Battery pack joint

Abstract

A system may include a battery subassembly having a flange. The flange may engage a first cross member and a second cross member of a battery pack using fasteners to clamp the battery subassembly with the first cross member and the second cross member.

Description

[0001] introduction

[0002] Electric vehicles may include various electrical components that provide power to the vehicle. These electrical components may be electrically coupled to vehicle components to power the vehicle. Summary of the invention

[0003] A clamping joint of a battery pack may include a plurality of fasteners, each fastener extending at least partially through a first cross member of the battery pack, a first flange of a battery subassembly, a flange of a thermal component of the battery subassembly, a second flange of the battery subassembly, and a second cross member of the battery pack to clamp the cross member, the first flange of the battery subassembly, the flange of the thermal component, the second flange of the battery subassembly, and the second cross member of the battery pack together in a stack. The clamping joint or one or more components of the clamping joint may include one or more features to facilitate absorbing a compressive load of the clamping joint. The clamping joint allows for robust manufacturing of the clamping joint and distribution of compressive loads throughout at least a portion of the clamping joint (e.g., as opposed to a point load applied at a specific location of the clamping joint). Distributing a line load across the width of the joint (e.g., at or between fasteners), as opposed to a point load at a specific location of the clamping joint, may facilitate reducing fatigue, stress, strain, or creep on the clamping joint, thereby allowing the joint to maintain structure for a longer period of time.

[0004] At least one aspect relates to a system. The system may include a battery subassembly having a flange. The flange may engage a first cross member and a second cross member of a battery pack using a fastener to clamp the battery subassembly to the first cross member and the second cross member.

[0005] At least one aspect relates to an electric vehicle. The electric vehicle may include a battery subassembly having a flange. The flange may engage a first cross member and a second cross member of a battery pack using a fastener to clamp the battery subassembly to the first cross member and the second cross member.

[0006] At least one aspect relates to a method. The method may include providing a battery subassembly having a flange. The method may include engaging a first cross member and a second cross member of a battery pack through the flange using a fastener to clamp the battery subassembly to the first cross member and the second cross member.

[0007] These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations, and provide an overview or framework for understanding the nature and characteristics of the protected aspects and implementations. The accompanying drawings provide illustration and further understanding of various aspects and implementations, and are incorporated into and constitute a part of this specification. The foregoing information and the following detailed description and the accompanying drawings include illustrative examples and should not be considered limiting. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The drawings are not intended to be drawn to scale. Like reference numbers and names indicate similar elements in the various drawings. For clarity, not every component may be labeled in every drawing. In the drawings:

[0009] Figure 1 An exemplary side view of an electric vehicle is depicted in accordance with an implementation.

[0010] Figure 2A Depicted is an exemplary perspective view of a battery pack according to a particular implementation.

[0011] Figure 2B Describes the specific implementation Figure 2A An exemplary perspective view of multiple battery subassemblies of a battery pack.

[0012] Figure 2C Depicted is a cross-sectional view of a battery cell according to a particular implementation.

[0013] Figure 2D Depicted is a cross-sectional view of a battery cell according to a particular implementation.

[0014] Figure 2E Depicted is a cross-sectional view of a battery cell according to a particular implementation.

[0015] Figure 2F An exemplary flow chart of a method of forming a battery subassembly according to a particular implementation is depicted.

[0016] Figure 2G Depicted are exemplary cross sections of battery packs according to specific implementations.

[0017] Figure 3A Describes the specific implementation Figure 2A An exemplary perspective view of a battery subassembly of a battery pack.

[0018] Figure 3B Describes a method according to a specific implementation Figure 3A An exemplary front cross-sectional view of a system of battery subassemblies in FIG.

[0019] Figure 4 Describes the specific implementation Figure 3BAn exemplary detailed view of a portion of a system.

[0020] Figure 5A Describes the specific implementation Figure 3B An exemplary front cross-sectional view of a system.

[0021] Figure 5B Describes the specific implementation Figure 3B An exemplary schematic diagram of a system.

[0022] Figure 5C Describes the specific implementation Figure 3B An exemplary perspective view of a portion of a system.

[0023] Fig. 6A Describes the specific implementation Figure 3B An exemplary front cross-sectional view of a system.

[0024] Figure 6B Describes the specific implementation Figure 3B An exemplary schematic diagram of a system.

[0025] Figure 6C Describes the specific implementation Figure 3B An exemplary perspective view of a portion of a system.

[0026] Fig.6D Describes the specific implementation Figure 3B An exemplary front cross-sectional view of a system.

[0027] Fig. 6E Describes the specific implementation Figure 3B An exemplary perspective view of a portion of a system.

[0028] Fig. 7A Describes the specific implementation Figure 3B An exemplary front cross-sectional view of a system.

[0029] Figure 7B Describes the specific implementation Figure 3B An exemplary schematic diagram of a system.

[0030] Figure 7C Describes the specific implementation Figure 3B An exemplary side view of a portion of a system.

[0031] Fig. 8A Describes the specific implementation Figure 3B An exemplary front cross-sectional view of a system.

[0032] Figure 8B Describes the specific implementation Figure 3B An exemplary schematic diagram of a system.

[0033] Fig. 9 Describes the specific implementation Figure 3B An exemplary top view of a portion of a system.

[0034] Fig.10 Describes the specific implementation Figure 3B An exemplary bottom view of a portion of a system in a first state.

[0035] Fig.11 Describes the specific implementation Figure 3B An illustrative view of a portion of a system in a second state.

[0036] Fig.12 Describes the specific implementation Figure 3B An exemplary view of a portion of a system in a first state.

[0037] Fig.13 Describes the specific implementation Figure 3B An illustrative view of a portion of a system in a second state.

[0038] Fig.14 Exemplary illustrations of procedures according to specific implementations are depicted.

[0039] Fig.15 Exemplary illustrations of procedures according to specific implementations are depicted. DETAILED DESCRIPTION

[0040] The following is a more detailed description of various concepts of methods, apparatuses, and systems for a clamping joint for one or more battery subassemblies (e.g., components that hold one or more battery cells) within a vehicle and specific implementations of these methods, apparatuses, and systems. The clamping joint may include a plurality of fasteners, each fastener extending at least partially through a first cross member of a battery pack, a first flange of the battery subassembly, a flange of a thermal component of the battery subassembly, a second flange of the battery subassembly, and a second cross member of the battery pack. The fasteners may clamp the first cross member, the first flange of the battery subassembly, the flange of the thermal component, the second flange of the battery subassembly, and the second cross member of the battery pack together in a stack to secure the battery subassembly with the first cross member and the second cross member. The clamping joint may include a second battery subassembly. For example, the fastener may additionally extend at least partially through the first flange of the second battery subassembly, the flange of the second thermal component of the second battery subassembly, and the second flange of the second battery subassembly to secure the two battery subassemblies together and with the first cross member and the second cross member. The clamping joint or one or more components of the clamping joint may include one or more features to facilitate absorbing compressive loads between the clamping joints.

[0041] The disclosed solution has the following technical advantages: robust manufacturing of a clamp joint and distribution of a compressive load throughout at least a portion of the clamp joint (e.g., as opposed to a point load applied at one specific location of the clamp joint). Distributing a line load across the width of the joint, as opposed to a point load at a specific location of the clamp joint, can facilitate reducing fatigue, stress, strain, or creep on the clamp joint, thereby allowing the joint to maintain structure for a longer period of time.

[0042] Figure 1 An exemplary cross-sectional view 100 of an electric vehicle 105 with at least one battery pack 110 installed is depicted. The electric vehicle 105 may include an electric truck, an electric sport utility vehicle (SUV), an electric van, an electric car, an electric car, an electric motorcycle, an electric scooter, an electric passenger car, an electric passenger or commercial truck, a hybrid vehicle or other vehicle, such as a marine or air vehicle, an airplane, a helicopter, a submarine, a ship, or a drone, among other possibilities. The battery pack 110 may also be used as an energy storage system to power a building such as a residential or commercial building. The electric vehicle 105 may be fully electric or partially electric (e.g., a plug-in hybrid), and further, the electric vehicle 105 may be fully autonomous, partially autonomous, or unmanned. The electric vehicle 105 may also be manually operated or non-autonomous. The electric vehicle 105, such as an electric truck or car, may include an onboard battery pack 110, a battery 115 or a battery subassembly 115, or a battery cell 120 to power the electric vehicle. The electric vehicle 105 may include a chassis 125 (e.g., a frame, an internal frame, or a support structure). The chassis 125 may support various components of the electric vehicle 105. The chassis 125 may span a front portion 130 (e.g., a hood or lid portion), a body portion 135, and a rear portion 140 (e.g., a luggage compartment, payload, or trunk portion) of the electric vehicle 105. The battery pack 110 may be mounted or placed within the electric vehicle 105. For example, the battery pack 110 may be mounted within one or more of the front portion 130, the body portion 135, or the rear portion 140 on the chassis 125 of the electric vehicle 105. The battery pack 110 may include or be connected to at least one bus bar, such as a current collector element. For example, the first bus bar 145 and the second bus bar 150 may include conductive materials to connect or otherwise electrically couple the battery 115, the battery subassembly 115, or the battery cell 120 to other electrical components of the electric vehicle 105, thereby providing electrical power to various systems or components of the electric vehicle 105.

[0043] Figure 2A An exemplary battery pack 110 is depicted. Figure 2A, among other things, the battery pack 110 can provide power to the electric vehicle 105. The battery pack 110 can include any arrangement or network of electrical, electronic, mechanical, or electromechanical devices to power any type of vehicle, such as the electric vehicle 105. The battery pack 110 can include at least one housing 205. The housing 205 can include at least one battery subassembly 115 or at least one battery cell 120, as well as other battery pack components. The battery subassembly 115 can be or include one or more groups of battery cells 120 of prismatic cells, cylindrical cells, pouch cells, or other form factors. For example, the battery subassembly 115 can be or include one or more battery cell carriers, thermal components 215, modules, or other components that join multiple battery cells 120 together. The housing 205 can include a shield on or below the bottom of the battery subassembly 115 to protect the battery subassembly 115 and / or the battery cells 120 from external conditions, for example, when the electric vehicle 105 is traveling on rough terrain (e.g., off-road sites, ditches, rocks, etc.). The battery pack 110 may include at least one cooling line 210, which may be part of a heat / temperature control or heat exchange system that may also include at least one thermal component (e.g., cold plate) 215 to distribute fluid through the battery pack 110. The thermal component 215 may be located relative to the top submodule and the bottom submodule, such as between the top submodule and the bottom submodule, among other possibilities. The battery pack 110 may include any number of thermal components 215. For example, there may be one or more thermal components 215 per battery pack 110 or per battery subassembly 115. The at least one cooling line 210 may be coupled to, partially coupled to, or independent of the thermal component 215.

[0044] Figure 2B A plurality of exemplary battery subassemblies 115 are depicted, and Figure 2C , Figure 2D and Figure 2EAn exemplary cross-sectional view of a battery cell 120 is depicted. The battery subassembly 115 may include at least one submodule. For example, the battery subassembly 115 may include at least one first (e.g., top) submodule 220 or at least one second (e.g., bottom) submodule 225. At least one thermal component 215 may be disposed between the top submodule 220 and the bottom submodule 225. For example, one thermal component 215 may be configured to exchange heat with one battery subassembly 115. The thermal component 215 may be disposed or thermally coupled between the top submodule 220 and the bottom submodule 225. One thermal component 215 may also be thermally coupled to more than one battery subassembly 115 (or more than two submodules 220, 225). The thermal components 215 shown as being adjacent to each other may be combined into a single thermal component 215 that spans the size of one or more submodules 220 or 225. The thermal component 215 may be positioned below the submodule 220 and above the submodule 225, between the submodules 220 and 225, on one or more sides of the submodules 220, 225, and other possibilities. The thermal component 215 may be disposed in a sidewall, a cross member, a structural beam, among various other components of a battery pack such as the battery pack 110 described above. The battery submodules 220, 225 may collectively form a battery subassembly 115. In some examples, each submodule 220, 225 may be considered a complete battery subassembly 115 rather than a submodule.

[0045] The battery subassemblies 115 may each include a plurality of battery cells 120. The battery subassemblies 115 may be disposed within the housing 205 of the battery pack 110. The battery subassemblies 115 may include battery cells 120 that are, for example, cylindrical cells or prismatic cells. The battery subassemblies 115 may operate as modular units of the battery cells 120. For example, the battery subassemblies 115 may collect current or electrical power from the battery cells 120 included in the battery subassemblies 115, and may provide current or electrical power as an output from the battery pack 110. The battery pack 110 may include any number of battery subassemblies 115. For example, the battery pack may have one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, or other number of battery subassemblies 115 disposed in the housing 205. It should also be noted that each battery subassembly 115 may include a top submodule 220 and a bottom submodule 225, and may have a thermal component 215 between the top submodule 220 and the bottom submodule 225. The battery pack 110 may include or define a plurality of areas for positioning the battery subassemblies 115 and / or the battery cells 120. The battery subassemblies 115 may be square, rectangular, circular, triangular, symmetrical, or asymmetrical. In some examples, the battery subassemblies 115 may be of different shapes, such that some battery subassemblies 115 are rectangular, but other battery subassemblies 115 are square, as well as other possibilities. The battery subassembly 115 may include or define a plurality of slots, holders, or containers for a plurality of battery cells 120. It should be noted that the illustrations and descriptions herein are provided for exemplary purposes and should not be construed as limiting. For example, the battery cells 120 may be inserted into the battery pack 110 without the battery modules 220 and 225. The battery cells 120 may be arranged in the battery pack 110 in a battery cell-battery pack configuration without the modules 220 and 225, as well as other possibilities.

[0046] The battery cell 120 has a variety of form factors, shapes, or sizes. For example, the battery cell 120 can have a cylindrical, rectangular, square, cubic, flat, pouch-shaped, elongated, or prismatic form factor. Figure 2C As depicted, for example, battery cell 120 may be cylindrical. Figure 2D As depicted, for example, battery cell 120 may be prismatic. Figure 2EAs depicted, for example, the battery cell 120 may include a pouch form factor. The battery cell 120 may be assembled, for example, by inserting a wound or stacked electrode roll (e.g., a jelly roll) including an electrolyte material into at least one battery cell housing 230. An electrolyte material such as an ion conductive fluid or another material may support an electrochemical reaction at the electrode to generate, store, or provide power for the battery cell by allowing ion conduction between the positive electrode and the negative electrode. The battery cell 120 may include an electrolyte layer, wherein the electrolyte layer may be or include a solid electrolyte material that can conduct ions. For example, a solid electrolyte layer may conduct ions without receiving a separate liquid electrolyte material. An electrolyte material such as an ion conductive fluid or another material may support ion conduction between electrodes, thereby generating or providing power for the battery cell 120. The housing 230 may have a variety of shapes, including, for example, a cylindrical or rectangular shape. An electrical connection may be formed between the electrolyte material and the components of the battery cell 120. For example, an electrical connection of the electrode to at least some of the electrolyte material may be formed at two points or areas of the battery cell 120, for example to form a first polarity terminal 235 (e.g., a positive terminal or anode terminal) and a second polarity terminal 240 (e.g., a negative terminal or cathode terminal). The polarity terminals may be made of a conductive material to carry current from the battery cell 120 to an electrical load, such as a component or system of the electric vehicle 105.

[0047] For example, the battery cell 120 may include at least one lithium-ion battery cell. In a lithium-ion battery cell, lithium ions may be transferred between the positive electrode and the negative electrode during the charging and discharging of the battery cell. For example, the battery cell anode may include lithium or graphite, and the battery cell cathode may include a lithium-based oxide material. The electrolyte material may be provided in the battery cell 120 to separate the anode and the cathode from each other and to facilitate the transfer of lithium ions between the anode and the cathode. It should be noted that the battery cell 120 may also take the form of a solid-state battery cell developed using a solid electrode and a solid electrolyte. The solid electrode or electrolyte may be or include an inorganic solid electrolyte material (e.g., an oxide, a sulfide, a phosphide, a ceramic), a solid polymer electrolyte material, a hybrid solid electrolyte, or a combination thereof. In some embodiments, the solid electrolyte layer may include a polyanion or oxide-based electrolyte material (e.g., lithium superionic conductor (LISICON), sodium superionic conductor (NASICON), perovskite with the formula ABO3 (A = Li, Ca, Sr, La and B = Al, Ti), garnet with the formula A3B2(XO4)3 (A = Ca, Sr, Ba and X = Nb, Ta), lithium phosphorus oxynitride (Li x PO y N z In some embodiments, the solid electrolyte layer may include a glassy, ​​ceramic, and / or crystalline sulfide-based electrolyte (e.g., Li3PS4, Li7P3S11 , Li2S-P2S5, Li2S-B2S3, SnS-P2S5, Li2S–SiS2, Li2S–P2S5, Li2S-GeS2, Li 10 GeP2S 12 ) and / or a sulfide-based lithium argyrodite (such as Li6PS5Cl) having the formula Li6PS5X (X=Cl, Br). In addition, the solid electrolyte layer may include a polymer electrolyte material (e.g., a hybrid or pseudo-solid electrolyte), such as polyacrylonitrile (PAN), polyethylene oxide (PEO), polymethyl methacrylate (PMMA), and polyvinylidene fluoride (PVDF), etc.

[0048] The battery cell 120 may be included in a battery subassembly 115 or a battery pack 110 to power components of the electric vehicle 105. The battery cell housing 230 may be disposed in the battery subassembly 115, the battery pack 110, or a battery array installed in the electric vehicle 105. The housing 230 may have any shape, such as having a circular shape (e.g., particularly as Figure 2C The shape of the housing 230 may also be a prism with a polygonal base, especially as shown in FIG. Figure 2D In particular, Figure 2E As shown, the housing 230 may include a pouch factor. The housing 230 may include other form factors, such as triangles, squares, rectangles, pentagons, and hexagons. In some embodiments, the battery subassembly may include a battery module or be provided as a battery module. In other embodiments, the battery pack may not include a module (e.g., no module). For example, the battery pack may have a module-free or battery cell-battery pack configuration, in which the battery cells are directly arranged in the battery pack without being assembled into a module.

[0049] The housing 230 of the battery cell 120 may include one or more materials or combinations thereof having various electrical or thermal conductivities. The electrically conductive and thermally conductive materials for the housing 230 of the battery cell 120 may include metal materials such as aluminum, alloys of aluminum with copper, silicon, tin, magnesium, manganese, or zinc (e.g., aluminum 1000, 4000, or 5000 series), iron, iron-carbon alloys (e.g., steel), silver, nickel, copper, and copper alloys, etc. The electrically insulating and thermally conductive materials for the housing 230 of the battery cell 120 may include ceramic materials (e.g., silicon nitride, silicon carbide, titanium carbide, zirconium oxide, beryllium oxide, etc.) and thermoplastic materials (e.g., polyethylene, polypropylene, polystyrene, polyvinyl chloride, or nylon), etc. In the case where the housing 230 of the battery cell 120 is prismatic (e.g., especially as Figure 2D as depicted) or cylindrical (e.g., especially as Figure 2CIn the example depicted in FIG. 20 , the housing 230 may include a rigid or semi-rigid material such that the housing 230 is rigid or semi-rigid (e.g., not easily deformed or manipulated into another shape or form factor). ... Figure 2E In the example depicted), the housing 230 may include a flexible, stretchable, or non-rigid material such that the housing 230 can be bent, deformed, manipulated into another form factor or shape.

[0050] The battery cell 120 may include at least one anode layer 245, which may be disposed within a cavity 250 defined by the housing 230. The anode layer 245 may include a first redox potential. During operation of the battery cell 120 (e.g., charging or discharging of the battery cell 120), the anode layer 245 may receive current into the battery cell 120 and output electrons. The anode layer 245 may include an active material. The active material may include, for example, activated carbon or a material infused with a conductive material (e.g., artificial or natural graphite or a mixture), lithium titanate (Li4Ti5O 12 ) or silicon-based materials (e.g., metallic silicon, oxides, carbides, pre-lithiated) or other lithium alloy anodes (Li-Mg, Li-Al, Li-Ag alloys, etc.) or composite anodes composed of lithium and carbon, silicon and carbon, or other compounds. The active material may include graphite carbon (e.g., with sp 2 Hybrid ordered or disordered carbon), Li metal anode, or silicon-based carbon composite anode, or other lithium alloy anode (Li-Mg, Li-Al, Li-Ag alloy, etc.) or composite anode composed of lithium and carbon, silicon and carbon or other compounds. In some examples, the anode material can be formed within the collector material. For example, the electrode can include a collector (e.g., copper foil) with an in-situ formed anode (e.g., Li metal) on the surface of the collector facing the separator or solid electrolyte. In such an example, the assembled battery cell does not contain an anode active material in an uncharged state.

[0051] The battery cell 120 may include at least one cathode layer 255 (e.g., a composite cathode layer, a compound cathode layer, a compound cathode, a composite cathode, or a cathode). The cathode layer 255 may include a second redox potential that may be different from the first redox potential of the anode layer 245. The cathode layer 255 may be disposed within the cavity 250. During the discharge of the battery cell 120, the cathode layer 255 may output current from the battery cell 120 and may receive electrons. During the discharge of the battery cell 120, the cathode layer 255 may also receive lithium ions. Conversely, during the charging of the battery cell 120, the cathode layer 255 may receive current into the battery cell 120 and may output electrons. During the charging of the battery cell 120, the cathode layer 255 may release lithium ions.

[0052] The battery cell 120 may include a layer 260 disposed within the cavity 250. The layer 260 may include a solid electrolyte layer. The layer 260 may include a separator wetted by a liquid electrolyte. The layer 260 may include a polymer material. The layer 260 may include a polymer separator. The layer 260 may be disposed between the anode layer 245 and the cathode layer 255 to separate the anode layer 245 from the cathode layer 255. The polymer separator may physically separate the anode and cathode from the battery cell short circuit. The separator may be wetted with a liquid electrolyte. The liquid electrolyte may diffuse into the anode layer 245. The liquid electrolyte may diffuse into the cathode layer 255. The layer 260 may facilitate the transfer of ions (e.g., Li+) between the anode layer 245 and the cathode layer 255. + ions). Layer 260 may transfer Li + The cations are transferred from the anode layer 245 to the cathode layer 255. Layer 260 can transfer lithium ions from the cathode layer 255 to the anode layer 245 during a charging operation of the battery cell 120.

[0053] The redox potential of the layer (e.g., the first redox potential of the anode layer 245 or the second redox potential of the cathode layer 255) may vary based on the chemistry of the corresponding layer or the chemistry of the battery cell 120. For example, a lithium-ion battery may include LFP (lithium iron phosphate) chemistry, LMFP (lithium iron manganese phosphate) chemistry, NMC (nickel manganese cobalt) chemistry, NCA (nickel cobalt aluminum) chemistry, OLO (overlithiated oxide) chemistry, or LCO (lithium cobalt oxide) chemistry for the cathode layer (e.g., cathode layer 255). A lithium-ion battery may include graphite chemistry, silicon-graphite chemistry, or lithium metal chemistry for the anode layer (e.g., anode layer 245).

[0054] For example, lithium-ion batteries may include olivine-type phosphate (LiMPO4, M = Fe and / or Co and / or Mn and / or Ni) chemistries for the cathode layer, LISICON-type or NASICON-type phosphate (Li3M2(PO4)3 and LiMPO4O x , M=Ti, V, Mn, Cr and Zr), such as lithium iron phosphate (LFP), lithium iron manganese phosphate (LMFP), layered oxide (LiMO2, M=Ni and / or Co and / or Mn and / or Fe and / or Al and / or Mg) examples, NMC (nickel manganese cobalt) chemistry, NCA (nickel cobalt aluminum) chemistry or LCO (lithium cobalt oxide) chemistry, lithium rich layer oxide (Li 1+x M 1-x O2) (Ni, and / or Mn, and / or Co), (OLO or LMR), spinel (LiMn2O4) and high pressure spinel (LiMn 1.5 Ni 0.5O4), disordered rock salts, fluorophosphates Li2FePO4F (M = Fe, Co, Ni), and fluorosulfates LiMSO4F (M = Co, Ni, Mn) (e.g., cathode layer 255). Lithium-ion batteries may include graphite chemistry, silicon-graphite chemistry, or lithium metal chemistry for the anode layer (e.g., anode layer 245). For example, a cathode layer with LFP chemistry may have 3.4V vs. Li / Li + The redox potential of the anode layer with graphite chemistry can have 0.2V vs.Li / Li + Redox potential.

[0055] Typically, in addition to conductive carbon materials, binders or other additives, the electrode layer may also include an anode active material or a cathode active material as a coating on the collector (metal foil). The chemical composition of the electrode layer can affect the redox potential of the electrode layer. For example, the cathode layer (e.g., cathode layer 255) may include a lithium transition metal oxide with a medium to high nickel content (50% to 80% or equal to 80% Ni), such as granular lithium nickel manganese cobalt oxide ("LiNMC"), lithium nickel cobalt aluminum oxide ("LiNCA"), lithium nickel manganese cobalt aluminum oxide ("LiNMCA") or lithium metal phosphates, such as lithium iron phosphate ("LFP") and lithium iron manganese phosphate ("LMFP"). The anode layer (e.g., anode layer 245) may include a conductive carbon material such as graphite, carbon black, carbon nanotubes, etc. The anode layer may include, for example, Super P carbon black material, Ketjen Black, acetylene black, SWCNT, MWCNT, graphite, carbon nanofibers or graphene.

[0056] The electrode layer may also include a chemical bonding material (e.g., a binder). The binder may include a polymer material such as polyvinylidene fluoride ("PVDF"), polyvinyl pyrrolidone ("PVP"), styrene-butadiene or styrene-butadiene rubber ("SBR"), polytetrafluoroethylene ("PTFE"), or carboxymethyl cellulose ("CMC"). The binder material may include agar, alginate, amylose, gum arabic, carrageenan, casein, chitosan, cyclodextrin (carbonyl beta), ethylene propylene diene monomer (EPDM) rubber, gelatin, gellan gum, guar gum, karaya gum, cellulose (natural), pectin, poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT-PSS), polyacrylic acid (PAA), poly(methyl acrylate) (PMA), poly(vinyl alcohol) (PVA), poly(vinyl acetate) (PVAc), polyacrylonitrile (PAN), polyisoprene (PIpr), polyaniline (PANi), polyethylene (PE), polyimide (PI), polystyrene (PS), polyurethane (PU), polyvinyl butyral (PVB), polyvinyl pyrrolidone (PVP), starch, styrene-butadiene rubber (SBR), tara gum, tragacanth gum, fluoroacrylate (TRD202A), xanthan gum, or a mixture of any two or more thereof.

[0057] The current collector material (e.g., a current collector foil to which the electrode active material is laminated to form a cathode layer or an anode layer) may include a metal material. For example, the current collector material may include aluminum, copper, nickel, titanium, stainless steel, or a carbonaceous material. The current collector material may be formed as a metal foil. For example, the current collector material may be an aluminum (Al) or copper (Cu) foil. The current collector material may be a metal alloy made of Al, Cu, Ni, Fe, Ti, or a combination thereof. The current collector material may be a metal foil coated with a carbon material, such as a carbon-coated aluminum foil, a carbon-coated copper foil, or another carbon-coated foil material.

[0058] Layer 260 may include a liquid electrolyte material or be made of a liquid electrolyte material. For example, layer 260 may be or may include at least one layer of a polymer material (e.g., polypropylene, polyethylene, or other material) that includes a pore that is wetted by a liquid electrolyte material (e.g., saturated with a liquid electrolyte material, soaked with a liquid electrolyte material, received, filled with a liquid electrolyte material) to enable ions to move between electrodes. The liquid electrolyte material may include a lithium salt dissolved in a solvent. The lithium salt of the liquid electrolyte material for layer 260 may include, for example, lithium tetrafluoroborate (LiBF4), lithium hexafluorophosphate (LiPF6), and lithium perchlorate (LiClO4). The solvent may include, for example, dimethyl carbonate (DMC), ethylene carbonate (EC), and diethyl carbonate (DEC). The liquid electrolyte does not have to be disposed near layer 260, but the liquid electrolyte can fill the battery cell 120 in many different ways. Layer 260 may include a solid electrolyte material or be made of a solid electrolyte material, such as a ceramic electrolyte material, a polymer electrolyte material, or a glass electrolyte material, or any combination thereof.

[0059] In some embodiments, the solid electrolyte membrane may include at least one layer of solid electrolyte. The solid electrolyte material of the solid electrolyte layer may include an inorganic solid electrolyte material (e.g., oxide, sulfide, phosphide, ceramic), a solid polymer electrolyte material, a hybrid solid electrolyte, or a combination thereof. In some embodiments, the solid electrolyte layer may include a polyanion or oxide-based electrolyte material (e.g., lithium superion conductor (LISICON), sodium superion conductor (NASICON), a perovskite with the formula ABO3 (A = Li, Ca, Sr, La and B = Al, Ti), a garnet type with the formula A3B2(XO4)3 (A = Ca, Sr, Ba and X = Nb, Ta), a lithium phosphorus oxynitride (Li x PO y N z In some embodiments, the solid electrolyte layer may include a glassy, ​​ceramic, and / or crystalline sulfide-based electrolyte (e.g., Li3PS4, Li7P3S 11 , Li2S-P2S5, Li2S-B2S3, SnS-P2S5, Li2S–SiS2, Li2S–P2S5, Li2S-GeS2, Li 10 GeP2S 12 ) and / or a sulfide-based lithium argyrodite (such as Li6PS5Cl) having the formula Li6PS5X (X=Cl, Br). In addition, the solid electrolyte layer may include a polymer electrolyte material (e.g., a hybrid or pseudo-solid electrolyte), such as polyacrylonitrile (PAN), polyethylene oxide (PEO), polymethyl methacrylate (PMMA), and polyvinylidene fluoride (PVDF), etc.

[0060] In an example where layer 260 includes a liquid electrolyte material, layer 260 may include a non-aqueous polar solvent. The non-aqueous polar solvent may include a carbonate, such as ethylene carbonate, propylene carbonate, diethyl carbonate, ethyl methyl carbonate, dimethyl carbonate, or a mixture of any two or more thereof. Layer 260 may include at least one additive. The additive may be or include vinylene carbonate, fluoroethylene carbonate, ethyl propionate, methyl propionate, methyl acetate, ethyl acetate, or a mixture of any two or more thereof. Layer 260 may include a lithium salt material. For example, the lithium salt may be lithium perchlorate, lithium hexafluorophosphate, lithium bis(fluorosulfonyl)imide, lithium bis(trifluorosulfonyl)imide, or a mixture of any two or more thereof. The lithium salt may be present in layer 260 at a concentration greater than 0 M to about 1.5 M. Once provided to the battery cell 120, the liquid electrolyte may be present and contact the battery subcomponents present in the battery cell 120. The battery subcomponents may include a cathode, an anode, a separator, a current collector, and the like.

[0061] Figure 2F An exemplary flow chart of a process for forming a battery subassembly 115 is depicted. At step 270, at least one battery cell 120 is loaded into a cell carrier (described herein). At step 272, an adhesive (e.g., a wicking adhesive) is applied to the battery cell 120 or the carrier to facilitate securing the battery cell 120 to the carrier. At step 274, a current collector assembly (CCA) is coupled to the battery cell 120. At step 276, the CCA is welded to at least one cell terminal (e.g., a button). At step 278, a first unit carrier, a thermal component 215, and a second unit carrier are coupled together to form a subassembly. At step 280, a terminal busbar and a series busbar are coupled to the subassembly. At step 282, various components such as fuses, switches, current sensors, temperature sensors, voltage sensors, thermistors, contactors, etc. may be coupled to the subassembly. For example, a thermistor harness and / or a battery voltage temperature monitor (BVT) configured to receive electrical signals, data packets, measurements, sensor readings, or other data indicative of characteristics of a battery subassembly such as temperature, voltage, state of charge, and / or fault status for communication to a battery management system (BMS) may be coupled to the subassembly. At step 284, potting (e.g., partially or completely filling the space between the cells with a compound to provide resistance to shock waves or vibration) occurs after the first carrier is coupled to the second carrier while the thermal component 215 is disposed between the carriers. At step 286, the touch cover may be coupled to the subassembly. A process of forming a subassembly as shown and described herein, wherein the thermal component 215 is a central unit and may act as a central datuming component, thereby eliminating shear walls and external reference surfaces and / or facilitating a more stable and efficient manufacturing process.

[0062] like Figure 2G As depicted, the battery subassembly 115 may include, among other things, a plurality of battery cells 120 and at least one current collector 290. The current collector 290 may include a conductive member that may electrically couple the plurality of battery cells 120 to one another. For example, the current collector 290 may electrically couple the plurality of battery cells 120 together in a series configuration, a parallel configuration, or some other configuration, such as by physically contacting one or more terminals of the plurality of battery cells 120. The battery pack 110 may include one current collector 290 for each battery subassembly 115. For example, as Figure 2G As depicted, each subassembly 115 may include, among other things, a plurality of battery cells 120 and a current collector 290 to electrically couple the battery cells 120 together.

[0063] The battery cells 120 may be positioned adjacent to each other such that at least a portion of the battery cells 120 is in contact with (e.g., touching, abutting) at least one adjacent battery cell 120. The battery cells 120 may be positioned such that at least a portion of the battery cells 120 is not in contact with an adjacent battery cell 120. For example, Figure 2G As depicted, due to the arrangement, configuration, and shape of the battery cells, the battery cell 120 may be positioned relative to at least one adjacent battery cell 120, with the gap region 295 positioned between the adjacent battery cells 120. The gap region 295 may include a space, gap, opening, or cavity positioned between the adjacent battery cells 120. The battery cell 120 may be completely or partially surrounded by the gap region 295 in the radial direction. For example, if the battery cell 120 does not contact any adjacent battery cell 120, the gap region 295 may surround the radial surface of the battery cell 120 in the radial direction (e.g., excluding the top and bottom, which may be coupled to, for example, the collector 290 or the thermal component 215). In an example where a portion of the battery cell 120 contacts at least one adjacent battery cell 120, the gap region 295 may partially surround the battery cell 120. For example, multiple discrete (e.g., separate, individual) gap regions 295 may exist within the subassembly 115, wherein each gap region 295 is separated from the other gap regions 295 because at least two battery cells are adjacent to (e.g., in contact, touching) each other. The gap regions 295 may exist as a product of the shape, arrangement, and configuration of the battery cells 120. For example, the battery cells 120 may be cylindrical in form such that a group of multiple (e.g., three, four, or some other number) adjacent battery cells 120 may contact each other only along lines or edges rather than surfaces (e.g., as in the case of prismatic battery cells 120). At least a portion (e.g., 80%-100%) of the gap regions 295 may be filled with potting, and at least a portion of the area between the battery cells 120 and the thermal component 215 may be filled with thermal adhesive. As Figure 2GAs depicted by the arrows in , this configuration of the battery pack 110 allows a load path to extend along the wall of the carrier described herein across the approximate midpoint of the battery cell 120 and through the flange of the carrier described herein.

[0064] Figure 3A depicts an exemplary perspective view of a first battery subassembly 305, and Figure 3B An exemplary front cross-sectional view of a system 300 having a first battery subassembly 305 is depicted. The first battery subassembly 305 may include various components to facilitate storing at least one battery cell 120 within the vehicle 105. For example, the first battery subassembly 305 may include a configuration similar to the battery subassembly 115 described herein. For example, the first battery subassembly 305 may include a first cell carrier 315, a second cell carrier 320, and a thermal member 215 (at least Figure 3B 315). The first unit carrier 315 may include one or more components to hold or carry at least one battery cell 120 in place. For example, the first unit carrier 315 may include one or more recesses (e.g., battery cell-shaped holes, clamps, or other components that can receive the battery cell 120 to couple the battery cell 120 to the first carrier 315). The second unit carrier 320 may include a similar configuration and size as the first unit carrier 315. For example, the second unit carrier 320 may include at least one recess to receive at least one battery cell 120. The thermal component 215 may be positioned at a middle portion of the first battery subassembly 305, between the first unit carrier 315 and the second unit carrier 320.

[0065] System 300 may be or may include a clamping joint of one or more battery subassemblies (e.g., battery subassembly 115 or a carrier for battery cell 120). For example, system 300 may include a first battery subassembly 305 and a second battery subassembly 310 (e.g., such as at least Figure 3B). The second battery subassembly 310 may include one or more components similar to the first battery subassembly 305. For example, the second battery subassembly 310 may include at least one battery cell 120. The second battery subassembly 310 may include a first unit carrier 315, a second unit carrier 320, and a thermal component 215. The first unit carrier 315 may include one or more components to hold or carry at least one battery cell 120 in an appropriate position. For example, the first unit carrier 315 may include one or more recesses (e.g., battery cell-shaped holes, clamps, or other components that can receive the battery cell 120 to couple the battery cell 120 to the first carrier 315). The second unit carrier 320 may include a configuration and size similar to the first unit carrier 315. For example, the second unit carrier 320 may include at least one recess to receive at least one battery cell 120. The thermal component 215 may be positioned at a middle portion of the first battery submodule 305, between the first unit carrier 315 and the second unit carrier 320.

[0066] The system 300 may include one or more components that may couple the first battery subassembly 305 to the second battery subassembly 310. For example, the system 300 may include one or more components that facilitate coupling the first battery subassembly 305 or the second battery subassembly 310 to one or more portions of the vehicle 105 (e.g., such that the battery cells 120 of the battery subassemblies 305, 310 are secured to the vehicle 105). The system 300 may include, for example, a first cross member 325 and a second cross member 330. The first cross member 325 may be substantially opposite the second cross member 330 (e.g., such that the first cross member 325 is positioned on top of the second cross member 330). The first cross member 325 and the second cross member 330 may include a beam extending through the battery pack 110 of the vehicle 105 (e.g., as described herein and at least Figure 3A The system 300 may include one or more fasteners 335 (e.g., such as a plurality of fasteners 335) that may extend at least partially through one or more of the first cross member 325, the first carrier 315 or the second carrier 320 of the subassembly 305, 310, the thermal component 215 of the subassembly 305, 310, or the second cross member 330 to clamp each of the components together and form a clamped joint. For example, at least one fastener 335 may clamp or bias at least the first cross member 325 and the second cross member 330 together. The first cross member 325 and the second cross member 330 may apply and distribute a clamping load to the first flange 340, the second flange 345, and the thermal component flange 350, such as Figure 2G(flanges 340 , 345 , 350 are not depicted). First cross member 325 or second cross member 330 may be coupled to a portion of vehicle 105 (eg, to a portion of battery pack 110 ) to mount system 300 to vehicle 105 .

[0067] One or more of the battery cell carriers 315, 320 and the one or more thermal components 215 may include a flange that may be clamped between the first cross member 325 and the second cross member 330. For example, the first cell carrier 315 (e.g., of the first battery subassembly 305 or the second battery subassembly 310) may include a first carrier flange 340, and the second cell carrier 320 (e.g., of the first battery subassembly 305 or the second battery subassembly 310) may include a second carrier flange 345. Each of the first carrier flange 340 and the second carrier flange 345 may extend or protrude substantially laterally from the respective cell carrier (e.g., such that the first carrier flange 340 defines an outermost portion of the first cell carrier 315 and the second carrier flange 345 defines an outermost portion of the second cell carrier 320). The thermal component 215 (e.g., of the first battery subassembly 305 or the second battery subassembly 310) may include a thermal component flange 350. The thermal member flange 350 can be disposed between and at least partially contact the first carrier flange 340 and the second carrier flange 345. The thermal member flange 350 can extend or protrude substantially laterally from the thermal member 215 (eg, such that the thermal member flange 350 defines an outermost portion of the thermal member 215).

[0068] Each of the first carrier flange 340, the thermal component flange 350, and the second carrier flange 345 may be stacked together in an outwardly protruding manner so that the first cross member 325 and the second cross member 330 may clamp the first carrier flange 340, the thermal component flange 350, and the second carrier flange 345 together through the fastener 335 to fix the first subassembly 305 or the second subassembly 310 together or to the vehicle 105. For example, at least one flange (e.g., one or more of the first flange 340, the second flange 345, or the thermal component flange 350) may be engaged with (e.g., at least partially contacted, coupled to, applied load to, subjected to load from, etc.) the first cross member 325 and the second cross member 330 using the fastener 335 to clamp the first battery subassembly 305 with the first cross member 325 and the second cross member 330. For example, fasteners 335 extending at least partially through the first cross member 325 (e.g., through an opening in the first cross member 325), the first carrier flange 340 (e.g., through a notch in the flange 340), the thermal component flange 350 (e.g., through a notch in the flange 350), the second carrier flange 345 (e.g., through a notch in the flange 345), or the second cross member 330 (e.g., through an opening in the second cross member 330) can form a clamped joint to secure the first battery subassembly 305 or the second battery subassembly 310 in position relative to the battery pack 110 or the vehicle 105. The system 300 can facilitate distributing a compressive load of the joint (e.g., via one or more fasteners 335) substantially evenly throughout a portion of the joint to create a line load displacement, such as an opposite point load.

[0069] The system 300 may extend at least partially through the battery pack 110 of the vehicle 105, such that the system 300 may include a plurality of fasteners 335 that may extend through a plurality of apertures, holes, or indentations formed in the first carrier flange 340, the thermal member flange 350, the second carrier flange 345, and the first and second cross members. For example, the system 300 may include five fasteners 335 to secure each battery subassembly 305, 310 or each group of battery subassemblies 305, 310 (e.g., five fasteners 335 for both the first battery subassembly 305 and the second battery subassembly 310). The system 300 may include more or fewer fasteners 335 and corresponding apertures, holes, or indentations (e.g., one fastener 335, two fasteners 335, three fasteners 335, four fasteners 335, or more than five fasteners 335).

[0070] Figure 4 A perspective cutaway view of a portion of system 300 is depicted. For example, Figure 4A close-up view of a first carrier flange 340, a thermal component flange 350, and a second carrier flange 345 (e.g., of a first subassembly 305) clamped together is depicted. The thermal component 215 may include one or more portions that make up the thermal component 215. For example, the thermal component 215 may include a first thermal component portion 405, a second thermal component portion 410, and a third thermal component portion 415. As at least Figure 3A and Figure 4 As depicted, the hot component flange 350 may include a first hot component portion 405, a second hot component portion 410, and a third hot component portion 415 that are stacked together to form the flange 350. The first hot component portion 405 and the third hot component portion 415 may diverge in opposite directions in a direction moving away from the hot component flange 350. The second hot component portion 410 may extend in a serpentine (e.g., "S"-shaped) manner such that at a first section of the hot component 215, at least a portion of the second hot component portion 410 is in direct contact with the first hot component portion 405 but not the third hot component portion 415 (e.g., such that a space is defined between the second hot component portion 410 and the third hot component portion 415), and at a second section of the hot component 215, at least a portion of the second hot component portion 410 is in direct contact with the third hot component portion 415 but not the first hot component portion 405 (e.g., such that a space is defined between the second hot component portion 410 and the first hot component portion 405).

[0071] System 300 may include various features to facilitate absorbing the compressive loads of a clamped joint to reduce fatigue, stress, strain, or creep at one or more portions of the joint. For example, Figure 5A , Figure 5B , Fig. 6A and Figure 6B An exemplary front cross-sectional view of a system 300 having at least one compression limiter 505 at a joint is depicted. Figure 5C depicts a perspective view of one of the cross-members (eg, the second cross-member 330) having a plurality of compression limiters 505, and Figure 6C A perspective view of one of the first carrier flanges 340 having a compression limiter 505 is depicted. FIG. 5A to FIG. 5CAs depicted, system 300 may include at least one compression limiter 505 coupled to at least one of first cross member 325 or second cross member 330 to support fastener 335. For example, compression limiter 505 may include a material that is more rigid or stronger than first cross member 325 or second cross member 330 (e.g., a metallic material such as steel or aluminum) coupled to first cross member 325 or second cross member 330 to facilitate absorbing or distributing loads applied by fastener 335 to clamp the joint. For example, compression limiter 505 may include a band of metallic material surrounding a hole, opening, or aperture in first cross member 325 or second cross member 330 that receives fastener 335, such that when fastener 335 is tightened, compression limiter 505 at least partially contacts one of first carrier flange 340 or second carrier flange 345. System 300 may include at least two compression limiters 505, such that a first compression limiter 505 is coupled to first cross member 325 and contacts at least one of first carrier flanges 340, and a second compression limiter 505 is coupled to second cross member 330 and contacts at least one of second carrier flanges 345. Compression limiters 505 may include bosses (e.g., protrusions) extending from one or more of first cross member 325 or second cross member 330 to facilitate maintaining the clamp load of the joint over time, such as Figure 5A In each of the first cross member 325 and the second cross member 330 , each hole that receives a fastener 335 may include a compression limiter 505 .

[0072] If at least FIG. 6A to FIG. 6E As depicted, the compression limiter 505 can be overmolded or insert molded onto one or more of the first carrier flange 340 or the second carrier flange 345. For example, at least a portion of the first carrier flange 340 or the second carrier flange 345 can include one or more plastic materials, and the compression limiter 505 can be molded into the plastic material to support the fastener 335. For example, as shown in FIG. Figure 6C As depicted, one or more of the first carrier flange 340 or the second carrier flange 345 may include a notch (e.g., substantially semicircular in shape) in the flange to at least partially receive a portion (e.g., about half the diameter of the fastener body) of the fastener 335. The notch of the flange may be overmolded with one or more metallic materials to form a compression limiter 505. The compression limiter 505 may facilitate distributing the load and maintaining the clamp load of the joint over time.

[0073] If at least Fig.6D and Fig. 6EAs depicted, the compression limiter 505 can be coupled to one of the first flange 340, the second flange 345, or a portion of the thermal member 215 at a location remote from the through hole that receives the fastener 335. For example, the compression limiter 505 can be coupled to a hole, notch, or other opening that may or may not receive the fastener 335 (e.g., to support the clamping load applied by the first and second cross members 325, 330 or the fastener 335 at a location located remote from the fastener 335). The compression limiter 505 can be coupled directly to a portion of the thermal member 215. For example, the compression limiter 505 can be coupled to a portion of the thermal member flange 350 of the thermal member 215.

[0074] System 300 may include at least one elastomer to facilitate absorbing the compressive load of the connector or to more evenly distribute the compressive load across flange 340. For example, Fig. 7A and Figure 7B An exemplary front cross-sectional view of the system 300 having an elastomeric material 705 (a gasket, O-ring, or other seal made of ethylene propylene diene monomer (EPDM) or a rigid elastomer) at a joint is depicted. For example, the elastomeric material 705 can be or include a high-strength, weather-resistant EPDM rubber sheet. The elastomeric material 705 can be coupled to one or more of the first flange 340, the second flange 345, the first cross-member 325, or the second cross-member 330. For example, one of the first flange 340, the second flange 345, the first cross-member 325, or the second cross-member 330 can include a groove to receive a portion of the elastomeric material 705. For example, Figure 7C A side view of a portion of the second cross member 330 is depicted. The second cross member 330 may include an elastomeric material 705 (e.g., an O-ring or other elastic component) coupled to a portion of the second cross member 330. The elastomeric material 705 may have an annular shape that includes an opening to receive a portion of the fastener 335. The elastomeric material 705 may at least partially surround the fastener 335 such that when the fastener 335 clamps the subassembly with the second cross member 330, the elastomeric material 705 engages the second cross member 330 and the second flange 345. The first cross member 325 may include an elastomeric material 705 at least partially surrounding the fastener 325 such that when the fastener 335 clamps the subassembly with the first cross member 325, the elastomeric material 705 engages the first cross member 335 and the first flange 340.

[0075] The elastomeric material 705 may include a gasket or seal extending across the entire width of the joint. For example, the elastomeric material 705 may extend along the entire width of the first cross member 325, the second cross member 330, or the first flange 340 or the second flange 345 at the surface where the first cross member 325 engages the first flange 340 or the surface where the second cross member 330 engages the second flange 345. The full width gasket of the elastomeric material 705 may be coupled to the first cross member 325, the second cross member 330, or one or both of the first flange 340 or the second flange 345 to facilitate sealing the joint along the full width of the joint. The system 300 may include at least one adhesive applied to at least a portion of the first flange 340, the second flange 345, the hot component flange 350, the first cross member 325, or the second cross member 330 to secure the first flange 340 or the second flange 345 relative to the first cross member 325 and the second cross member 330.

[0076] System 300 may include at least one bracket to facilitate absorbing the compressive load of the joint. Fig. 8A and Figure 8B An exemplary front cross-sectional view of a system 300 is depicted, the system having at least one bracket 805 coupled to a first flange 340 or a second flange 345 at a joint. For example, the bracket 805 can be molded (e.g., overmolded or insert molded) onto a portion of the first flange 340 or the second flange 345. The bracket 805 can be made of a variety of materials, including, but not limited to, steel or aluminum. When the fastener 335 clamps one or more battery subassemblies between the first cross member 325 and the second cross member 330 (e.g., when the fastener is torqued), the bracket 805 can facilitate absorbing the compressive load from the first cross member 325 or the second cross member 330. For example, the bracket 805 can engage with the first cross member 325 or the second cross member 330 to facilitate distributing the load throughout the first flange 340 or the second flange 345 to maintain the clamping load of the joint formed by the fastener 335 over time.

[0077] Fig. 9 A top-down view of the second cross member 330 is depicted. Fig. 9 As depicted, the second cross member 330 (and corresponding first cross member 325) may include a plurality of openings to receive one or more fasteners 335. As described herein, the system 300 may include a plurality of openings along the top surface of the second cross member 330. Fig. 9 An adhesive or gasket extending in a left-to-right direction (eg, along at least a portion or the entire length of second cross member 330 ) may be provided.

[0078] Fig.10 and Fig.12A bottom view of a portion of the first flange 340 is depicted. The first flange 340 or the second flange 345 may include at least one deformable protrusion 1005. The deformable protrusion 1005 may include, for example, one or more teeth 1010 extending from a surface of the first flange 340 in a direction toward the second flange 345 and the thermal member 215. For example, the teeth 1010 may extend circumferentially around a center 1020 of the deformable protrusion 1005. The deformable protrusion 1005 may include at least one rib 1015 extending outwardly from the teeth 1010 along the flange 340 to increase the strength of the teeth 1010. At least one of the teeth 1010 may deform in response to contacting or engaging one or more of the first cross member 325, the second cross member 330, the thermal member 215 (e.g., the thermal member flange 350), or the second flange 345. For example, teeth 1010 may be deformed to facilitate absorbing loads applied to first subassembly 305 or second subassembly 310 when first cross member 325, second cross member 330, thermal component 215 (e.g., thermal component flange 350), or second flange 345 are clamped together by fasteners 335. For example, Fig.11 and Fig.13 The deformable protrusion 1005 is depicted in a deformed state when the tooth 1010 contacts a portion of the joint, such as the hot component flange 350. Figures 10 to 13 As depicted, the deformable protrusion 1005 can include any number of teeth 1010 of one or more sizes (eg, four teeth 1010, eight teeth 1010, or more or fewer teeth 1010).

[0079] Fig.14 An exemplary method 1400 is depicted. The method 1400 may include providing a battery subassembly, as depicted by action 1405. For example, the battery subassembly may be or include a first battery subassembly 305 or a second battery subassembly 310. The first battery subassembly 305 (or the second battery subassembly 310) may include various components to facilitate storing at least one battery cell 120 within the vehicle 105. For example, the first battery subassembly 305 may include a first unit carrier 315, a second unit carrier 320, or a thermal component 215. The first unit carrier 315 may include one or more components to hold or carry at least one battery cell 120 in place. The second unit carrier 320 may include a configuration and size similar to the first unit carrier 315. The thermal component 215 may be positioned at a middle portion of the first battery submodule 305, between the first unit carrier 315 and the second unit carrier 320.

[0080] The first unit carrier 315 (e.g., of the first battery subassembly 305 or the second battery subassembly 310) may include a first carrier flange 340, and the second unit carrier 320 (e.g., of the first battery subassembly 305 or the second battery subassembly 310) may include a second carrier flange 345. Each of the first carrier flange 340 and the second carrier flange 345 may extend or protrude substantially laterally from the respective unit carrier (e.g., such that the first carrier flange 340 defines an outermost portion of the first unit carrier 315 and the second carrier flange 345 defines an outermost portion of the second unit carrier 320). The thermal component 215 (e.g., of the first battery subassembly 305 or the second battery subassembly 310) may include a thermal component flange 350. The thermal component flange 350 may be disposed between and in at least partial contact with the first carrier flange 340 and the second carrier flange 345. The thermal member flange 350 may extend or protrude substantially laterally from the thermal member 215 (eg, such that the thermal member flange 350 defines an outermost portion of the thermal member 215 ).

[0081] The method 1400 may include engaging the first cross member 325 or the second cross member 330 of the battery pack 110, as depicted by action 1410. For example, a flange (e.g., the first flange 340, the second flange 345, or the thermal component flange 350) may engage the first cross member 325 and the second cross member 330 using fasteners 335 to clamp the battery subassembly 305 to the first cross member 325 and the second cross member 330. For example, each of the first carrier flange 340, the thermal component flange 350, and the second carrier flange 345 may be stacked together in an outwardly protruding manner so that the first cross member 325 and the second cross member 330 may clamp the first carrier flange 340, the thermal component flange 350, and the second carrier flange 345 together through the fasteners 335 to secure the first subassembly 305 or the second subassembly 310 together or to the vehicle 105. For example, one or more of the first flange 340, the second flange 345, or the thermal component flange 350 may be engaged with the first cross member 325 and the second cross member 330 using fasteners 335 to clamp the first battery subassembly 305 to the first cross member 325 and the second cross member 330. For example, fasteners 335 extending at least partially through the first cross member 325 (e.g., through an opening in the first cross member 325), the first carrier flange 340 (e.g., through a notch in the flange 340), the thermal component flange 350 (e.g., through a notch in the flange 350), the second carrier flange 345 (e.g., through a notch in the flange 345), or the second cross member 330 (e.g., through an opening in the second cross member 330) may form a clamping joint to secure the first battery subassembly 305 or the second battery subassembly 310 in position relative to the battery pack 110 or the vehicle 105.

[0082] Fig.15 An exemplary method 1500 is depicted. The method 1500 may include providing a system 300, as depicted by act 1505. The system 300 may include at least one battery subassembly 305, 310 having a flange (e.g., a first flange 340 or a second flange 345) that may engage (e.g., at least partially contact, couple together, etc.) a first cross member 325 and a second cross member 330 via a fastener 335 to clamp the battery subassembly with the first cross member 325 and the second cross member 330 (e.g., to form a clamping joint to secure one or more battery subassemblies 305, 310 to the battery pack 110 or the vehicle 105).

[0083] Although operations are depicted in a particular order in the drawings, these operations need not be performed in the particular order shown or in sequential order, and not all of the operations shown need be performed. The actions described herein may be performed in a different order.

[0084] Now that some exemplary implementations have been described, it is apparent that the foregoing is illustrative rather than restrictive and has been presented by way of example. Specifically, although many of the examples presented herein relate to specific combinations of method actions or system elements, these actions and these elements may be combined in other ways to achieve the same purpose. The actions, elements, and features discussed in conjunction with one implementation are not intended to be excluded from similar roles in other implementations.

[0085] The words and terms used herein are for descriptive purposes and should not be construed as limiting. The use of "including," "comprising," "having," "containing," "involving," "characterized by," and variations thereof herein is intended to encompass the items listed thereafter, their equivalents and additional items, and alternative implementations consisting solely of the items listed thereafter. In one implementation, the systems and methods described herein consist of one, each combination of more than one, or all of the elements, acts, or components described.

[0086] Any implementation or element or action of the system and method mentioned in the singular form herein may also include an implementation comprising a plurality of these elements, and any plural form of any implementation or element or action herein may also include an implementation comprising only a single element. Reference in the singular or plural form is not intended to limit the currently disclosed system or method, its parts, actions or elements to a single or multiple configurations. Reference to any action or element based on any information, action or element may include a specific implementation in which the action or element is based at least in part on any information, action or element.

[0087] Any implementation disclosed herein may be combined with any other implementation or embodiment, and references to "an implementation," "some implementations," "an implementation," etc. are not necessarily mutually exclusive, but are intended to indicate that a particular feature, structure, or characteristic described in conjunction with an implementation may be included in at least one implementation or embodiment. Such terms as used herein do not necessarily all refer to the same implementation. Any implementation may be combined, inclusively or exclusively, with any other implementation in any manner consistent with the aspects and implementations disclosed herein.

[0088] References to "or" may be interpreted as inclusive, such that any term described using "or" may indicate any of a single, more than one, and all of the terms. References to at least one of a conjunctive list of terms may be interpreted as inclusive OR to indicate any of a single, more than one, and all of the terms. For example, references to "at least one of 'A' and 'B'" may include only "A," only "B," and both "A" and "B." Such references used in conjunction with "including" or other open-ended terms may include additional items.

[0089] Where a technical feature in the drawings, detailed description or any claims is followed by a reference numeral, the reference numeral is included to enhance the intelligibility of the drawings, detailed description and claims. Therefore, the presence or absence of a reference numeral has no limiting effect on the scope of any claim element.

[0090] Without departing substantially from the teachings and advantages of the subject matter disclosed herein, modifications may be made to the elements and actions, such as changes in size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, color, orientation of the various elements. For example, an element shown as being integrally formed may be composed of multiple parts or elements, the position of elements may be reversed or otherwise changed, and the nature or number or position of discrete elements may be changed or varied. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure.

[0091] For example, the joint may include more or fewer fasteners than shown in the figure. An element described as a negative element may be configured as a positive element, while an element described as a positive element may be configured as a negative element. For example, an element described as having a first polarity may have a second polarity, while an element described as having a second polarity may have a first polarity. Further relative parallel, vertical, vertical or other positioning or orientation descriptions include changes within + / -10% or + / -10 degrees of pure vertical, parallel or vertical positioning. Unless otherwise expressly stated, references to "approximately", "substantially" or other degree terms include changes of + / -10% with a given measurement, unit or range. The connected elements may be electrically connected, mechanically connected or physically connected to each other directly or through an intermediate element. Therefore, the scope of the systems and methods described herein is indicated by the appended claims rather than the foregoing description, and changes falling within the meaning and scope of the equivalents of the claims are included therein.

Claims

1. A system comprising: a battery subassembly comprising a flange; and The flange is configured to engage a first cross member and a second cross member of a battery pack using fasteners to clamp the battery subassembly to the first cross member and to the second cross member.

2. The system according to claim 1, comprising: the battery subassembly including a second flange and a thermal component at least partially disposed between the flange and the second flange; The fastener is used to at least partially clamp the first cross member and the second cross member; and The first cross member and the second cross member are used to apply a clamping load to the flange and the second flange.

3. The system according to claim 1, comprising: The fastener is used to clamp at least a portion of the second battery subassembly between the first cross member and the second cross member to couple the battery subassembly and the second battery subassembly to the battery pack.

4. The system according to claim 1, comprising: A compression limiter is coupled to the flange to support the fastener.

5. The system according to claim 1, comprising: a compression limiter coupled to at least one of the first cross member or the second cross member; and The compression limiter is used to support the fastener.

6. The system according to claim 1, comprising: an elastomeric component coupled to the first cross member; and The elastomeric member is configured to engage the flange.

7. The system according to claim 1, comprising: a bracket coupled to the flange; and The bracket is configured to engage one of the first cross member or the second cross member.

8. The system according to claim 1, comprising: The flange includes a protrusion configured to deform in response to the fastener clamping the flange between the first cross member and the second cross member.

9. The system according to claim 1, comprising: An adhesive is applied to at least a portion of at least one of the flange, the first cross member, or the second cross member to secure the flange relative to the first cross member and the second cross member.

10. The system according to claim 1, comprising: The fastener is configured to extend at least partially through the flange, the first cross member, and the second cross member to clamp the battery subassembly with the first cross member and the second cross member.

11. An electric vehicle comprising: a battery subassembly comprising a flange; and The flange is configured to engage a first cross member and a second cross member of a battery pack using fasteners to clamp the battery subassembly to the first cross member and to the second cross member.

12. The electric vehicle according to claim 11, comprising: the battery subassembly including a second flange and a thermal component at least partially disposed between the flange and the second flange; The fastener is used to at least partially clamp the first cross member and the second cross member; and The first cross member and the second cross member are used to apply a clamping load to the flange and the second flange.

13. The electric vehicle according to claim 11, comprising: The fastener is used to clamp at least a portion of the second battery subassembly between the first cross member and the second cross member to couple the battery subassembly and the second battery subassembly to the battery pack.

14. The electric vehicle according to claim 11, comprising: A compression limiter is coupled to the flange to support the fastener.

15. The electric vehicle according to claim 11, comprising: a compression limiter coupled to at least one of the first cross member or the second cross member; and The compression limiter is used to support the fastener.

16. The electric vehicle according to claim 11, comprising: an elastomeric component coupled to the first cross member; and The elastomeric member is configured to engage the flange.

17. The electric vehicle according to claim 11, comprising: a bracket coupled to the flange; and The bracket is configured to engage one of the first cross member or the second cross member.

18. The electric vehicle according to claim 11, comprising: The flange includes a protrusion configured to deform in response to the fastener clamping the flange between the first cross member and the second cross member.

19. A method comprising: providing a battery subassembly including a flange; as well as A first cross member and a second cross member of the battery pack are engaged with fasteners through the flanges to clamp the battery subassembly to the first cross member and the second cross member.

20. The method according to claim 19, comprising: The battery subassembly includes a second flange and a thermal component at least partially disposed between the flange and the second flange; at least partially clamping the first cross member and the second cross member via the fastener; as well as A clamping load is applied to the flange and the second flange through the first cross member and the second cross member.

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