Battery system

Abstract

The invention provides a battery system. The battery system may include a first cell carrier having a first reference portion. The first reference portion of the first unit carrier may be aligned with a second reference portion of a thermal component and at least partially receive a positioning feature of a second unit carrier.

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 battery system may facilitate coupling at least two battery cell carriers with a thermal component to form a battery system. The battery system may include a first unit carrier defining a reference portion (e.g., an opening) and a second unit carrier having a positioning feature portion (e.g., a column) that can be aligned with the reference portion and extend through the reference portion. The battery system may include a thermal component disposed between the first unit carrier and the second unit carrier. The thermal component may define a reference portion (e.g., an opening) that substantially matches the reference portion of the first unit carrier, such that the reference portions can be aligned to each at least partially receive the positioning feature portion of the second unit carrier. The second unit carrier (or the first unit carrier) may include at least one protruding rib extending from a surface of the second unit carrier toward the thermal component and the first unit carrier. With this configuration, the first unit carrier, the second unit carrier, and the thermal component may be aligned together (e.g., by aligning the positioning feature portion and the reference portion together), and may be coupled to each other by inserting the positioning feature portion through the reference portion. In response to coupling the first unit carrier, the second unit carrier, and the thermal component together, the protruding rib may be at least partially deformed to absorb the compressive load between the first unit carrier, the second unit carrier, and the thermal component.

[0004] At least one aspect relates to a battery system. The battery system may include a first unit carrier having a first datum portion. The first datum portion of the first unit carrier may be aligned with a second datum portion of a thermal component and at least partially receive a locating feature portion of a second unit carrier.

[0005] At least one aspect relates to an electric vehicle. The electric vehicle may include a battery system. The battery system may include a first unit carrier having a first reference portion. The first reference portion of the first unit carrier may be aligned with a second reference portion of a thermal component and at least partially receive a positioning feature portion of a second unit carrier.

[0006] At least one aspect relates to a method. The method may include providing a first unit carrier having a first datum and a second unit carrier having a locating feature. The method may include aligning the first datum of the first unit carrier with the second datum of the thermal component, and inserting the locating feature of the second unit carrier at least partially through the first datum and the second datum to couple the first unit carrier, the second unit carrier, and the thermal component.

[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 example side view of an electric vehicle is depicted according to a particular implementation.

[0010] Figure 2A Depicted are example perspective views of a battery pack according to particular implementations.

[0011] Figure 2B Describes the specific implementation Figure 2A An example 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 example flow chart of a method of forming a battery subassembly according to a particular implementation is depicted.

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

[0017] Figure 3 Depicted are example exploded perspective views of battery systems according to particular implementations.

[0018] Figure 4 Describes the specific implementation Figure 3 An example detailed view of a portion of a battery system.

[0019] Figure 5 Describes the specific implementation Figure 3 Another example detailed view of a portion of a battery system.

[0020] Figure 6 Describes the specific implementation Figure 3 Another example detailed view of a portion of a battery system.

[0021] Figure 7 Describes the specific implementation Figure 3 An example side cutaway view of a portion of a battery system.

[0022] Figure 8 Describes the specific implementation Figure 3 An example perspective view of a portion of a battery system.

[0023] Fig. 9 Describes the specific implementation Figure 3 An example perspective view of a portion of a battery system in a first state.

[0024] Fig.10 Describes the specific implementation Figure 3 An example perspective view of a portion of a battery system in a second state.

[0025] Fig.11 Describes the specific implementation Figure 3 An example perspective view of a portion of a battery system in a first state.

[0026] Fig.12 Describes the specific implementation Figure 3 An example perspective view of a portion of a battery system in a second state.

[0027] Fig.13 Depicted are example illustrations of procedures according to specific implementations.

[0028] Fig.14 Depicted are example illustrations of procedures according to specific implementations. DETAILED DESCRIPTION

[0029] Various concepts related to methods, apparatus, and systems for aligning and coupling battery systems together and specific implementations of the methods, apparatus, and systems are described in further detail below. For example, a battery system may have a first unit carrier defining a reference portion (e.g., an opening) and a second unit carrier having a positioning feature portion (e.g., a column) that can be aligned with the reference portion and extend through the reference portion. The battery system may include a thermal component disposed between the first unit carrier and the second unit carrier. The thermal component may define a reference portion (e.g., an opening) that substantially matches the reference portion of the first unit carrier, such that these reference portions can be aligned to each at least partially receive the positioning feature portion of the second unit carrier. The second unit carrier (or the first unit carrier) may include at least one protruding rib extending from a surface of the second unit carrier toward the thermal component and the first unit carrier. With this configuration, the first unit carrier, the second unit carrier, and the thermal component can be aligned together (e.g., by aligning the positioning feature portion and the reference portion together) and can be coupled to each other by inserting the positioning feature portion through the reference portion. In response to coupling the first unit carrier, the second unit carrier, and the thermal component together, the protruding ribs may at least partially deform to absorb a compressive load between the first unit carrier, the second unit carrier, and the thermal component.

[0030] The disclosed solution has technical advantages with internal part-to-part references. For example, by designing and forming the positioning features and references directly on or with the first unit carrier, the second unit carrier, or the thermal component, the battery system reduces or eliminates the need for external reference strategies (e.g., references external to the first unit carrier, the second unit carrier, or the thermal component) or references for aligning and coupling the battery system together. In addition, manufacturing deviations are greatly reduced due to the interaction of different parts and assembly tolerances involved in the coupling process of the battery system. In addition, since no external positioning fixtures are required, process cycle times and takt times are greatly improved, thereby improving manufacturing output and yield for mass production. In addition, part-to-part positioning eliminates assembly deviations and helps reduce scrap costs.

[0031] Figure 1An example 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 sedan, 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 busbar 145 and the second busbar 150 may include conductive materials to connect or otherwise electrically couple the battery 115 , battery subassembly 115 , or battery cell 120 to other electrical components of the electric vehicle 105 to provide electrical power to various systems or components of the electric vehicle 105 .

[0032] Figure 2A An example 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 located 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 as part of a heat / temperature control or heat exchange system that may also include at least one thermal component (e.g., cold plate) 215 that can distribute a 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.

[0033] Figure 2B An example battery subassembly 115 is depicted, and Figure 2C , Figure 2D and Figure 2EAn example 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.

[0034] 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 submodules 220 and 225, as well as other possibilities.

[0035] 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, such as 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). These polarity terminals may be made of conductive materials to carry current from the battery cell 120 to an electrical load, such as a component or system of the electric vehicle 105.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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 can 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.

[0042] 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).

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] Figure 2F An example flow chart of a process of 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 for 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.

[0051] 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.

[0052] 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.

[0053] Figure 3 An example exploded perspective view of a battery system 300 is depicted. The battery system 300 may include a first unit carrier 305, a second unit carrier 310, and a thermal component 215. The first unit carrier 305 may include one or more components to hold or carry at least one battery cell 120 in place. For example, the first unit carrier 305 may include one or more recesses (e.g., battery cell-shaped holes, clamps, or other components that can receive a battery cell 120 to couple the battery cell 120 to the first carrier 305). The second unit carrier 310 may include a similar configuration and size as the first unit carrier 305. For example, the second unit carrier 310 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 battery system 300, between the first unit carrier 305 and the second unit carrier 310.

[0054] Figure 4 and Figure 5 An example detailed view of a portion of a battery system 300 is depicted. For example, Figure 4 and Figure 5 A portion of the second battery cell carrier 310 is depicted coupled to a portion of the thermal component 215. For example, at least one of the first cell carrier 305 or the second cell carrier 310 may include a locating feature 405. The locating feature 405 may be or may include a post (e.g., a protrusion, a projection, or the like extending from a surface of the cell carrier). For example, as at least Figure 4 and Figure 5 As depicted, the locating feature 405 may include a post extending from the second unit carrier 310 in a direction toward the thermal component 215 and the first unit carrier 305. The thermal component 215 may include at least one corresponding datum 410. For example, the datum 410 may be or may include an opening (e.g., a hole, a slot, an aperture) that may at least partially receive a portion of the locating feature 405.

[0055] The battery system 300 may include a plurality of locating features 405 that may each be aligned with one another and a plurality of corresponding datums 410 on the thermal component 215. For example, the second unit carrier 310 may include four locating features 405 (e.g., two locating features 405 each positioned on opposite sides of the unit carrier). Two of the locating features 405 may extend through at least a portion of a first type of datum 410 of the thermal component 215, and two of the locating features 405 may extend through at least a portion of a second type of datum 410 of the thermal component 215. For example, the first type of datum 410 may be or may include a bidirectional datum (e.g., such as Figure 4 The bidirectional datum may constrain the first unit carrier 305 or the second unit carrier 310 relative to the thermal component 215 along one axis (e.g., in two degrees of freedom of movement). The second type of datum 410 may be or may include a four-way datum (e.g., such as Figure 5 The four-way datum may constrain the first unit carrier 305 or the second unit carrier 310 relative to the thermal component 215 along two axes (e.g., in four degrees of freedom of movement). For example, the thermal component 215 may include two two-way datums 410 and two four-way datums 410 positioned on opposite sides of the thermal component 215. The system 300 may include more or fewer positioning features 405 or more or fewer datums 410. For example, the system 300 may include one positioning feature 405 or datum 410, two positioning features 405 or datum 410, three positioning features 405 or datum 410, or more than four positioning features 405 or datum 410.

[0056] One or more positioning features 405 may include various shapes or sizes. For example, Figure 6 A perspective view of an example locating feature 405 is depicted. The locating feature 405 may include a body 605 having at least one cutout 610. For example, the body 605 may define a substantially rounded or cylindrical shape, and the cutout 610 may include a portion of the body 605 that is at least partially discontinuous or cut away from a portion of the body 605 toward a central portion of the body 605. The body 605 may include a plurality of cutouts 610. For example, as at least Figure 4 and Figure 5As depicted, the positioning feature 405 may include a plurality of (e.g., four) cutouts located in the circumferential direction of the positioning feature 405 to define a cross-shaped cross section. The positioning feature 405 may include other types of cutout 610 shapes. For example, the body 605 may include a rectangular shape, a pentagonal shape, an octagonal shape, a square shape, an asymmetric shape, or another shape. The body 605 may include more or fewer cutouts 610. For example, the body 605 may include one cutout 610, two cutouts 610, three cutouts 610, more than four cutouts 610, or the body 605 may not have any cutouts 610. As described herein, the cutouts 610 may at least partially accommodate adhesive to improve adhesive flow path control.

[0057] At least a portion of the body 605 of the locating feature 405 may taper in at least one direction (e.g., at a topmost section of the locating feature, taper from a surface of the unit carrier in a direction away from the unit carrier). For example, at least a portion of the outer diameter of the body 605 may decrease in a direction away from the unit carrier.

[0058] Figure 7 An example side cross-sectional view of a portion of a battery system 300 is depicted. For example, Figure 7 Depicted is a portion of a second unit carrier 310 having at least one locating feature 405, a portion of a first unit carrier 305, and a portion of a thermal component 215 disposed between and at least partially in contact with the first and second unit carriers 305 and 310. Figure 7 As depicted, the first unit carrier 305 or the second unit carrier 310 may include at least one corresponding reference portion 705. The reference portion 705 may be or may include an opening that may at least partially receive the positioning feature portion 405 of the second unit carrier 310. For example, as at least Figure 7As depicted, the datum 705 of the first unit carrier 305 may be at least partially aligned with the corresponding datum 410 of the thermal component 215 and at least partially receive the positioning feature 405. In other words, the positioning feature 405 may extend through both the datum 410 of the thermal component 215 and the datum 705 of the first unit carrier 305 to facilitate aligning each of the first unit carrier 305, the second unit carrier 310, and the thermal component 215 with each other. The first unit carrier 305 may include a plurality of datums 705. At least one of the datums 705 may include a first type of datum (e.g., a bi-directional datum), and at least one of the datums 705 may include a second type of datum (e.g., a four-way datum). For example, the first unit carrier 305 may include two bi-directional datums 705 and two four-way datums 705 positioned on opposite sides of the first unit carrier 305. The system 300 may include more or fewer datums 705. For example, the system 300 may include one fiducial 705 , two fiducials 705 , three fiducials 705 , or more than four fiducials 705 .

[0059] Each of the first unit carrier 305 and the second unit carrier 310 may include one or more positioning features 405 and one or more references 705. For example, one side of the first unit carrier 305 (e.g., one flange extending beyond the side wall) may include a bidirectional reference 705, a first positioning feature 405, a four-way reference 705, and a second positioning feature 405. The opposing second unit carrier 310 may include a corresponding first positioning feature 405 for insertion into the bidirectional reference 705 of the first unit carrier 305, a bidirectional reference 705 that receives the first positioning feature 405 of the first unit carrier 305, a second positioning feature 405 for insertion into the four-way reference 705 of the first unit carrier 305, and a four-way reference 705 that receives the second positioning feature 405 of the first unit carrier 305. The thermal component 215 may include at least one reference portion 410, which is a reference portion of the same type as the reference portion 705 of the first unit carrier 305 or the second unit carrier 310 (for example, a bidirectional reference portion 410 that is aligned and matched with the corresponding bidirectional reference portion 705 of the first unit carrier 305 or the second unit carrier 310, or a four-way reference portion 410 that is aligned and matched with the corresponding bidirectional reference portion 705 of the first unit carrier 305 or the second unit carrier 310).

[0060] Each of the first unit carrier 305, the second unit carrier 310, and the thermal component 215 may include a plurality of datums 410, 705 and positioning features 405 to align the first unit carrier 305, the second unit carrier 310, and the thermal component 215 in a plurality of directions. For example, the second unit carrier 310 may include a positioning feature 405 located substantially at each corner of the second unit carrier 310, and each of the first unit carrier 305 and the thermal component 215 may include a corresponding datum 410, 705. The datums 410, 705 and positioning features 405 may be formed as part of the respective unit carrier 305, 310 and the thermal component 215 to eliminate or reduce the need for datums or other positioning features that are located external to the system 300 (e.g., not formed integrally with at least one of the first unit carrier 305, the second unit carrier 310, or the thermal component 215).

[0061] The thermal component 215 may include one or more parts that make up the thermal component 215. For example, the thermal component 215 may include a first thermal component part 710, a second thermal component part 715, and a third thermal component part 720. Figure 7 As depicted, the first thermal component portion 710, the second thermal component portion 715, and the third thermal component portion 720 can at least partially define the reference portion 410 of the thermal component 215. For example, the first thermal component portion 710, the second thermal component portion 715, and the third thermal component portion 720 can be stacked together to form the thermal component 215, and the reference portion 410 (e.g., an opening) can extend through each of the first thermal component portion 710, the second thermal component portion 715, and the third thermal component portion 720. In other words, the thermal component 215 can include a plurality of at least partially stacked sections that define the reference portion 410.

[0062] The first and third thermal component portions 710, 720 may diverge in opposite directions in at least one direction. For example, the second thermal component portion 715 may extend in a serpentine (e.g., "S"-shaped) manner such that at a first section of the thermal component 215, at least a portion of the second thermal component portion 715 is in direct contact with the first thermal component portion 710 but not with the third thermal component portion 720 (e.g., such that a space is defined between the second and third thermal component portions 715, 720), and at a second section of the thermal component 215, at least a portion of the second thermal component portion 715 is in direct contact with the third and third thermal component portions 720 but not with the first thermal component portion 710 (e.g., such that a space is defined between the second and first thermal component portions 715, 710). The diameter of the reference portion 410 of the thermal component 215 may vary. For example, the diameter of the reference portion 410 in at least one of the plurality of sections (e.g., the first thermal component portion 710, the second thermal component portion 715, or the third thermal component portion 720) may vary in diameter relative to one of the remaining sections. For example, at the reference portion 410, the diameter of the second thermal component portion 715 may be smaller than that of the first thermal component portion 710 or the third thermal component portion 720.

[0063] At least a portion of the system 300 may include an added adhesive 725 to facilitate securing the first unit carrier 305, the second unit carrier 310, and the thermal component 215 relative to each other after they are aligned (e.g., after the datums 410, 705 receive at least a portion of the corresponding positioning features 405). For example, the system 300 may include an adhesive 725 applied between the first unit carrier 305 and the second unit carrier 310. The adhesive 725 may flow throughout a portion of the system 300. For example, at least a portion of the positioning features 405 (e.g., one or more cutouts 610) may receive the adhesive 725. In other words, the cutouts 610 of the positioning features 405 or the tapering at the topmost portion of the positioning features 405 allow for a flow path for the adhesive 725. The flow path may facilitate increased control of the adhesive (e.g., causing the adhesive to flow within the flow path in a controlled manner).

[0064] At least a portion of the reference portion 705 of the first unit carrier 305 may be tapered to facilitate forming a flow path for the adhesive 725 to flow. For example, the reference portion 705 may be defined by a first wall 730, an opposing second wall 735, and a third wall 740 extending between the first wall 730 and the second wall 735. The first wall 730 or the second wall 735 may be tapered in a direction extending from the opening of the reference portion 705 toward the third wall 740 to facilitate the adhesive 725 to flow into a portion of the reference portion 705 (e.g., so that the adhesive 725 may at least partially contact the positioning feature 405). For example, the diameter at the beginning of the opening of the reference portion 705 may be greater than the diameter or length of the third wall 740.

[0065] Figure 8 An example perspective view of a portion of a second unit carrier 310 (or first unit carrier 305) having at least one deformable protrusion 805 (e.g., a deformable protruding rib protruding from the unit carrier) is depicted. The deformable protrusion 805 may at least partially protrude beyond a surface 810 of the second unit carrier 310. For example, Fig. 9 and Fig.11 A detailed view of a deformable protrusion 805 is depicted. The deformable protrusion 805 may include, for example, one or more teeth 905 extending from a surface 810 of a corresponding carrier (e.g., the second unit carrier 310) in a direction toward the thermal component 215 and the opposing other carrier (e.g., the first unit carrier 305). For example, the teeth 905 may extend circumferentially around a center 915 of the deformable protrusion 805. The deformable protrusion 805 may include at least one spoke 910 extending outwardly from the tooth 905 along the unit carrier to increase the strength of the tooth 905. At least one of the teeth 905 may deform in response to contact or engagement with one or more of the thermal component 215 or another unit carrier (e.g., the first unit carrier 305). For example, the tooth 905 may deform to facilitate absorbing a load applied to the thermal component 215 by the first unit carrier 305 or the second unit carrier 310 when the components are coupled together. For example, Fig.10 and Fig.12 The deformable protrusion 805 is depicted in a deformed state when the tooth 905 contacts a portion of the thermal component 215 (or a portion of the first unit carrier 305). Figures 8 to 12 As depicted, the deformable protrusion 805 may include any number of teeth 905 of one or more sizes (eg, four teeth 905, eight teeth 905, or more or fewer teeth 905).

[0066] Fig.13An example method 1300 is depicted. The method 1300 may include providing a first unit carrier 305 and a second unit carrier 310, as depicted by actions 1305 and 1310. Each of the first unit carrier 305 and the second unit carrier 310 may hold one or more battery cells 120. The second unit carrier 310 may include at least one locating feature 405. For example, the locating feature 405 may be or may include a post (e.g., a protrusion, a projection, an extension, a cylindrical rod, etc.). The first unit carrier 305 may include a datum 705 (e.g., an opening, an orifice, etc.) that may at least partially receive the locating feature 405. The thermal component 215 may be disposed between the first unit carrier 305 and the second unit carrier 310 and may include a datum 410 that may at least partially receive the locating feature 405.

[0067] The method 1300 may include aligning the datum portion 410 of the thermal component 215 and the datum portion 705 of the first unit carrier 305, as depicted by action 1315. For example, the datum portions 410, 705 may be aligned so that they substantially overlap one another (e.g., so that the locating feature portion 405 may protrude continuously through each of the datum portions 705, 410), such as at least Figure 7 Depicted.

[0068] The method 1300 may include inserting the locating feature 405 of the second unit carrier 310 with the datum 410 of the thermal component 215 and with the datum 705 of the first unit carrier 305, as depicted by action 1320. For example, the locating feature 405 may protrude through the datum 410 of the thermal component 305 and the datum 705 of the first unit carrier 310 to align the first unit carrier 215, the second unit carrier 305, and the thermal component with each other and facilitate coupling them to each other.

[0069] Fig.14 An example method 1400 is depicted. The method 1400 may include providing a battery system 300, as depicted by action 1405. The battery system 300 may include a first unit carrier 305, a second unit carrier 310, or a thermal component 215. The first unit carrier 305 may include one or more components to hold or carry at least one battery cell 120 in place. The second unit carrier 310 may include a similar configuration and size as the first unit carrier 305. The thermal component 215 may be positioned at a middle portion of the battery system 300, between the first unit carrier 305 and the second unit carrier 310.

[0070] The battery system 300 may include a plurality of locating features 405 and a plurality of corresponding datums 410 on the thermal component 215. For example, the second unit carrier 310 may include four locating features 405. Two of the locating features 405 may extend through at least a portion of a first type of datum 410 of the thermal component 215, and two of the locating features 405 may extend through at least a portion of a second type of datum 410 of the thermal component 215. For example, the first type of datum 410 may be or may include a two-way datum. The second type of datum 410 may be or may include a four-way datum.

[0071] The first unit carrier 305 or the second unit carrier 310 may include at least one respective datum 705. The datum 705 may be or may include an opening that may at least partially receive the locating feature 405 of the second unit carrier 310. For example, the datum 705 of the first unit carrier 305 may at least partially align with the respective datum 410 of the thermal component 215 and at least partially receive the locating feature 405. In other words, the locating feature 405 may extend through both the datum 410 of the thermal component 215 and the datum of the first unit carrier 305 to facilitate aligning each of the first unit carrier 305, the second unit carrier 310, and the thermal component 215 with each other. The first unit carrier 305 may include a plurality of datums 705. At least one of the datums 705 may include a first type of datum (e.g., a two-way datum), and at least one of the datums 705 may include a second type of datum (e.g., a four-way datum).

[0072] To align and couple the battery system 300 together, the datum 705 of the first unit carrier 305 may be aligned with the datum 410 of the thermal component 215. The locating features 405 of the second unit carrier 310 may at least partially protrude through the aligned datums 705, 410 to align the first unit carrier 305 with the thermal component 215 and with the second unit carrier 310.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] For example, the first unit carrier or the second unit carrier may include any amount of reference or positioning features positioned at different positions of the carrier. 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 coupled elements may be electrically coupled, mechanically coupled or physically coupled 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 battery system comprising: a first unit carrier, the first unit carrier comprising a first reference portion; The first reference portion of the first unit carrier is configured as: aligning with a second datum of the thermal component; and The locating feature of the second unit carrier is at least partially received.

2. The battery system according to claim 1, comprising: The locating feature comprises a post having at least one cutout; and At least a portion of the at least one cutout is configured to receive an adhesive.

3. The battery system according to claim 1, comprising: The locating feature includes at least one tapered portion to provide an adhesive flow path.

4. The battery system according to claim 1, comprising: the second unit carrier comprising a rib protruding beyond a surface of the second unit carrier; and The rib is configured to deform in response to the second unit carrier being coupled to the first unit carrier.

5. The battery system according to claim 1, comprising: The thermal component includes a plurality of at least partially stacked segments defining the second reference portion; and A diameter of the second reference portion in at least one of the plurality of segments is different from a diameter of the second reference portion in the remaining segments of the plurality of segments.

6. The battery system according to claim 1, comprising: The first reference portion includes a bidirectional reference portion to restrict the first unit carrier to two degrees of freedom of movement.

7. The battery system according to claim 1, comprising: The second reference includes a four-way reference to restrict the first unit carrier to four degrees of freedom of movement.

8. The battery system according to claim 1, comprising: The first reference portion and the second reference portion include the same type of reference portion.

9. An electric vehicle comprising: A battery system, the battery system comprising: a first unit carrier, the first unit carrier comprising a first reference portion; The first reference portion of the first unit carrier is configured as: aligning with a second datum of the thermal component; and The locating feature of the second unit carrier is at least partially received.

10. The electric vehicle according to claim 9, comprising: The locating feature comprises a post having at least one cutout; and At least a portion of the at least one cutout is configured to receive an adhesive.

11. The electric vehicle according to claim 9, comprising: The locating feature includes at least one tapered portion to provide an adhesive flow path.

12. The electric vehicle according to claim 9, comprising: the second unit carrier comprising a rib protruding beyond a surface of the second unit carrier; and The rib is configured to deform in response to the second unit carrier being coupled to the first unit carrier.

13. The electric vehicle according to claim 9, comprising: The thermal component includes a plurality of at least partially stacked segments defining the second reference portion; and A diameter of the second reference portion in at least one of the plurality of segments is different from a diameter of the second reference portion in the remaining segments of the plurality of segments.

14. The electric vehicle according to claim 9, comprising: The first reference portion includes a bidirectional reference portion to restrict the first unit carrier to two degrees of freedom of movement.

15. The electric vehicle according to claim 9, comprising: The second reference includes a four-way reference to restrict the first unit carrier to four degrees of freedom of movement.

16. The electric vehicle according to claim 9, comprising: The first reference portion and the second reference portion include the same type of reference portion.

17. A method comprising: providing a first unit carrier including a first reference portion and a second unit carrier including a locating feature portion; aligning the first reference portion of the first unit carrier with the second reference portion of the thermal component; as well as The locating feature of the second unit carrier is at least partially inserted through the first datum and the second datum to couple the first unit carrier, the second unit carrier, and the thermal component.

18. The method according to claim 17, comprising: The locating feature comprises a post having at least one cutout; and At least a portion of the at least one cutout is configured to receive an adhesive.

19. The method according to claim 17, comprising: The locating feature includes at least one tapered portion to provide an adhesive flow path.

20. The method according to claim 17, comprising: the second unit carrier comprising a rib protruding beyond a surface of the second unit carrier; and The rib is configured to deform in response to the second unit carrier being coupled to the first unit carrier.

Images