another embodiment, the total number N of battery cells in the battery module is an odd number.

[0335] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern - / + / - / +. A first C-shaped electrical "overlapping" bus interconnects the first negative battery terminal with the third positive terminal; a second interleaved C-shaped electrical "overlapping" bus interconnects the second negative battery terminal with the fourth positive terminal, and so on along the left side of the battery module. A similar but reversed set of interleaved C-shaped overlapping buses is used along the right side of the module.

[0336] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern - / + / - / +. A four-way "overlapping" bus electrically interconnects the second positive terminal with the fourth positive terminal, the fifth negative terminal, and the seventh negative terminal; this repeats in an alternating manner along the left side of the battery module. On the right side of the module, a first vertical bus interconnects the first positive terminal with the second negative terminal, the third positive terminal, and the fourth negative terminal. This vertical bus pattern repeats along the right side of the battery module.

[0337] In one embodiment, the battery cells in the battery module are arranged in an "alternating dual-cell" pattern ++ / -- / ++ / --. A first C-shaped "bypass" bus electrically interconnects the first positive terminal and the fourth negative terminal. A first straight bus interconnects the second positive terminal and the third negative terminal. These patterns are repeated along the module. A first resistor may be connected between the first and second positive terminals. A second resistor may be connected between the third and fourth negative terminals. This pattern of interconnecting resistors is repeated along the module.

[0338] In one embodiment, the battery cells in the battery module are arranged in an "alternating dual-cell" pattern ++ / -- / ++ / --. A first vertical bus electrically interconnects the first positive terminal to the second positive terminal, the third negative terminal, and the fourth negative terminal. These patterns are repeated along the module. This interconnection architecture is an example of a "2P4S" pattern. A first fuse may be connected between the first and second positive terminals. A second fuse may be connected between the third and fourth negative terminals. This interconnection fuse pattern is repeated along the module.

[0339] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern: - / + / - / +. On the left side of the module, a first four-way C-shaped overlapping bus interconnects the second positive terminal with the fourth positive terminal, the fifth negative terminal, and the seventh negative terminal. On the right side of the module, a first straight bus interconnects the first positive terminal with the second negative terminal, the third positive terminal, and the fourth negative terminal. These patterns are repeated along the module.

[0340] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern: - / + / - / +. A first C-shaped overlapping bus interconnects the first negative terminal with the third negative terminal. A second interleaved C-shaped overlapping bus interconnects the second positive terminal with the fourth positive terminal. A first diagonal bus interconnects the fourth positive terminal with the adjacent fifth negative terminal. These patterns are repeated along the module.

[0341] In one embodiment, the battery cells are arranged in an "alternating four-cell" pattern: ---- / ++++ / ---- / ++++. On the left, a first four-pronged, non-uniformly spaced C-shaped overlapping bus interconnects the second negative terminal with the fourth negative terminal, the fifth positive terminal, and the seventh positive terminal. On the right, a second four-pronged, uniformly spaced C-shaped overlapping bus interconnects the first positive terminal with the third positive terminal, the fifth negative terminal, and the seventh negative terminal. These patterns are repeated along the module.

[0342] In one embodiment, the battery cells in the battery module are arranged in an "alternating single cell" pattern: - / + / - / +. On the left side, a first four-pronged, evenly spaced C-shaped overlapping bus interconnects the fifth positive terminal with the seventh positive terminal, the ninth negative terminal, and the eleventh negative terminal. On the right side, a second four-pronged, evenly spaced C-shaped overlapping bus interconnects the first positive terminal with the third positive terminal, the fifth negative terminal, and the seventh negative terminal. These patterns are repeated along the module.

[0343] Detailed descriptions and accompanying drawings or figures are provided to support and describe this teaching, but the scope of this teaching is defined only by the claims. While some best modes and other embodiments for carrying out this teaching have been described in detail, various alternative designs and embodiments exist for practicing the teaching as defined in the appended claims. All embodiments and examples disclosed herein are non-limiting embodiments and non-limiting examples. The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate the presence of at least one item.

[0344] Furthermore, for example, approximate words such as “approximately,” “almost,” “basically,” “generally,” “approximately,” etc., may each be used herein to indicate “within, close to, or almost within,” or “within 0-10% of,” or “within acceptable manufacturing tolerances,” or any logical combination thereof. Finally, directional adjectives and adverbs, such as forward, aft, inside, outside, starboard, port, vertical, horizontal, up, down, forward, aft, left, right, etc., may be relative to the motor vehicle, for example, the forward direction of travel of the motor vehicle when it is operatively oriented on a horizontal driving surface.

Claims

1. A battery module, comprising: The first square repeating battery sub-unit includes: Four adjacent positions, including position #1, position #2, position #3 and position #4, are confined within the first square repeating sub-unit and stacked in ascending order from position #1 to position #2 to position #3 to position #4; The first square battery cell located at position #1 includes a first positive terminal and a first negative terminal; The second square battery cell located at position #2 includes a second positive terminal and a second negative terminal; The third-shaped battery cell located at position #3 includes a third positive terminal and a third negative terminal; The fourth square battery cell located at position #4 includes a fourth positive terminal and a fourth negative terminal; and The second square repeatable battery sub-cell, located adjacent to the first square repeatable battery sub-cell, includes: Four additional adjacent positions, including positions #5, #6, #7 and #8, are confined within the second square repeating battery sub-cell and stacked in ascending order from position #5 to position #6 to position #7 to position #8. The fifth square battery cell located at position #5 includes the fifth positive terminal and the fifth negative terminal; The sixth square battery cell located at position #6 includes the sixth positive terminal and the sixth negative terminal; The seventh square battery cell, located at position #7, includes the seventh positive terminal and the seventh negative terminal; and The eighth square battery cell, located at position #8, includes the eighth positive terminal and the eighth negative terminal.

2. The battery module according to claim 1, in, The battery module has a first side and an opposite second side; Among them, the first, second, fifth and sixth positive terminals are located on the opposite second side of the battery module; Among them, the third, fourth, seventh and eighth positive terminals are located on the first side of the battery module; The first, second, fifth, and sixth negative terminals are located on the first side of the battery module; and The third, fourth, seventh, and eighth negative terminals are located on the opposite second side of the battery module.

3. The battery module according to claim 2, further comprising: The first bus electrically connects the first negative terminal to the third positive terminal; The second bus electrically connects the second negative terminal to the fourth positive terminal; The third bus connects the third negative terminal to the fifth positive terminal; The fourth bus connects the fourth negative terminal to the sixth positive terminal. The fifth bus connects the fifth negative terminal to the seventh positive terminal. The sixth bus connects the sixth negative terminal to the eighth positive terminal. The seventh bus electrically connects the first positive terminal to the second positive terminal; and The eighth bus connects the seventh negative terminal to the eighth negative terminal.

4. The battery module according to claim 3, in, The first, second, third, fourth, fifth, and sixth buses are all C-shaped; The first bus and the second bus are intertwined; The third and fourth buses are intertwined; The fifth and sixth buses are intertwined. The seventh bus is an inline bus; and The eighth bus is an inline bus.

5. The battery module according to claim 2, further comprising: The third square repeating battery sub-unit includes: The ninth position #9 is confined within the third-shaped repeating battery sub-cell and stacked adjacent to the position #8 of the second square repeating battery sub-cell; and The ninth square battery cell, located at position #9 of the ninth stack, includes the ninth positive terminal and the ninth negative terminal; and The first bus electrically connects the second positive terminal to the fourth negative terminal; The second bus connects the fourth positive terminal to the sixth negative terminal; The third bus connects the sixth positive terminal to the eighth negative terminal; The fourth bus connects the first negative terminal to the third positive terminal. The fifth bus connects the third negative terminal to the fifth positive terminal. The sixth bus connects the fifth negative terminal to the seventh positive terminal; The seventh bus connects the seventh negative terminal to the ninth positive terminal. The eighth bus connects the eighth positive terminal to the ninth negative terminal. A more negative input bus connected to the second negative terminal; and The corrected output bus is connected to the first positive terminal.

6. The battery module according to claim 5, in, The first, second, third, fourth, fifth, and sixth buses are all C-shaped; The first bus and the fifth bus are intertwined; The second bus and the sixth bus are intertwined; The third and seventh buses are intertwined; and The eighth bus is an inline bus.

7. The battery module according to claim 2, further comprising: The first bus electrically connects the first positive terminal to the second positive terminal, the third negative terminal, and the fourth negative terminal; The second bus electrically connects the fifth positive terminal to the sixth positive terminal, the seventh negative terminal, and the eighth negative terminal; The third bus connects the first negative terminal to the second negative terminal; The fourth bus connects the third positive terminal to the fourth positive terminal, the fifth negative terminal, and the sixth negative terminal. as well as The fifth bus connects the seventh positive terminal to the eighth positive terminal.

8. The battery module according to claim 7, further comprising: The first fuse is disposed between the first positive terminal and the second positive terminal; A second fuse is provided between the third and fourth negative terminals; A third fuse is located between the fifth and sixth positive terminals; A fourth fuse is located between the seventh and eighth negative terminals; The fifth fuse is located between the first negative terminal and the second negative terminal; A sixth fuse is located between the third and fourth positive terminals; The seventh fuse is located between the fifth and sixth negative terminals; and The eighth fuse is located between the seventh positive terminal and the eighth positive terminal.

9. The battery module according to claim 2, further comprising: A first resistor is disposed between the first positive terminal and the second positive terminal; A second resistor is disposed between the third negative terminal and the fourth negative terminal; A third resistor is positioned between the fifth and sixth positive terminals; A fourth resistor is positioned between the seventh and eighth negative terminals; A fifth resistor is disposed between the third positive terminal and the fourth positive terminal; and a sixth resistor is disposed between the fifth negative terminal and the sixth negative terminal.

10. The battery module according to claim 2, further comprising: The first bus electrically connects the first positive terminal to the fourth negative terminal; The second bus electrically connects the second positive terminal to the third negative terminal; The third bus connects the fifth positive terminal to the eighth negative terminal; The fourth bus connects the sixth positive terminal to the seventh negative terminal. The fifth bus connects the first negative terminal to the second negative terminal. The sixth bus connects the third positive terminal to the sixth negative terminal. The seventh bus connects the fourth positive terminal to the fifth negative terminal. as well as The eighth bus connects the seventh positive terminal to the eighth positive terminal; and The first fuse is disposed between the first positive terminal and the second positive terminal; A second fuse is provided between the third and fourth negative terminals; A third fuse is located between the fifth and sixth positive terminals; A fourth fuse is located between the seventh and eighth negative terminals; The fifth fuse is positioned between the third and fourth positive terminals; and The sixth fuse is located between the fifth and sixth negative terminals.

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