Car battery conductor plate with fusible link

Abstract

The present invention describes a conductor plate assembly for providing electrical connections between multiple battery cells of a battery pack of an electric vehicle. The conductor plate assembly includes: multiple first conductor plates; at least one second conductor plate; multiple fusible links, the multiple fusible links are located at the at least one second conductor plate, and the multiple fusible links are configured to connect the at least one second conductor plate to multiple battery cells; and multiple non-fusible links, the multiple non-fusible links are located at the multiple first conductor plates, and the multiple non-fusible links are configured to connect the multiple first conductor plates to multiple battery cells. The present invention also describes related devices, systems, and methods.

Description

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 721,951, filed on August 23, 2018, entitled “Automotive Battery Conductor Plates With Fusible Links,” the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present disclosure relates to batteries for motor vehicles including electric vehicles, and more particularly, to conductor plates for multi-cell batteries for electric motor vehicles. Background Art

[0003] Electric vehicles typically have multi-cell batteries as energy storage devices. Such batteries must undergo severe duty cycles including charging and discharging. Typical batteries have multiple electrochemical cell modules that are combined into carefully optimized packages, some of which are electrically connected in series and some of which are electrically connected in parallel. Automotive design requirements require the use of hundreds and sometimes thousands of individual electrochemical cells in a single vehicle battery. A large number of cells, limitations on manufacturing capabilities, and strict duty cycles can lead to failure of one or more cells in a car battery. When such a cell failure occurs, and sometimes when such a failure has not yet occurred but is about to occur, the resistance of an individual cell or group of cells may drop. Depending on the electrical configuration of the battery pack, such a drop in resistance can result in a significant increase in the current flowing through the affected cell. High currents can cause the cell and other battery components to overheat, causing thermal runaway and endangering the safety of the electric vehicle.

[0004] Battery designers have used various methods to reduce the probability of such thermal events. Some known devices and techniques for improving the thermal robustness of electric vehicle batteries include the use of current interrupt devices (CIDs), pressure temperature current (PTC) switches, and cell-level fuses. Known cell-level fuses are typically wire bonds introduced between cells. In the event of an overload current that causes overheating, such wire bonds are designed to melt and disconnect the electrical connection to the affected cell. When a cell is no longer electrically connected to the rest of the battery, no current flows through the cell, which can help prevent the initiation or propagation of a thermal runaway event.

[0005] However, the inventors have observed that wire bonding has technical limitations and may adversely affect the battery. For example, wire bonding significantly increases pack-level resistance, and the use of wire bonding also increases manufacturing time and cost. Typically, wire bonds are ultrasonically welded to battery cells, a process that can take up to two seconds per cell. With approximately 7,500 cells in a typical electric vehicle battery, wire bonding accounts for more than two hours in battery manufacturing time. In addition, this process typically has a low yield and may require a lot of rework. If wire bonding manufacturing reliability is 99%, then when two wire bonds per cell are used, approximately 150 bonds per battery may require rework. Rework is typically a manual process, which results in a significant amount of cost and time added to battery manufacturing.

[0006] Therefore, the present inventors have observed a need for an alternative method of providing protection to electric vehicle multi-cell batteries that would improve reliability, reduce cost, and increase manufacturing yield. Summary of the invention

[0007] According to one example, a battery for a motor vehicle includes a plurality of battery cells and a first conductor plate assembly, the first conductor plate assembly providing electrical connections between the plurality of battery cells. The first conductor plate assembly includes: a plurality of first conductor plates; at least one second conductor plate; a plurality of fusible links, the plurality of fusible links being located at the at least one second conductor plate, for connecting the at least one second conductor plate to the plurality of battery cells; and a plurality of non-fusible links, the plurality of non-fusible links being located at the plurality of first conductor plates, for connecting the plurality of first conductor plates to the plurality of battery cells.

[0008] According to another example, a method of electrically connecting electrochemical cells in an automotive battery is described. The method includes: providing a plurality of battery cells; providing a first conductor plate assembly, the first conductor plate assembly including a plurality of first conductor plates and at least one second conductor plate; electrically connecting the plurality of battery cells to the at least one second conductor plate using a plurality of fusible links; and electrically connecting the plurality of battery cells to the plurality of first conductor plates using a plurality of non-fusible links.

[0009] According to another example, a conductor plate assembly for providing electrical connections between a plurality of battery cells of a battery pack of an electric vehicle is described. The conductor plate assembly includes: a plurality of first conductor plates; at least one second conductor plate; a plurality of fusible links located at the at least one second conductor plate and configured to connect the at least one second conductor plate to a plurality of battery cells; and a plurality of non-fusible links located at the plurality of first conductor plates and configured to connect the plurality of first conductor plates to a plurality of battery cells.

[0010] The subject matter described herein may provide numerous technical advantages, including, for example, faster manufacturing of automotive multi-cell batteries at the module level, robust protection of multi-cell batteries during thermal events, prevention of overcurrent initiation of thermal runaway, and improved vehicle safety. Examples of the subject matter described herein are set forth in the accompanying drawings and the following description. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1A to Figure 1B is a diagram showing an example of a battery for a motor vehicle.

[0012] FIG. 2A to FIG. 2C is a diagram showing an example of a conductor plate assembly.

[0013] Figure 3 is a diagram showing examples of fusible links and non-fusible links of a conductor plate.

[0014] FIG. 4A to FIG. 4B is a diagram showing examples of fusible links and non-fusible links of a conductor plate assembly.

[0015] Figure 5 2 is a diagram showing an example of a button portion and a frame edge fusible link.

[0016] FIG. 6A to FIG. 6C is a diagram showing examples of fusible links and non-fusible links of a conductor plate assembly.

[0017] 7A to 7C is a diagram showing an example of a battery having a fusible link and a non-fusible link of a conductor plate assembly.

[0018] FIG. 8A to FIG. 8B is a diagram showing an example of a top cell holder.

[0019] Fig. 9A is a top view showing an exemplary conductor plate assembly.

[0020] Fig. 9B The frame members are shown attached. Fig. 9A A top view of an exemplary conductor plate assembly.

[0021] Fig. 9C It is shown in Fig. 9A 0026] A top view of the lower left portion of an exemplary conductor plate assembly is shown in FIG.

[0022] Fig.9D Shown in Fig. 9B A bottom view of a portion of an exemplary conductor plate assembly is shown in FIG.

[0023] Fig.9E Viewed from the right without the wiring harness Fig. 9AA side view of a portion of an exemplary conductor plate assembly is shown in FIG.

[0024] Like reference symbols in the various drawings generally indicate like elements. DETAILED DESCRIPTION

[0025] Figure 1A to Figure 1B 1 is a diagram showing an example of a battery for an electric vehicle, such as a motor vehicle that can be used to transport passengers and / or cargo on a road, wherein the battery is configured to supply power to an electric drive system to provide propulsion of the vehicle and to supply power to other vehicle systems. A typical battery pack 101 may include two battery modules or assemblies 103 and 105, each battery module or assembly including a plurality of electrochemical battery cells 115, Figure 1A Only some of the electrochemical battery cells are shown in order to avoid obscuring the other parts of the modules 103 and 105. The top module 103 can be the same as the bottom module 105. In other words, the top module 103 and the bottom module 105 can have the same structure and have the same number of electrochemical battery cells 115. In this case, the modules 103 and 105 can be referred to as the top half pack 103 and the bottom half pack 105. Alternatively, the top module 103 and the bottom module 105 can have the same structure but have different numbers of electrochemical cells 115. The battery pack 101 can also include only one module or more than two modules.

[0026] Each module 103, 105 may be structured to have a rectangular frame that serves as an enclosure for enclosing and protecting the electrochemical cells 115. Figure 1A and Figure 1BAs shown in , the modules 103, 105 may each include a first frame member 117 (also referred to as a tray), which may include a plurality of recesses 117a (also referred to as nests) that receive and hold (fix) at least one end of the battery cell 115. The recesses 117a each have a cross-sectional shape (e.g., circular) and a depth configured to fix the battery cell 115, the end of which fits into the recess 117a. The recesses 117a may be arranged in a pattern or array, such as a hexagonal close-packed array, a square array, or any other suitable array or pattern. The modules 103, 105 may also include a second frame member 118 and two or more side frame members 111 (or side panels). In some examples, the second frame member 118 may be configured as a rectangular ring of structural material positioned at the periphery of the module 103. In some examples, the second frame member 118 may extend across the length and width of the battery pack 101 and may include a hole that permits a portion of the battery cell 115 to extend therethrough so that the battery cell can be further secured and supported. The side panels 111, first frame member 117, and second frame member 118 may be secured together using any suitable fastening mechanism, such as bolts, screws, fastening clips, rivets, welding, adhesives, etc., to provide a structurally rigid assembly for holding and securing the battery cells 115, and may be made of any suitably strong material, such as metal alloys (e.g., aluminum alloys, steel alloys, etc.), carbon fiber composites, other composite materials, plastics, etc., including combinations thereof. The module 103 also includes a conductor plate assembly 113 secured to the module 103, which provides electrical connections between the electrochemical cells 115 and will be described in more detail herein. Similarly, the module 105 also includes a conductor plate assembly (described in more detail herein) that is identical to the conductor plate assembly 113. Figure 1A (not visible in the image).

[0027] For the sake of illustration, Figure 1B Only one electrochemical cell 115 is shown, and Figure 1AOnly a few electrochemical cells are shown to avoid obscuring other aspects of the module structure, but it will be understood that a typical module 103, 105 may have a large number of cells 115. The number of cells 115 in the modules 103, 105 and the number of modules 103, 105 in the battery pack 101 determine the total number of cells 115 in the battery pack 101. The total number of cells in the battery depends largely on the electric vehicle design requirements. A larger number of cells can provide greater energy storage, a larger range, the ability to maintain sufficient range while utilizing faster acceleration, and greater power delivery (for example, for larger vehicles), etc. for electric vehicles. A smaller number of cells in the battery can reduce battery cost, weight, and size and may have lower cooling requirements. The number of cells 115 in the battery pack 101 may be between ten and one hundred, between one hundred and one thousand, between one thousand and ten thousand, or between ten thousand and one hundred thousand. The number of battery cells 115 in the battery modules 103 , 105 may be between ten and one hundred, between one hundred and one thousand, between one thousand and five thousand, or between five thousand and twenty thousand.

[0028] As reflected above, the side plates 111 provide structural stability to the modules 103, 105, which are configured to have a size and strength suitable for holding the desired number of battery cells 115. The side plates 111 can also control the spacing between the conductor plate assembly 113 and the tray 117. The side plates 111 can be hollow to allow better cooling of the modules 103 and the cells 115, and can have design features that allow the modules 103 to be more easily connected to another module 105 when the battery pack 101 has more than one module. The side plates 111 can also have measures for fixing the battery 101 in its packaging space in the vehicle. The side plates 111 can be made of metal alloys (e.g., aluminum alloys, steel alloys, etc.), carbon fiber composites, other composite materials, plastics, etc. (including combinations thereof). The modules 103, 105 can each have two side plates 111, in which case the two side plates 111 can be located on two opposite sides of the modules 103, 105. The modules 103 , 105 may each have four side panels 111 , in which case these four side panels 111 may be located between the conductor plate assembly 113 and the tray 117 on each of the four sides of the modules 103 , 105 .

[0029] like Figure 1AAs shown in , the battery pack 101 may have a cold plate 107 for cooling the battery cells 115. The cold plate 107 may be attached to the frame member (tray) 117 at the side of the module 103 and may extend along the entire length of that side of the module 103. If the battery pack 101 has two half packs 103 and 105, the battery pack 101 may have a cold plate 107 located between the two half packs 103 and 105 and constrained by the two half packs, and the cold plate is in thermal contact with the frame member 117 or 118 to provide battery cooling. For example, in the case where the battery pack 101 has two or more modules 103, 105, the battery pack 101 may include more than one cold plate 107. In some examples, the number of cold plates may be one less than the number of modules in the battery pack. In this case, each cold plate 107 may be located between a pair of adjacent modules and constrained by the pair of adjacent modules. Each cold plate 107 may allow a coolant to flow through the cold plate. Each cold plate may have two coolant connectors 109 , one of which may be used for a coolant inlet and the other of which may be used for a coolant outlet.

[0030] As described above, module 103 may have a conductor plate assembly 113 that provides electrical connection between electrochemical cells 115, and module 105 may also have such a conductor plate assembly. Conductor plate assembly 113 may be made of any conductive material, including, but not limited to, aluminum, copper, nickel, alloys thereof, other metal alloys, other conductive materials, and combinations thereof. Those skilled in the art will appreciate that the selection of materials for conductor plate assembly 113 may depend on the design requirements of battery 101. Although higher conductivity, lower density, lower cost, and better manufacturing properties (to allow faster and cheaper stamping, extrusion, and welding) are preferred, the selection of suitable materials may involve balancing these considerations. Conductor plate assembly 113 may have measures (e.g., projections, holes, latches, etc.) for attaching module 103 to other modules in the battery for fastening. Conductor plate assembly 113 may also have measures (e.g., projections, holes, latches, etc.) for attaching battery 101 to its packaging space in the vehicle for fastening.

[0031] As described above, modules 103 and 105 may have a tray 117. The tray 117 provides support for the electrochemical cells 115. The tray 117 may be a thin rectangular structure that includes a recess 117a (or nest) on one side for positioning individual electrochemical cells 115. The tray 117 also allows control of the spacing between adjacent battery cells 115. The side of the tray 117 opposite to the side where the cells are located may be adjacent to the cold plate 107. The tray 117 may be made of a metal alloy (e.g., an aluminum alloy, a steel alloy, etc.), a carbon fiber composite material, other composite materials, plastics, etc. (including combinations thereof). The specific geometry and material of the tray 117 may be selected based on the battery design requirements. Preferably, the tray is thinner and has a higher thermal conductivity to provide better cooling of the cells 115 through the cold plate 107. On the other hand, a thicker tray made of a stronger material can provide better structural stability to the module 103 and better support to the cells 115. It is also desirable for the tray material to have lower density and good manufacturing properties to allow for lower cost, shorter manufacturing time and higher yield.

[0032] FIG. 2A to FIG. 2C It is shown that it can be used, for example, in Figure 1A and Figure 1B 2 is a diagram of an example of a conductor plate assembly 213 of the conductor plate assembly 113 shown in FIG. The conductor plate assembly 213 may have a top (first) conductor plate set 219 and a bottom (second) conductor plate set 225. It should be understood that the words top and bottom are not intended to limit any particular orientation of the battery pack 101 in the vehicle herein, and are only used to indicate ease of description, for example, in this example, top may refer to being farther away from the battery cells 115 and bottom may refer to being closer to such battery cells 115. As shown in FIG. Figure 2B As shown in , the top conductor plate set 219 may have one or more top conductor plates 220. The top conductor plate 220 may include one or more top conductor end plates 221 and one or more top conductor intermediate plates 223. In one example, the top conductor plate set 219 has two top conductor end plates 221 and at least one top conductor intermediate plate 223. In one example, the top conductor plate set 219 has two top conductor intermediate plates 223. Figure 2C As shown in , the bottom conductor plate set 225 may have one or more bottom conductor plates 227. In one example, the bottom conductor plate set 225 has three bottom conductor plates 227. In one example, the number of bottom conductor plates 227 may be one less than the number of top conductor plates 220. The top conductor plate or the bottom conductor plate may be simply referred to as a conductor plate.

[0033] In such an arrangement, some bottom conductor plates 227 correspond to one top conductor end plate 221 and half of one top conductor intermediate plate 223 adjacent to the top conductor end plate 221. Other bottom conductor plates 227 correspond to half of one top conductor intermediate plate 223 and half of another top conductor intermediate plate 223, wherein the two top conductor intermediate plates are adjacent to each other. Each top conductor end plate 221 corresponds to half of one bottom conductor plate 227. Each top conductor intermediate plate 223 corresponds to half of one bottom conductor plate 227 and half of another bottom conductor plate 227, wherein the two bottom conductor plates 227 are adjacent to each other. In this paragraph, the term "corresponding" means that the conductor plates referred to are electrically connected to the same electrochemical cell.

[0034] The top conductor plate assembly 219 and the bottom conductor plate assembly 225 can be thin rectangular structures having approximately the same area. They can be assembled together to form the conductor plate assembly 213. When so assembled, the top conductor plate assembly 219 and the bottom conductor plate assembly 225 are electrically isolated from each other by an electrically insulating material, such as an electrically insulating sheet (not shown). When the conductor plate assembly 213 is assembled into a battery pack, the bottom conductor plate assembly 225 is positioned adjacent to the electrochemical cell so that the bottom conductor plate assembly is sandwiched between the electrochemical cell and the top conductor plate assembly 219, wherein the electrically insulating material (e.g., an electrically insulating sheet) is disposed between the top conductor plate assembly 219 and the bottom conductor plate assembly 225.

[0035] For a given group of cells, the plate that is partially the top plate has the opposite polarity to the plate that is partially the bottom plate. For an adjacent group of cells, the polarity of the corresponding plates that are partially the top plate and the bottom plate can be reversed. This arrangement allows electrochemical cells to be assembled into many groups so that the groups of cells are electrically connected in series, while all cells within the same group are electrically connected in parallel. The more groups that are connected in series, the higher the voltage that the battery will be able to provide. The more cells that are connected in parallel in each group, the higher the energy storage capacity that the battery will have.

[0036] Each top conductor plate 220 and each bottom conductor plate 227 may have one or more beams 229. In one example, all conductor plates 220 in the top conductor plate assembly have the same number of beams 229, and all conductor plates 227 in the bottom conductor plate assembly have the same number of beams. The beam 229 may have a rectangular cross section, one side of which is longer than the other side. The short side of the cross section of the beam may be referred to as the thickness of the beam. The long side of the cross section of the beam may be referred to as the width of the beam. The dimension of the beam in a direction perpendicular to both the thickness and width of the beam may be referred to as the length of the beam. The width of the beam 229 may be coplanar with the conductor plate assembly. The length of the beam 229 may also be coplanar with the conductor plate assembly. The thickness of the beam 229 may be perpendicular to the plane of the conductor plate assembly. The ratio of the width of the beam 229 to the thickness of the beam 229 may be 2:1 or 5:1 or 10:1 or 20:1 or between 2:1 and 5:1 or between 5:1 and 20:1 or between 20:1 and 100:1. The ratio of the length of beam 229 to the width of beam 229 may be 5:1 or 10:1 or 20:1 or 50:1 or between 2:1 and 5:1 or between 5:1 and 20:1 or between 20:1 and 100: 1. The number of beams on each conductor plate may be between 2 and 5, between 5 and 10, or between 10 and 100.

[0037] In one example, the beams 229 belonging to the same conductor plate may be parallel to each other. The beams 229 belonging to the same conductor plate may be equidistant from each other. Adjacent beams 229 belonging to the same conductor plate may be connected by a flat plate 230. The flat plate 230 may have the same thickness as the beam 229. The width of the flat plate 230 may be the same as the width of the beam 229, or may be between 0.5 times and 2.0 times the width of the beam 229. The ratio of the length of the flat plate 230 to its width may be 1:1 or 1.5:1 or 2:1 or between 0.5:1 and 2:1 or between 1:1 and 5:1. Each beam except the beams on the edge of the conductor plate may have two flat plates connected to the beam. In this case, the two flat plates may be connected to the same position along the length of the beam. In one example, the two flat plates are connected to two different positions along the length of the beam, so that the two flat plates are offset from each other. The ratio of this offset to the length of the flat plate may be 0.5:1 or 1:1 or 2:1 or between 0.2:1 and 1:1 or between 1:1 and 10:1. The beams 229 and plates 230 may be made of the same material. In one example, the beams and plates of each conductor plate may be formed from sheet metal in a stamping operation. The top conductor end plate may have rails added to it after the stamping operation to allow the conductor plate assembly to be secured to the rest of the battery module, or for securing the battery module to the rest of the battery pack, or for securing the battery pack to its location within the vehicle.

[0038] Figure 3is a diagram showing examples of fusible links and non-fusible links of a conductor plate. In one example, each beam 329 may have one or more fusible links 331 and one or more non-fusible links 341. The fusible link 331 may provide an electrical connection between the beam 329 and one or two electrochemical cells of the battery module. The non-fusible link 341 may also provide an electrical connection between the beam 329 and one or two electrochemical cells of the battery module. The fusible link 331 and the non-fusible link 341 may be made of a conductive material such as a metal or a metal alloy. In one example, the fusible link 331 and the non-fusible link 341 may be stamped from copper, aluminum, nickel, or alloys thereof.

[0039] The fusible link 331 may have a root 335, and the non-fusible link 341 may have a root 343. The roots 335 and 343 are areas where the fusible link 331 and the non-fusible link 341 are connected to the beam 329, respectively. The fusible link 331 and the non-fusible link 341 may be made in the same stamping process that produces the beam 329 and the conductor plate. Alternatively, the fusible link 331 and the non-fusible link 341 may be made in a separate process (e.g., by a stamping process) and subsequently welded to the beam 329. The fusible link 331 and the non-fusible link 341 may have pads. The fusible link 331 may have a pad 337, and the non-fusible link may have a pad 345. Both the pad 337 of the fusible link 331 and the pad 345 of the non-fusible link may be thinner than the beam 329 and thinner than the flat plate 330. The ratio of the thickness of the beam 329 to the thickness of the pad 337 of the fusible link 331 may be 2:1 or 10:1 or 100:1 or between 1:1 and 5:1 or between 5:1 and 100:1 or between 50:1 and 1000:1. The ratio of the thickness of the plate 330 to the thickness of the pad 337 of the fusible link 331 may be 2:1 or 10:1 or 100:1 or between 1:1 and 5:1 or between 5:1 and 100:1 or between 50:1 and 1000:1. The ratio of the thickness of the beam 329 to the thickness of the pad 345 of the non-fusible link 341 may be 2:1 or 10:1 or 100:1 or between 1:1 and 5:1 or between 5:1 and 100:1 or between 50:1 and 1000:1. The ratio of the thickness of the plate 330 to the thickness of the pad 345 of the non-fusible link 341 331 may be 2:1 or 10:1 or 100:1 or between 1:1 and 5:1 or between 5:1 and 100:1 or between 50:1 and 1000:1.

[0040] The main difference between the fusible link 331 and the non-fusible link 341 is that the fusible link 331 includes a fuse portion that is a narrower and / or thinner area as an electrical conductor that can be structured as a neck 333, while the non-fusible link 341 may not have a fuse portion, that is, no neck. The neck 333 is a portion of the fusible link 331 between the root 335 and the pad 337 of the fusible link. The thickness of the neck 333 may be the same as the thickness of the root 335, or between 0.5 times and 2.0 times the thickness of the root 335. The thickness of the neck 333 may be the same as the thickness of the pad 337, or between 0.5 times and 2.0 times the thickness of the pad 337. The cross-sectional area of ​​the neck 333 may be smaller than the cross-sectional area of ​​the root 335 and smaller than the cross-sectional area of ​​the pad 337. The ratio of the cross-sectional area of ​​the root 335 to the cross-sectional area of ​​the neck 333 may be 1.5:1 or 2:1 or 5:1 or 10:1 or between 1:1 and 5:1 or between 5:1 and 20:1. The ratio of the cross-sectional area of ​​the pad 337 to the cross-sectional area of ​​the neck 333 may be 1.5:1 or 2:1 or 5:1 or 10:1 or between 1:1 and 5:1 or between 5:1 and 20:1.

[0041] The neck 333 of the fusible link 331 can protect the electrochemical battery cell 115, the battery module 103, the battery pack 101, and the vehicle in the event of a cell failure or incipient failure. When an electrochemical cell fails or approaches failure, its resistance may decrease. With a decrease in resistance, the current flowing through such a cell may increase. This may cause overheating of the cell and surrounding components. The fusible link 331 in contact with such a cell may also heat up in proportion to the ohmic heating due to the current passing through the fusible link. The ohmic heating of the fusible link may be highest at the narrowest portion of the fusible link, which is the neck 333 of the fusible link. With the appropriate selection of the fusible link material and the size of the neck 333, heating to the melting point of that material can be achieved before the failure of the cell causes thermal runaway of the battery pack 101. When the melting point is reached, the neck 333 may melt, thereby disconnecting the electrical connection between the cell to which the fusible link is attached and the beam 329 of the conductor plate. Without an electrical connection, current may no longer flow through the battery cell, thereby preventing further degradation of the battery cell. In other words, neck 333 may allow fusible link 331 to act as a fuse for the battery cell to which fusible link 331 is connected.

[0042] Another difference between the fusible link 331 and the non-fusible link 341 is that the pad 337 of the fusible link 331 may have an oval shape, while the pad 345 of the non-fusible link 341 may have a rectangular shape.

[0043] The pad 337 of the fusible link 331 may have an orifice 339. The orifice 339 may have a circular shape or an oval shape. The orifice 339 is a through hole in the pad 337. The orifice 339 may be formed during the same process of forming the fusible link 331 or during the same process of forming the pad 337 or in a separate process after forming the pad 337. The fusible link 331 and the pad 337 may be formed in the same process. If the orifice 339 is formed in a separate process, it may be formed by stamping or by perforating or by cutting or by drilling. For example, the cutting or drilling may be mechanical or laser cutting or drilling.

[0044] The pad 345 of the non-fusible link 341 may have an orifice 347. The orifice 347 may have a rectangular shape, an oval shape, or a rectangular shape with rounded corners. The orifice 347 is a through hole in the pad 345. The orifice 347 may be formed during the same process of forming the non-fusible link 341 or during the same process of forming the pad 345 or in a separate process after forming the pad 345. The non-fusible link 341 and the pad 345 may be formed in the same process. If the orifice 347 is formed in a separate process, it may be formed by stamping or by perforating or by cutting or by drilling. The cutting or drilling may be mechanical or laser.

[0045] Welding can be used to connect the pad 337 of the fusible link 331 and the pad 345 of the non-fusible link 341 to the electrochemical cell. In one example, laser welding can be used. Ultrasonic welding, resistance welding, or another type of welding can also be used. In one example, all fusible links 331 on the same beam 329 can be located on the same side of the beam 329 relative to the flat plate 330, and all non-fusible links 341 on the beam 329 can be located on the other (opposite) side of the beam relative to the flat plate. In one example, all fusible links 331 on the beam 329 and all non-fusible links 341 connected to the same beam 329 can be located on the side of the beam where the same flat plate of two flat plates 330 is connected to the beam.

[0046] Figure 4A 4 is a perspective view (e.g., a top perspective view) showing examples of fusible links and non-fusible links of a conductor plate assembly. This view shows a top conductor end plate 421, a top conductor intermediate plate 423, and a bottom conductor plate 427. Figure 4A (not shown) the bottom conductor plate 427 is electrically isolated from the top conductor end plate 421 and the top conductor intermediate plate 423, the electrical insulating material being such as an electrical insulating sheet or film. Figure 4B It is shown Figure 4A423 and 424. A cross-sectional view of a portion of a conductor plate 427, wherein an electrically insulating material 428 is disposed between a bottom conductor plate 427 and top conductor plates 421 and 423. When the top conductor plates 421, 423 and the bottom conductor plate 427 are assembled together into a conductor plate assembly, the beams 429 of all the conductor plates can be aligned. The beams of adjacent top conductor plates can be aligned longitudinally in the direction of their lengths. The beams of adjacent top and bottom conductor plates can be aligned transversely in a direction perpendicular to their lengths. When the conductor plates are assembled in the conductor plate assembly, there can be a gap between adjacent top conductor plates. This gap between two adjacent top conductor plates can be aligned with the position of the flat plate of the bottom conductor plate on the corresponding bottom conductor plate. When the conductor plates are assembled in the conductor plate assembly, there can be a gap between adjacent bottom conductor plates. This gap between two adjacent bottom conductor plates can be aligned with the position of the flat plate of the top conductor plate on the corresponding top conductor plate.

[0047] like Figure 4A As shown in the example of , the fusible link 431 and the non-fusible link 441 can be spaced apart on their respective conductor plates in a manner such that when the top conductor plate and the bottom conductor plate are assembled into a conductor plate assembly, there can be at least one fusible link adjacent to each non-fusible link, and there can be at least one non-fusible link adjacent to each fusible link.

[0048] Figure 5 is a diagram showing examples of button-shaped fusible links and frame-side fusible links. The beam 529 of the conductor plate may have one or more fusible links 531. The fusible links 531 may be of different types, such as button-shaped fusible links 549 and frame-side fusible links 559. The button-shaped fusible link 549 is designed to be connected to the button of an electrochemical cell. The button of an electrochemical cell is typically the positive terminal of the cell. The frame-side fusible link 559 is designed to be connected to the frame of an electrochemical cell. The frame of an electrochemical cell is typically the negative terminal of the cell. The button and frame of a given battery cell may typically be arranged at the same end of the battery cell.

[0049] The button-shaped fusible link 549 may have a neck 551, a root 553, a solder pad 555, and an orifice 557. The structure and function of these elements may be as described above with respect to Figure 3The same as discussed. The frame edge fusible link 559 can be designed to be connected to the frame edges of two adjacent cells. Therefore, the pad of the frame edge fusible link 559 is split into two parts: a first pad 565 and a second pad 567. The first pad 565 and the second pad 567 of the frame edge fusible link 559 can be separated by a slit 569. The slit 569 can be a straight and narrow opening between the two pads 565 and 567. The width of the slit 569 can be less than the width of the pads 565 and 567. The ratio of the width of the pads 565 and 567 to the width of the slit 569 can be 1.5:1 or 2:1 or 5:1 or between 1:1 and 2:1 or between 2:1 and 10:1 or between 10:1 and 100:1. The width of the slit 569 can be 0.1mm or 1mm or 5mm or between 0.1mm and 1mm or between 1mm and 10mm.

[0050] At one end of the slit 569, the slit may be open. At the other end of the slit 569, the slit may terminate at the root 564 of the frame edge fusible link 559. At the terminal end of the slit 569, an expansion 571 may be located. The expansion 571 may be used for the purpose of reducing the width of the first neck 561 of the first pad 565 of the frame edge fusible link 559 and reducing the width of the second neck 563 of the second pad 567 of the frame edge fusible link 559. In one example, the frame edge fusible link may be symmetrical about the central axis of the slit 569, so that the areas of the pads 565 and 567 are the same, and the cross-sectional areas of the necks 561 and 563 are the same. The term "same" must be understood to be within the limits of manufacturing tolerances.

[0051] The pads 565 and 567 can be connected to the frame edges of two adjacent electrochemical cells. If one of the two adjacent cells fails, the corresponding neck of the frame edge fusible link 559 (neck 561 of pad 565 or neck 563 of pad 567) can melt, which can prevent current from flowing through the failed cell. At the same time, the other of the two adjacent cells connected to the other of the two pads can continue to function normally because its corresponding neck of the same frame edge fusible link 559 will not melt.

[0052] FIG. 6A to FIG. 6C is a diagram showing examples of fusible links and non-fusible links of a conductor plate assembly according to one embodiment. Fig. 6ATwo top conductor plates 620, one bottom conductor plate 627, and electrochemical cells 615 are shown. The bottom conductor plate 627 is electrically isolated from the top conductor plate 620 using an electrically insulating material (not shown), such as an electrically insulating sheet or film. Each cell 615 may have a button 673, which is typically the positive terminal of the cell. Each cell 615 may have a frame edge 675, which is typically the negative terminal of the cell. The cells 615 may be cylindrical electrochemical cells with buttons on one end of the cylinder. A group of cells 615 may be positioned parallel to each other. The buttons of all cells in the group may be oriented in the same direction. Fig. 6A In the view of FIG. 1 , the cells are oriented such that all buttons of the cells shown in this view are oriented upward.

[0053] The bottom conductor plate 627 can be located between a group of electrochemical cells and the two top conductor plates 620. In one embodiment, the conductor plates 627 and 620 have holes 677. The holes 677 can have different shapes, such as a first shape 679 (e.g., elongated, with two end portions narrower than a wider center portion) and a second shape 681 (e.g., elongated, with two end portions wider than a narrow center portion). The holes 677 can be arranged on the conductor plates in a manner such that when the conductor plates are assembled, each hole 677 on the top conductor plate 620 having a first hole shape 679 can be superimposed on a hole 677 on the bottom conductor plate 627 having a second hole shape 681. Each hole 677 on the top conductor plate 620 having a second hole shape 681 can be superimposed on a hole 677 on the bottom conductor plate 627 having a first hole shape 679. Each hole 677 having a first hole shape on the bottom conductor plate 627 may correspond to a hole 677 having a second hole shape 681 on the top conductor plate 620 , and each hole 677 having a second hole shape 681 on the bottom conductor plate 627 may correspond to a hole 677 having a first hole shape 679 on the top conductor plate 620 .

[0054] As described above, in one example, the first hole shape 679 may have a larger opening in the middle than the opening at either end thereof. In one example, the second hole shape 681 may have a narrower opening in the middle than the opening at either end thereof. When the fusible link and the non-fusible link are welded to the battery cell, this arrangement of the hole shape may allow welding equipment to more easily approach the button 673 and the frame edge 675 of the battery cell. The hole may allow access to any appropriate joining tool, including an ultrasonic welding head, a laser welding head, a laser welding fixture, a laser beam. In one embodiment, the fusible link and the non-fusible link are connected to the portion of the conductor plate at the narrow portion of the hole. In this embodiment, both the end of the fusible link and the end of the non-fusible link may be connected to the portion of the conductor plate. The top conductor plate 620 may carry the non-fusible link 641, and the bottom conductor plate 627 may carry the frame edge fusible link 659 and the button fusible link 649.

[0055] Figure 6B A view of the conductor plate assembly is shown from the bottom. The non-fusible links may have different widths, depending on whether they are connected to the button or frame edge of the battery cell. The frame edge non-fusible link 685 may be wider than the button non-fusible link 683. Each of the frame edge non-fusible links 685 may have the same width that may be constant along its length. Each of the button non-fusible links 683 may have the same width that may be constant along its length. Each of the button fusible links 649 may have a pad 655 located in the center along its length and two necks 651 located on each side of the pad 655. Each of the frame edge fusible links 659 may have a slit 669 that separates the first pad 665 of the frame edge fusible link from the second pad 667 of the frame edge fusible link. The two pads 665 and 667 may be symmetrical about the central axis of the slit 669. Each of the pads 665 and 667 may be connected to a corresponding conductor plate on two of its sides.

[0056] All fusible links and non-fusible links may protrude out of the plane of their corresponding conductor plates toward the battery cell. Both ends of each fusible link and non-fusible link may be connected to (e.g., attached to) portions of its corresponding conductor plate. The pads of each fusible link and non-fusible link located near the center of the link are farthest from the plane of the corresponding conductor plate.

[0057] Figure 6C A cross-sectional view of a conductor plate assembly is shown. A top conductor plate 620 may be located above a bottom conductor plate 627. A non-fusing interlayer 687 may be connected to the bottom of the top conductor plate 620. A fusing interlayer 691 may be connected to the bottom of the bottom conductor plate 627. Figure 6C689 between the bottom of the non-fusible intermediate layer 687 and the top of the bottom conductor plate 627 is shown, and the gap 689 can accommodate an electrically insulating material, such as an electrically insulating film (not shown). The frame edge fusible link 659 can be connected to the fusible intermediate layer 691. The button-shaped portion fusible link 649 can also be connected to the fusible intermediate layer 691. The frame edge non-fusible link 685 can be connected to the non-fusible intermediate layer 687. The button-shaped portion non-fusible link 683 can also be connected to the non-fusible intermediate layer 687.

[0058] The electrical insulating film may be designed to withstand voltages up to, for example, 2000V, 3000V, 4000V, or 5000V, but is not limited to these values. In normal operation, the maximum operating voltage may be up to, for example, 500V or up to 1000V or up to 2000V. The battery pack may be designed to withstand a cell-to-cell current within the same cell group, which is, for example, between 3A and 5A or between 5A and 10A, but is not limited to these values. The maximum current through a single cell within a group connected in series in normal operation may be up to, for example, 50A, and ranges between, for example, 2A and 30A or between 5A and 20A or between 15A and 40A, but is not limited to these values, and may be expected to vary within a given application. The conductor plate configuration as described herein can tolerate a maximum current of about 3500A (nominal 2200A in normal operation) flowing between cell groups and reaching at a given time for the entire battery pack. The typical maximum current flowing through the entire battery pack at a given time in normal operation may be up to 2200A (nominal), and the root mean square (RMS) current in a given ten minute period in normal operation may also be in various ranges, such as between 50A and 400A, between 300A and 500A, between 100A and 1000A, but not limited to these values. The battery pack may be designed to operate at the maximum current for, for example, one second or between one second and two seconds or between two seconds and twenty seconds or between twenty seconds and two minutes, but not limited to these ranges. The battery pack may be designed to operate at the highest level of 10-minute RMS current, for example, for 20 minutes or between 20 minutes and 1 hour or between 1 hour and 3 hours or between 3 hours and 10 hours, but not limited to these ranges. The fusible link may be designed not to melt when the maximum current flowing through the individual cells is within their normal operating range. The battery may be designed to have an ambient temperature rise in normal operation of, for example, up to 20 degrees Celsius or between 20 and 30 degrees Celsius or between 30 and 50 degrees Celsius or between 50 and 100 degrees Celsius, but not limited to these ranges.

[0059] 7A to 7C is a diagram showing an example of a battery having a fusible link and a non-fusible link of a conductor plate assembly. Fig. 7AA group of cylindrical electrochemical cells 715 is shown. The conductor plate assembly 713 may have a top conductor plate 720 and a bottom conductor plate 727. In this example, a group of cells has sixteen cells 715 arranged in a 2s8p configuration. This name means that a group of cells has two groups of eight cells in each group, so that the eight cells in each group are electrically connected in parallel, and the two groups of cells are electrically connected in series.

[0060] Figure 7B The conductor plate assembly 713 is shown from the top. In this example, the conductor plate assembly 713 has two top conductor plates 720 and one bottom conductor plate 727. The conductor plates may have holes 777. Some holes 777 may have portions with circular hole shapes 779, while other holes 777 may have portions with rectangular hole shapes 781. Each circular hole shape 779 may have two fingers 793 on diametrically opposite sides. The shapes of the two fingers 793 may be the same. Each finger 793 may have a rectangular shape. The gap between the two fingers 793 of the same hole may be approximately equal to the width of the finger. In one embodiment, the circular hole shape 779 may correspond to the button of the battery cell 715, while the rectangular hole shape 781 may correspond to the frame edge of the battery cell 715. The hole 777 with the circular hole shape 779 may have a button fusible link 749 or a button non-fusible link 783. Aperture 777 having a rectangular hole shape 779 may have a frame edge fusible link 759 or a frame edge non-fusible link 785 .

[0061] Figure 7C The conductor plate assembly 713 is shown from the bottom. This view shows details of the holes of the fusible and non-fusible links and the conductor plates according to one embodiment. The holes with rectangular hole shapes 781 on the bottom conductor plate 727 may have the same size as the corresponding holes of the same shape on the top conductor plate 720. Such an arrangement of holes with rectangular hole shapes 781 can be used for the frame edge fusible link 759. In this arrangement, the frame edge fusible link 759 can be connected at (e.g., attached to) the bottom conductor plate 727. The holes with rectangular hole shapes 781 on the bottom conductor plate 727 can be larger than the corresponding holes of the same shape on the top conductor plate 720. Such an arrangement of holes with rectangular hole shapes 781 can be used for the frame edge non-fusible link 759. In this arrangement, the frame edge non-fusible link 785 can be connected at (e.g., attached to) the top conductor plate 720. In one example, all fusible links are connected at (e.g., attached to) the bottom conductor plate 727.

[0062] The fusible link may be made of a thin metal sheet. The metal may be aluminum or copper or nickel or an aluminum alloy or a copper alloy or a nickel alloy or another suitable metal. The fusible link may have a thickness of 0.01 mm to 0.1 mm or between 0.05 mm and 0.2 mm or between 0.1 mm and 0.5 mm. The fusible link may have a width of between 0.1 mm and 0.2 mm or between 0.2 mm and 1 mm or between 0.5 mm and 5 mm. The fusible link may have, for example, a width of 0.1 mm to 0.2 mm or between 0.2 mm and 1 mm or between 0.5 mm and 5 mm. 2 With 0.2mm 2 Between or within 0.2mm 2 With 0.5mm 2 Between or within 0.5mm 2 With 1mm 2 The cross-sectional area is between, but not limited to, these values.

[0063] The holes with circular hole shapes 779 on the bottom conductor plate 727 may have the same size as the corresponding holes of the same shape on the top conductor plate 720. Such an arrangement of holes with circular hole shapes 779 may be used for the button-shaped fusible link 749. In this arrangement, the button-shaped fusible link 749 may be connected at (e.g., attached to) the bottom conductor plate 727. The holes with circular hole shapes 779 on the bottom conductor plate 727 may have shorter fingers 793 than the corresponding holes of the same shape on the top conductor plate 720. Such an arrangement of holes with circular hole shapes 779 may be used for the button-shaped non-fusible link 783. In this arrangement, the button-shaped non-fusible link 783 may be connected at (e.g., attached to) the top conductor plate 720.

[0064] The button-shaped fusible link 749, the button-shaped non-fusible link 783, the frame edge fusible link 759 and the frame edge non-fusible link 785 may all have pads in the center, and each center of each link may have two connections to its corresponding conductor plate. Each center may protrude away from the plane of the conductor plate assembly 713 on the side of the bottom conductor plate 727. The arrangement and shape of the hole 777 can be designed to accommodate easy access to the fusible link and the non-fusible link to attach them to the battery cell. In one example, the fusible link and the non-fusible link are laser welded to the battery cell. Other attachment methods may include ultrasonic welding, resistance welding and other types of welding.

[0065] Fig. 8A A top cell holder 870 is shown, which is positioned at the conductor plates 820 and 827 and is configured to hold a cell (not shown). Figure 8BThe same top cell holder 870 is shown with the conductor plate removed. The top cell holder 870 may be made of a non-conductive material such as injection molded plastic. The cell holder may be manufactured, for example, by injection molding using a mold that is separated into two or more sections and provides the desired shape of the cell holder 870 when in a closed (molded) position. Suitable materials include, for example, polycarbonate, polypropylene, nylon, mixtures thereof, and the like. The color of the plastic material may be transparent, opaque or colored, such as black or orange. In order to reduce the possibility of damage in a thermal event, flame retardant additives such as tetrabromobisphenol A, tris (tribromophenyl) cyanurate or others may be included in the plastic material. For example, the plastic may be designed to meet the UL94V-0 standard at 3mm. When a densely packed cylindrical cell-based battery pack is subjected to end cooling, it may be advantageous to connect the local top conductor plate 820 to the cell button and the local bottom conductor plate 827 to the frame edge of the cell.

[0066] like Figure 8B As shown in , the top cell holder 870 can have a substantially planar portion 872 that can be positioned between the conductor plate and the cell. The thickness of the substantially planar portion 872 can be, for example, between 0.5 mm and 2 mm, between 1 mm and 5 mm, between 2 mm and 10 mm, but is not limited to these values. The top cell holder 870 can also have a wall portion 874 that can surround the top portion of the side of the cell. The wall portion 874 can be tapered to be thicker in a transverse cross-section closer to the conductor plate and narrower in a transverse cross-section away from the conductor plate.

[0067] The thickness of the wall portion 874 can vary, wherein the minimum thickness occurs in a cross section taken along a plane passing through the central axis of two adjacent battery cells. The minimum thickness of the wall portion 874 can be between 0.1mm and 0.5mm, between 0.2mm and 1mm, between 0.5mm and 2mm, between 1mm and 5mm. The height of the wall portion 874 can be between 1mm and 5mm, between 2mm and 10mm, between 5mm and 30mm, between 10mm and 50mm. The wall portion can extend to the entire height of the battery cell. The wall portion 874 can be characterized by a locator 876, which can assist in guiding the battery cell into the top battery cell holder 870 during assembly, and assist in positioning the battery cell in the top battery cell holder during operation. The battery cell can be additionally held by a bottom battery cell holder located near the bottom of the battery cell.

[0068] The top cell holder 870 may have access holes (holes) 878 and 880 for making electrical connections between the conductor plate and the cell. Access hole (hole) 878 may provide an opening for connecting the conductor plate to the button portion of the cell. Access hole (hole) 880 may provide an opening for connecting the conductor plate to the frame edge of the cell. As the spacing between adjacent cells decreases, the access holes for the frame edge connection may hinder the mold flow during the manufacture of the injection molded part. FIG. 8A to FIG. 8B The arrangement shown in can allow for tighter cell packing that maintains the mold flow for continuous injection molding of the top cell holder 870 at the button end of the cell collection.

[0069] The submodule conductor plates 820 and 827 can be arranged so that they do not cover any of the three holes (two holes 878 and one hole 880) of each pair of cells. In one embodiment, the cells can be parts of the same parallel cell brick (cell group) so that the two buttons are electrically connected to the same conductor plate and the two frame edges are electrically connected to the same conductor plate (different from the conductor plate connected to the button in this example). In this embodiment, the cells can be electrically connected in parallel to each other. In one example of this embodiment, two frame edges of adjacent cells can use two different tabs to form their electrical connection to the conductor plate. In another example of this embodiment, two frame edges of adjacent cells can share a common tab.

[0070] In another embodiment, two frame sides of adjacent cells may be electrically connected to different conductor plates, and two buttons may also be electrically connected to different conductor plates. In one example of this embodiment, two cells may be electrically connected to each other in series.

[0071] In the top cell holder described, with three holes per pair of adjacent cells, there may also be substantially plastic between the conductor plate and the cells at a reasonable thickness so that there is enough plastic cross section 882 between the groups of cells to allow the plastic to completely fill the mold without requiring separate doors on either side of each group of cells. The cross-sectional area of ​​cross section 882 may be, for example, 0.05 mm 2 With 0.1mm 2 Between 0.2mm 2 With 1mm 2 Between 0.5mm 2 With 2mm 2 Between, within 1mm 2 With 5mm 2 Between, within 2mm 2 With 10mm 2 Between, within 5mm 2 With 20mm 2 Between, within 10mm2 With 100mm 2 The exemplary embodiments may reduce the cost and complexity of mold processing to support increased cell density in a battery pack, and thus reduce the volume requirements of the battery pack.

[0072] Fig. 9A FIG. 9 is a top view illustration of another exemplary conductor plate assembly 913 according to the present disclosure. Figure 1A and Figure 1B Like the conductor plate assembly 113 shown in FIG. 1 , the conductor plate assembly 913 can be used in a battery pack, such as in Figure 1A For example, the exemplary conductor plate assembly 913 may be used at the top module of the battery pack and at the bottom module of the battery pack along with the cold plate, the first frame member (or tray), the second frame member, the battery cells, and other features such as the top module 103, the bottom module 105, the cold plate 107, the first frame member (or tray) 117, the second frame member 118, the battery cells 115, and other features such as at the top module 103, the bottom module 105, the cold plate 107, the first frame member (or tray) 117, the second frame member 118, the battery cells 115, and other features such as at the bottom module 105. Figure 1A For the sake of brevity, description of other features shown in the figure will not be repeated here.

[0073] The conductor plate assembly 913 provides electrical connections between multiple battery cells in the battery pack, such as Figure 1A The battery cell 115 of the battery pack shown in FIG. Fig. 9A As shown in FIG. 1 , the conductor plate assembly 913 includes a plurality of first conductor plates 923 and at least one second conductor plate 921. Fig. 9A In the example of , five first conductor plates 923 and two second conductor plates 921 are shown. As with the conductor plate assembly 113, the first conductor plates 923 and the second conductor plates 921 can be made of any suitable conductive material, including (but not limited to) aluminum, copper, nickel, alloys thereof, other metal alloys, other conductive materials, and combinations thereof, and considerations for selecting the conductive material have been discussed previously herein. As with the conductor plate assembly 113, the conductor plate assembly 913 may include measures for securing the conductor plate to other parts of the battery pack 101 for fastening, such as protrusions, holes, latches, etc.

[0074] The first conductor plate 923 and the second conductor plate 921 include a beam 929 and a plate 930. Fig. 9A As shown in the example and in Figure 1A Like the conductor plate assembly 113 shown in FIG. 1 , the beam may be in one direction (e.g., in Fig. 9A The plate may be an elongated portion of metal oriented horizontally in the plane of the page in the drawing, and the plate may be oriented in another direction (e.g., in Fig. 9AAs with the conductor plate assembly, the plate 930 provides electrical interconnection between the associated beams 929 of a given conductor plate. Appropriate dimensions of the plate 930 and beams 929 may be selected as previously discussed herein to meet the current and voltage handling requirements, physical strength requirements, and desired packing density of the battery cells consistent with the overall structure, and to support the provisions provided by the overall battery module and one or more frame members supporting the conductor plate assembly 913. Fig. 9A As shown in the example of , the plate 930 may have a curved shape (i.e., not straight) in a plan view in the plane of the conductor plate assembly 913, so that the two ends of a given plate 930 that intersect the corresponding beam 929 are laterally offset from each other, i.e., laterally displaced from each other, connected by a curved middle portion of the plate 930. Such a curved structure of the plate 930 with offset ends may provide the following advantages: providing space for a fusible link or non-fusible link at the end of a given beam 929 to increase the packing density of the battery cells in the battery pack.

[0075] The first conductor plate 923 and the second conductor plate 921 may be assembled together to form a conductor plate assembly 913. Fig. 9B , which in one example may be, for example, an electrically insulating injection molded plastic frame or other frame that provides adequate structural support and electrical isolation, may provide support for the first and second conductor plates 923 and 921 by attaching the first and second conductor plates 923 and 921 to the frame 917. The conductor plates 923, 921 may be attached to the frame using any suitable fastening method as previously described herein, including adhesives such as any suitable methyl methacrylate adhesives, and depending on the material used for the electrically insulating frame, including heat riveting, ultrasonic welding, laser welding, and mechanically snapping the parts together. Fig. 9B As shown in the example of , frame 917, such as in the configuration shown, may include interconnected ribs extending in two or more directions, such as ribs 917A oriented in a first direction and ribs 917A oriented in a second direction substantially perpendicular to the first direction (e.g., for ease of reference, in Fig. 9AThe present disclosure is not limited to such exemplary orientations, however, and ribs oriented in other directions may be used, and the ribs may be oriented in more than two directions. The position and orientation of such ribs 917A, 917B may correspond to the position and orientation of the associated beams 929 and flat plates 930 of the conductor plates 923, 921, and may also be provided at additional locations to achieve additional structural stability (for example, additional frame ribs 917B may be provided at one or more locations between adjacent flat plates 930). In addition, the frame 917 may also include a peripheral portion at the periphery of the frame 917. As shown Fig. 9A and Fig. 9B As shown in , when assembled, the conductor plate assembly 913 may have an overall rectangular shape profile in a top view or a bottom view, but the profile is not limited to a rectangular shape. When so assembled, and in the absence of battery cells connected to the conductor plates 932, 921, the conductor plates are electrically isolated from each other by the electrically insulating material of the frame 917. The dimensions of the frame 917 and its ribs 917A, 917B may generally correspond to the dimensions of the associated beams 929 and plates 930 of the conductor plate assembly 913. The dimensions of the other conductor plates, beams, and plates previously described herein apply to the conductor plate assembly 913. Consistent with and in view of the support provided by the other structural members of the battery pack, the thickness of the frame 917 (i.e., at right angles to the conductor plates) may be increased. Fig. 9B The thickness of the battery cell assembly 917 and the conductor plate assembly 913 is selected to provide adequate electrical isolation and structural support, and such thickness may be, for example, between 1 mm and 5 mm, between 2 mm and 10 mm, between 5 mm and 30 mm, between 10 mm and 50 mm, but the thickness is not limited to these values. In addition, it is noted that the frame 917 and the conductor plate assembly 913 are provided at the button-frame side (e.g., for ease of reference, the top side) of the battery cell assembly, and it will be understood that the cell holder may be provided at the opposite side (e.g., for ease of reference, the bottom side) of the battery cell assembly, such as at Fig. 8A and Figure 8B In this way, a battery pack (such as in Figure 1A The battery pack 101 shown in FIG. 1 may be supported at both its top and bottom ends. As previously described, a cold plate (such as in FIG. Figure 1A The cold plate 107 shown in FIG. 1 is used for a single module arrangement (e.g., only using Figure 1A Module 103 shown in FIG. 1 ) or a dual module arrangement (e.g., using Figure 1A Both modules 103 and 105 shown in FIG. 1 ).

[0076] As with the conductor plate assembly 913, adjacent conductor plates 923 and / or 921 may have an interdigitated structure whereby the beams 929 of one conductor plate 923, 921 extend adjacent to and between the beams 929 of one or two adjacent conductor plates 923, 921. Such an interdigitated structure may facilitate increased packing density of battery cells.

[0077] like Fig. 9A As shown in the example of , the first conductor plate 923 may include a conductor plate of a first type 923A, which may be considered an outer or external type because that type includes beams 929 positioned at the outer edge of the conductor plate assembly 913. Fig. 9A As shown in the example of , the first conductor plate 923 may also include a conductor plate of a second type 923B, which may be considered an inner or inside plate type because none of the beams 929 of that type are positioned at the outer edge of the conductor plate assembly 913.

[0078] like Fig. 9A As shown in FIG. 1 , the conductor plate assembly 913 may also include a second conductor plate 921 (in this example, Fig. 9A The conductor plate assembly 913 may further include a plurality of non-fusible links 941 at the plurality of first conductor plates 923, the plurality of non-fusible links being configured to connect the plurality of first conductor plates 923 to the plurality of battery cells. Fig. 9A Also shown in FIG. 1 , another second conductor plate 921 (eg, in this example, Fig. 9A ) may include a plurality of non-fusible links 941 at the other second conductor plate. In one example, such as at Fig. 9A As shown in FIG. , a second conductor plate 921 (eg, Fig. 9A The right-hand side of the conductor plate assembly 913 may include only the fusible link 931 and no non-fusible link 941. In addition, in one example, another (different) second conductor plate 921 (e.g., Fig. 9A The left-hand side of the second conductor plate (of the first conductor plate) may include only the non-fusible link 941 and no fusible link 931. However, the present disclosure is not limited thereto, and one or more second conductor plates may include both the fusible link 931 and the non-fusible link 941. Moreover, the plurality of first conductor plates may each include both the fusible link 931 and the non-fusible link 941. In addition, the fusible link may be any of a button type (button fusible link) or a frame edge type (frame edge fusible link), and the non-fusible link may be a button type (button non-fusible link) or a frame edge type (frame edge non-fusible link) such as previously described herein, and the previous discussion of this herein (including the discussion of configuration, materials, and dimensions) applies to 9A to 9E .

[0079] Fig. 9C is shown in an expanded view. Fig. 9A A top view of the lower left portion of the exemplary conductor plate assembly shown in FIG. Fig. 9A , Fig. 9B and Fig. 9C As shown in , a wiring harness 912 including an electrical connector 914, a cable 916, and a plurality of sub-cables 926 may be provided to monitor the voltage at each conductor plate 923, 921. Specifically, the sub-cables 926 may be attached to the conductor plates 923, 921 at the connection point 922 for voltage monitoring using a suitable voltage monitoring circuit (not shown). Fig. 9C As shown in FIG. 1 , the conductor plates 923, 921 also include alignment features (prons or fingers) 951 that facilitate proper alignment of the conductor plates 923, 921 with the frame, as shown in FIG. Fig.9D Further discussion.

[0080] Fig.9D Shown in Fig. 9B A bottom view of a portion of an exemplary conductor plate and frame assembly shown in FIG. Fig.9D An expanded view at a higher magnification of two adjacent first conductor plates 923 is shown, each having a beam 929 and a plate 930 such as previously described above. The conductor plates 923 are attached to the frame 917 using any suitable fastening means such as an adhesive. The frame 917, which again can be or include an injection molded plastic, includes a plurality of first alignment features, such as pegs or pins 952, and the conductor plates 923 (and 921) include second alignment features, such as prongs or fingers 951, whereby the prongs / fingers 951 are positioned about the pegs / pins 952 to align the structure during assembly. In addition, the frame 917 includes protruding spacers 954 and 953 that are used to separate portions of adjacent conductor plates 923 (and 921) to further facilitate alignment during assembly. As shown in FIG. Fig.9D As shown in , the frame 917 may also include a cable guide 955, which includes a hole through which the cable or wire can pass and a protrusion located above the hole to assist in holding the cable or wire in place. If desired, the frame 917 may also include a protrusion 956 located on the vertical ribs or horizontal ribs, which is used to assist in securing an additional electrical insulating sheet that can be placed on top of the conductive plate / frame assembly.

[0081] exist 9A to 9E In the example shown in Fig.9DAs shown in the expanded view in FIG. 1 , each fusible link 931 of this example includes a pad 937 having a rounded, slightly circular shape and positioned to coincide with the button of the associated battery cell. In this example, such fusible link 931 is a button fusible link. Fig.9D As shown in FIG. 1 and as previously described, the button-shaped fusible link 931 may include a neck 933 as a fuse portion, a pad 937, and a root 935, wherein the neck 933 has a smaller cross-sectional area than the root 935 and the pad 937. The small cross-sectional area of ​​the neck 933 permits the neck to be used as a fuse portion. In addition, as Fig.9D As shown in , the non-fusible link 941 in this example has a pad 945 having a slightly rectangular shape with an indented side. Those non-fusible links 941 include a root 943 and a pad 945, but no fuse portion. In this example, each pad 945 is positioned to coincide with the frame edges of two associated battery cells, a portion of one frame edge of one battery cell is connected to one side of the pad 945, and a portion of the frame edge of the other battery cell is connected to the opposite side of the pad 945. In this example, such non-fusible links are frame edge non-fusible links. However, the present disclosure is not limited thereto, and as previously described, one or more first conductor plates and one or more second conductor plates may include both fusible links 931 and non-fusible links 941. In addition, the fusible link may be any of a button type (button fusible link) or a frame type (frame fusible link), and the non-fusible link may be a button type (button non-fusible link) or a frame type (frame non-fusible link) such as previously described herein. 9A to 9E The fusible link 931 and the non-fusible link 941 in the example of the reference are not shown with slits or openings (holes), but if necessary, the pads or other parts of the fusible link 931 and the non-fusible link 941 can be provided with slits and / or openings / holes. In addition, other aspects of the fusible link and the non-fusible link previously described herein (including discussions of configuration, materials and dimensions, manufacturing, etc.) are applicable to 9A to 9E .

[0082] Therefore, it will be appreciated that, in one example, each of the plurality of battery cells may include a button and a frame edge, and the plurality of fusible links 931 may include a button fusible link, and the plurality of non-fusible links 941 may include a frame edge non-fusible link. Alternatively or in addition, in one example, the plurality of fusible links 931 may include a frame edge fusible link, and the plurality of non-fusible links 941 may include a button non-fusible link. Additionally, in one example, each of the first conductor plates 923 may include a button link connected to the button and may also include a frame edge link connected to the frame edge, such that the first of the second conductor plates 921 includes a button link connected to the button without a frame edge link connected to the frame edge, and wherein the second of the second conductor plates includes a frame edge link connected to the frame edge without a button link connected to the button.

[0083] Fig.9E Viewed from the right without the wiring harness Fig. 9A A side view (not in cross-section) of a portion of an exemplary conductor plate assembly is shown in FIG. Fig.9E As shown in Fig. 9A When the conductor plate assembly 913 is shown, the side of the second conductor plate 921 is visible, which is part of a row of fusible links 931 and an adjacent row of non-fusible links 941. Fig.9E In the side view shown in Fig. 9A The additional rows of fusible links 931 and non-fusible links 941 further to the left of are shielded. Fig. 9A The additional conductor plates 923 and 921 further to the left of Fig.9E From 9A to 9D The discussion can also be understood. Fig.9E The example shows that the first conductor plate 923 and the second conductor plate 921 can be arranged in a planar configuration, so that the first conductor plate 923 and the second conductor plate 921 are set in the same plane, and the fusible link 931 and the non-fusible link 941 include portions extending below the plane of the conductor plates 923 and 921 to form electrical contact with the button portions and frame edges of the corresponding battery cells.

[0084] See again FIG. 2A to FIG. 4B , it will be appreciated that the first conductor plate and the second conductor plate may alternatively be arranged in a stacked configuration such that the first conductor plate is disposed in a first plane and the second conductor plate is disposed in a second plane, the first plane and the second plane being displaced from each other in a direction perpendicular to the first plane and the second plane. In such cases, a layer of electrically insulating material may separate the first conductor plate and the second conductor plate, such as in Figure 4A and Figure 4B, where first conductor plates 421 and 423 are separated from bottom conductor plate 427 by electrically insulating material 428. In some examples, it is contemplated that a given battery pack may utilize battery modules having conductor plate assemblies in a planar configuration and battery modules having conductor plate assemblies in a stacked configuration.

[0085] It should be understood that Figures 1A to 8B The present disclosure is intended to be applicable to 9A to 9E The examples disclosed in the specification and all variations and combinations relating to the described features are intended to be applicable in combination with 9A to 9E Examples described include, but are not limited to, the shape, material, size, manufacture, connection, fastening, etc. of conductor plates, fusible links and non-fusible links, cell holders, cooling features, safety protection features, structural members such as frame members and side panels, battery modules and battery packs, etc.

[0086] In the above description and in the claims, phrases such as "at least one of" or "one or more of" may be followed by a connected list of elements or features. The term "and / or" may also appear in a list of two or more elements or features. Unless otherwise implicitly or explicitly denied by the context in which the wording is used, such wording is intended to refer to any of the elements or features listed individually or any of the recited elements or features in combination with any of the other recited elements or features. It will also be understood that, as used in the description herein and throughout the appended claims, the meaning of "a", "an", and "the" includes plural references unless the context clearly dictates otherwise. Moreover, as used in the description herein and throughout the appended claims, the meaning of "in" includes "in" and "on", unless the context clearly dictates otherwise. Finally, as used in the description herein and throughout the appended claims, the meanings of "and" and "or" include both conjunctions and disjunctive conjunctions and are used interchangeably unless the context clearly dictates otherwise; the wording "exclusive or" may be used to indicate situations where only the disjunctive conjunction meaning is applicable. In addition, as used in the description herein and throughout the appended claims, the meanings of "about" and / or "approximately" refer to ±10% of the indicated amount, unless otherwise indicated. In addition, the use of the term "based on" above and in the claims is intended to mean "based at least in part on," such that unrecited features or elements are also permissible.

[0087] The subject matter described herein may be embodied in systems, devices, methods and / or articles depending on the desired configuration. The specific implementations stated in the foregoing description do not represent all specific implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although several variations have been described in detail above, other modifications or additions are possible. Specifically, other features and / or variations other than the features and / or variations stated herein may be provided. For example, the specific implementations described above may be directed to various combinations and sub-combinations of the disclosed features, and / or combinations and sub-combinations of several other features disclosed above. Other specific implementations may be within the scope of the appended claims.

Claims

1. A battery for a motor vehicle, the battery comprising: Multiple battery cells; and A first conductor plate assembly, wherein the first conductor plate assembly provides electrical connection between the plurality of battery cells, and the first conductor plate assembly comprises: a plurality of first conductor plates, the first conductor plates comprising a plurality of beams, wherein adjacent beams are connected together by one or more flat plates; at least one second conductor plate, the second conductor plate comprising a plurality of beams, wherein adjacent beams are connected together by one or more flat plates; a plurality of fusible links located at the at least one second conductor plate and connecting the at least one second conductor plate to the plurality of battery cells, wherein at the at least one second conductor plate, the plurality of fusible links are connected adjacent to each beam without intervening plates; and A plurality of non-fusible links are located at the plurality of first conductor plates and connect the plurality of first conductor plates to the plurality of battery cells, wherein at the plurality of first conductor plates, the plurality of non-fusible links are connected adjacent to each beam without intervening plates.

2. The battery according to claim 1, further comprising: A plurality of non-fusible links are provided, wherein the plurality of non-fusible links are located at the at least one second conductor plate.

3. The battery according to claim 2, further comprising: A plurality of fusible links are provided, wherein the plurality of fusible links are located at the plurality of first conductor plates.

4. The battery of claim 1, comprising a plurality of second conductor plates, wherein a first one of the second conductor plates comprises only fusible links and no non-fusible links.

5. The battery of claim 4, wherein a second one of the second conductor plates includes only non-fusible links and no fusible links.

6. The battery of claim 1, wherein each of the plurality of battery cells comprises a button and a frame edge, and wherein the plurality of fusible links comprises button fusible links, and wherein the plurality of non-fusible links comprises frame edge non-fusible links.

7. The battery of claim 1, wherein each of the plurality of battery cells comprises a button and a frame, and wherein the plurality of fusible links comprises a frame fusible link, and wherein the plurality of non-fusible links comprises a button non-fusible link.

8. The battery of claim 1 , wherein each of the plurality of battery cells comprises a button portion and a frame edge, Each of the first conductor plates includes a button-shaped portion connecting piece connected to the button-shaped portion and a frame edge connecting piece connected to the frame edge, and wherein the at least one second conductor plate comprises a plurality of second conductor plates, wherein the first of the second conductor plates comprises a button-shaped portion connecting piece connected to the button-shaped portion and has no frame edge connecting piece connected to the frame edge, and The second one of the second conductor plates includes a frame edge connecting piece connected to the frame edge and has no button-shaped portion connecting piece connected to the button-shaped portion.

9. The battery of claim 1 , wherein the first conductor plate and the at least one second conductor plate are arranged in a stacked configuration such that the first conductor plate is disposed in a first plane and the at least one second conductor plate is disposed in a second plane, the first plane and the second plane being displaced from each other in a direction perpendicular to the first plane and the second plane.

10. The battery of claim 1, wherein the first conductor plate and the at least one second conductor plate are arranged in a planar configuration such that the first conductor plate and the at least one second conductor plate are disposed in a same plane.

11. The battery according to claim 1, further comprising: a first battery pack, the first battery pack comprising a first half of the plurality of battery cells; a second battery pack, the second battery pack comprising a second half of the plurality of battery cells; a cold plate, the cold plate being located between the first battery pack and the second battery pack; and a second conductor plate assembly, The first half of the plurality of battery cells are located between the cold plate and the first conductor plate assembly, and the second half of the plurality of battery cells are located between the cold plate and the second conductor plate assembly.

12. The battery of claim 1, wherein each of the plurality of battery cells comprises a button and a frame edge, and The plurality of fusible links include a plurality of button-shaped fusible links and a plurality of frame edge fusible links, and The plurality of non-fusible links include a plurality of button-shaped non-fusible links and a plurality of frame edge non-fusible links.

13. The battery of claim 12, wherein the plurality of button-shaped fusible links and the plurality of button-shaped non-fusible links provide electrical connections between the first conductor plate assembly and the buttons of the plurality of battery cells, and A plurality of frame-side fusible cells and a plurality of frame-side non-fusible cells provide electrical connections between the first conductor plate assembly and the frame sides of the plurality of battery cells.

14. The battery of claim 12, wherein each of the plurality of button-shaped fusible links comprises a root of the button-shaped fusible link, a neck of the button-shaped fusible link, a pad of the button-shaped fusible link, and an orifice of the button-shaped fusible link, and Each of the plurality of button-shaped non-fusible links includes a root of the button-shaped non-fusible link, a solder pad of the button-shaped non-fusible link, and an orifice of the button-shaped non-fusible link, but does not include a neck of the button-shaped non-fusible link.

15. The battery according to claim 12, wherein each of the plurality of frame side fusible links comprises a root of the frame side fusible link, two necks of the frame side fusible link, two pads of the frame side fusible link and a slit of the frame side fusible link, and Each of the plurality of frame side non-fusible links includes a root of the frame side non-fusible link, a solder pad of the frame side non-fusible link, but does not include a slit of the frame side non-fusible link and does not include a neck of the frame side non-fusible link.

16. The battery of claim 15, wherein the slit of the frame side fusible link includes a widened portion proximate the root of the frame side fusible link.

17. The battery of claim 1, wherein each fusible link of the plurality of fusible links and each non-fusible link of the plurality of non-fusible links are stamped products.

18. The battery of claim 17, wherein each fusible link of the plurality of fusible links has a rectangular cross-section having a larger side of more than 1.0 mm and a smaller side of more than 0.1 mm.

19. The battery of claim 17, wherein each fusible link of the plurality of fusible links and each non-fusible link of the plurality of non-fusible links are made of one of the following materials: aluminum, aluminum alloy, copper, copper alloy, nickel, nickel alloy.

20. A method for electrically connecting electrochemical cells in an automotive battery, the method comprising: Providing multiple battery cells; A first conductor plate assembly is provided, the first conductor plate assembly comprising: a plurality of first conductor plates, the first conductor plates comprising a plurality of beams, wherein adjacent beams are connected together by one or more plates; and at least one second conductor plate, the second conductor plate comprising a plurality of beams, wherein adjacent beams are connected together by one or more plates; The plurality of battery cells are electrically connected to the at least one second conductor plate using a plurality of fusible links, wherein at the at least one second conductor plate, the plurality of fusible links are connected adjacent to each beam without intervening plates; and the plurality of battery cells are electrically connected to the plurality of first conductor plates using a plurality of non-fusible links, wherein at the plurality of first conductor plates, the plurality of non-fusible links are connected adjacent to each beam without intervening plates.

21. The method according to claim 20, further comprising: A plurality of non-fusible links are provided, wherein the plurality of non-fusible links are located at the at least one second conductor plate.

22. The method according to claim 21, further comprising: A plurality of fusible links are provided, wherein the plurality of fusible links are located at the plurality of first conductor plates.

23. The method of claim 20, comprising a plurality of second conductor plates, wherein a first one of the second conductor plates comprises only fusible links and no non-fusible links.

24. The method of claim 23, wherein a second one of the second conductor plates includes only non-fusible links and no fusible links.

25. The method of claim 20, wherein each of the plurality of battery cells comprises a button and a frame edge, and wherein the plurality of fusible links comprises button fusible links, and wherein the plurality of non-fusible links comprises frame edge non-fusible links.

26. The method of claim 20, wherein each of the plurality of battery cells comprises a button and a frame, and wherein the plurality of fusible links comprises a frame fusible link, and wherein the plurality of non-fusible links comprises a button non-fusible link.

27. The method of claim 20, wherein each of the plurality of battery cells comprises a button and a frame edge, Each of the first conductor plates includes a button-shaped portion connecting piece connected to the button-shaped portion and a frame edge connecting piece connected to the frame edge, and wherein the at least one second conductor plate comprises a plurality of second conductor plates, wherein the first of the second conductor plates comprises a button-shaped portion connecting piece connected to the button-shaped portion and has no frame edge connecting piece connected to the frame edge, and The second one of the second conductor plates includes a frame edge connecting piece connected to the frame edge and has no button-shaped portion connecting piece connected to the button-shaped portion.

28. The method of claim 20, wherein the first conductor plate and the at least one second conductor plate are arranged in a stacked configuration such that the first conductor plate is disposed in a first plane and the at least one second conductor plate is disposed in a second plane, the first plane and the second plane being displaced from each other in a direction perpendicular to the first plane and the second plane.

29. The method of claim 20, wherein the first conductor plate and the at least one second conductor plate are arranged in a planar configuration such that the first conductor plate and the at least one second conductor plate are disposed in a same plane.

30. The method according to claim 20, further comprising: providing a first battery pack, the first battery pack comprising a first half of the plurality of battery cells; providing a second battery pack, the second battery pack comprising a second half of the plurality of battery cells; providing a cold plate, the cold plate being located between the first battery pack and the second battery pack; and providing a second conductor plate assembly, The first half of the plurality of battery cells are located between the cold plate and the first conductor plate assembly, and the second half of the plurality of battery cells are located between the cold plate and the second conductor plate assembly.

31. The method of claim 20, wherein each of the plurality of battery cells comprises a button and a frame, and The plurality of fusible links include a plurality of button-shaped fusible links and a plurality of frame edge fusible links, and The plurality of non-fusible links include a plurality of button-shaped non-fusible links and a plurality of frame edge non-fusible links.

32. The method of claim 31 , wherein the plurality of button-shaped fusible links and the plurality of button-shaped non-fusible links provide electrical connections between the first conductor plate assembly and the buttons of the plurality of battery cells, and A plurality of frame-side fusible cells and a plurality of frame-side non-fusible cells provide electrical connections between the first conductor plate assembly and the frame sides of the plurality of battery cells.

33. The method of claim 31 , wherein each of the plurality of button-like fusible links comprises a root of the button-like fusible link, a neck of the button-like fusible link, a pad of the button-like fusible link, and an orifice of the button-like fusible link, and Each of the plurality of button-shaped non-fusible links includes a root of the button-shaped non-fusible link, a solder pad of the button-shaped non-fusible link, and an orifice of the button-shaped non-fusible link, but does not include a neck of the button-shaped non-fusible link.

34. The method according to claim 31, wherein each of the plurality of frame edge fusible links comprises a root of the frame edge fusible link, two necks of the frame edge fusible link, two pads of the frame edge fusible link, and a slit of the frame edge fusible link, and Each of the plurality of frame side non-fusible links includes a root of the frame side non-fusible link, a solder pad of the frame side non-fusible link, but does not include a slit of the frame side non-fusible link and does not include a neck of the frame side non-fusible link.

35. The method of claim 34, wherein the slit of the frame edge fusible link includes a widened portion proximate the root of the frame edge fusible link.

36. The method of claim 20, wherein each fusible link of the plurality of fusible links and each non-fusible link of the plurality of non-fusible links are stamped products.

37. The method of claim 36, wherein each fusible link of the plurality of fusible links has a rectangular cross-section having a larger side greater than 1.0 mm and a smaller side greater than 0.1 mm.

38. The method of claim 36, wherein each of the plurality of fusible links and each of the plurality of non-fusible links is made of one of the following materials: aluminum, aluminum alloy, copper, copper alloy, nickel, nickel alloy.

39. A conductor plate assembly for providing electrical connections between a plurality of battery cells of a battery pack of an electric vehicle, the conductor plate assembly comprising: a plurality of first conductor plates, the first conductor plates comprising a plurality of beams, wherein adjacent beams are connected together by one or more flat plates; at least one second conductor plate, the second conductor plate comprising a plurality of beams, wherein adjacent beams are connected together by one or more flat plates; a plurality of fusible links located at the at least one second conductor plate and configured to connect the at least one second conductor plate to the plurality of battery cells, wherein at the at least one second conductor plate, the plurality of fusible links are connected adjacent to each beam without intervening plates; and A plurality of non-fusible links are located at the plurality of first conductor plates and are configured to connect the plurality of first conductor plates to the plurality of battery cells, wherein at the plurality of first conductor plates, the plurality of non-fusible links are connected adjacent to each beam without intervening plates.

40. The conductor plate assembly of claim 39, further comprising: A plurality of non-fusible links are provided, wherein the plurality of non-fusible links are located at the at least one second conductor plate.

41. The conductor plate assembly of claim 39, further comprising: A plurality of fusible links are provided, wherein the plurality of fusible links are located at the plurality of first conductor plates.

42. The conductor plate assembly of claim 39, comprising a plurality of second conductor plates, wherein a first one of the second conductor plates comprises only fusible links and no non-fusible links.

43. The conductor plate assembly of claim 42, wherein a second one of the second conductor plates includes only non-fusible links and no fusible links.

44. The conductor plate assembly of claim 39, wherein each of the plurality of battery cells comprises a button and a frame edge, and wherein the plurality of fusible links comprises a button fusible link, and wherein the plurality of non-fusible links comprises a frame edge non-fusible link.

45. The conductor plate assembly of claim 39, wherein each of the plurality of battery cells comprises a button and a frame edge, and wherein the plurality of fusible links comprises a frame edge fusible link, and wherein the plurality of non-fusible links comprises a button non-fusible link.

46. ​​The conductor plate assembly of claim 39, wherein each of the plurality of battery cells comprises a button and a frame edge, Each of the first conductor plates includes a button-shaped portion connecting piece connected to the button-shaped portion and a frame edge connecting piece connected to the frame edge, and wherein the at least one second conductor plate comprises a plurality of second conductor plates, wherein the first of the second conductor plates comprises a button-shaped portion connecting piece connected to the button-shaped portion and has no frame edge connecting piece connected to the frame edge, and The second one of the second conductor plates includes a frame edge connecting piece connected to the frame edge and has no button-shaped portion connecting piece connected to the button-shaped portion.

47. A conductor plate assembly according to claim 39, wherein the first conductor plate and the at least one second conductor plate are arranged in a stacked configuration, so that the first conductor plate is arranged in a first plane and the at least one second conductor plate is arranged in a second plane, and the first plane and the second plane are shifted from each other in a direction perpendicular to the first plane and the second plane.

48. The conductor plate assembly of claim 39, wherein the first conductor plate and the at least one second conductor plate are arranged in a planar configuration such that the first conductor plate and the at least one second conductor plate are disposed in a same plane.

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