Conductive device

Abstract

A conductive member may include a first opening and a second opening. The first opening of the conductive member may engage a first member of a battery carrier such that the conductive member is at least partially aligned with the battery carrier. The second opening of the conductive member is engageable with a second member of the battery carrier for coupling the conductive member with the battery carrier.

Description

Background Art

[0001] An electric vehicle includes a battery unit coupled to a conductive member to provide power to the electric vehicle. Summary of the invention

[0002] The present disclosure relates to a busbar for a battery module. The busbar may include at least one opening to engage with a stake (e.g., a pin) of a battery cell carrier (e.g., a shipping box, a battery module shipping box), wherein the pin may heat rivet the busbar to the battery carrier. The busbar may include at least one second opening to receive at least one reference locator (e.g., a two-way locator and a four-way locator) protruding from the battery carrier. The busbar may include an overmolded component, the overmolded component including at least one retaining arm to engage with an opening of the battery carrier, thereby coupling the busbar and the overmolded component to the battery carrier. The busbar may include an edge that may be coupled (e.g., welded) to a downwardly folded tab of a module collector. The busbar may include a module-to-module ("M2M") terminal block. For example, the M2M block may be coupled to the busbar via a welding operation; the M2M terminal block may be a separate component coupled to the busbar, such that the M2M terminal block may include a different thickness or plating layer than the busbar. The busbar overmold may include a retaining device to retain a cable (e.g., a ribbon cable of a voltage sensing harness) against the busbar. For example, the busbar overmold may include a first retaining member for retaining a tail of the voltage sensing harness and a second retaining member for retaining, for example, a thermistor wire.

[0003] At least one aspect relates to an apparatus. The apparatus may be a conductive member. The conductive member may include a first opening and a second opening. The first opening of the conductive member may engage a first member of a battery carrier so that the conductive member is at least partially aligned with the battery carrier. The second opening of the conductive member may engage a second member of the battery carrier for coupling the conductive member to the battery carrier.

[0004] At least one aspect relates to a system. The system may include a busbar, a battery carrier, and a component. The battery carrier may include a battery carrier opening. The component may include a retaining arm and a component opening. The retaining arm of the component may engage with the battery carrier opening to couple the component to the battery carrier. The component opening may receive a protrusion of the battery carrier. The protrusion may be configured to expand within the component opening to couple the busbar to the battery carrier.

[0005] At least one aspect relates to a method. The method may include engaging a locator of a battery carrier with a locating opening of a busbar. The locator may at least partially align the busbar with the battery carrier. The method may include engaging a thermal stake of the battery carrier with a thermal stake opening of the busbar, the thermal stake being used to couple the busbar to the battery carrier.

[0006] 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

[0007] 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:

[0008] Figure 1 An exemplary electric vehicle according to some aspects is depicted.

[0009] Figure 2 Depicted are example battery packs according to some aspects.

[0010] Figure 3 Depicted are example battery modules according to some aspects.

[0011] Figure 4 Depicted are example battery packs having bus bar assemblies according to some aspects.

[0012] Figure 5 Depicted are example battery packs having bus bar assemblies according to some aspects.

[0013] Figure 6 Depicted are exemplary terminal blocks for bus bar assemblies according to some aspects.

[0014] Figure 7 Depicted are example battery packs having bus bar assemblies according to some aspects.

[0015] Figure 8 Depicted are exemplary current collectors coupled to a bus bar assembly according to some aspects.

[0016] Fig. 9 Depicted are exemplary current collectors according to some aspects.

[0017] Fig.10 Depicted are exemplary terminal blocks for bus bar assemblies according to some aspects.

[0018] Fig.11 Depicted are exemplary terminal blocks for bus bar assemblies according to some aspects.

[0019] Fig.12Depicted are exemplary retention arms for a bus bar assembly according to some aspects.

[0020] Fig.13 Depicted are exemplary retention arms for a bus bar assembly according to some aspects.

[0021] Fig.14 Depicted are exemplary retention arms for a bus bar assembly according to some aspects.

[0022] Fig.15 Depicted are detailed views of exemplary bus bar assemblies according to some aspects.

[0023] Fig.16 Depicted are exemplary retention clamps for bus bar assemblies according to some aspects.

[0024] Fig.17 Depicted is a cross-sectional view of an exemplary battery cell according to some aspects.

[0025] Fig.18 Depicted is a cross-sectional view of an exemplary battery cell according to some aspects.

[0026] Fig.19 Depicted is a cross-sectional view of an exemplary battery cell according to some aspects.

[0027] Fig. 20 is a flow chart of an exemplary method of installing a bus bar assembly according to some aspects. DETAILED DESCRIPTION

[0028] Various concepts related to methods, devices and systems for busbars of battery packs or battery modules and their implementation are described in more detail below. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways.

[0029] The present disclosure relates to a busbar for a battery module. The busbar may include at least one opening to engage with a stake (e.g., a pin) of a battery carrier (e.g., a shipping box, a battery module shipping box, or some other carrier), wherein the pin may heat rivet the busbar to the battery carrier. The busbar may include at least one second opening to receive at least one reference locator (e.g., a two-way locator and a four-way locator) protruding from the battery carrier. The busbar may include an overmolded component, the overmolded component including at least one retaining arm extending therefrom. The retaining arm may engage with an opening (e.g., a slot) of the battery carrier to couple the busbar and the overmolded component to the battery carrier. The busbar may include an edge that may couple (e.g., weld) a downwardly folded tab of a module collector. The busbar may include a module-to-module ("M2M") terminal block. For example, the M2M block may be coupled to the busbar via a welding operation; the M2M terminal block may be a separate component coupled to the busbar, such that the M2M terminal block may include a thickness different from that of the busbar. Because the busbar and the M2M terminal block can be separate components, the busbar can be plated while the M2M terminal block can be non-plated (e.g., without any plating layer or with a different type of plating layer). The busbar overmold can include a retaining device to retain a cable (e.g., a ribbon cable of a voltage sensing harness) against the busbar. For example, the retaining device can be a fork arm, a clamp, a latch, a cage, or other device. For example, the busbar overmold can include a first retaining member for retaining the tail of the voltage sensing harness and a second retaining member for retaining a thermistor wire.

[0030] Figure 1An 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 module 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 main body portion 135, and a rear portion 140 (e.g., a luggage compartment, a payload, or a 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 main body portion 135, or the rear portion 140 on the chassis 125 of the electric vehicle 105. The battery pack 110 may include at least one bus bar, such as a current collector element, or be connected thereto. For example, first busbar 145 and second busbar 150 may include conductive materials to connect or otherwise electrically couple battery 115 , battery module 115 , or battery cell 120 to other electrical components of electric vehicle 105 to power various systems or components of electric vehicle 105 .

[0031] Figure 2 An exemplary battery pack 110 is depicted. With particular reference to Figure 2, the battery pack 110 can provide power to the electric vehicle 105. The battery pack 110 may 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 may include at least one housing 200. The housing 200 may include at least one battery module 115 or at least one battery cell 120, as well as other battery pack components. The battery module 115 may be or may include one or more groups of prismatic batteries, cylindrical batteries, pouch batteries, or other form factor battery cells 120. The housing 200 may include a shield on or below the bottom of the battery module 115 to protect the battery module 115 and / or the battery cell 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 205 that may distribute fluid through the battery pack 110 as part of a heat / temperature control or heat exchange system that may also include at least one thermal component (e.g., cold plate) 210. The thermal component 210 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 210. For example, there may be one or more thermal components 210 per battery pack 110 or per battery module 115. The at least one cooling line 205 may be coupled to the thermal component 210, as part of the thermal component, or independent of the thermal component.

[0032] Figure 3 An exemplary battery module 115 is depicted, and Fig.17 , Fig.18 and Fig.19An exemplary cross-sectional view of a battery cell 120 is depicted. The battery module 115 may include at least one submodule. For example, the battery module 115 may include at least one first (e.g., top) submodule 300 or at least one second (e.g., bottom) submodule 305. At least one thermal component 210 may be disposed between the top submodule 300 and the bottom submodule 305. For example, one thermal component 210 may be configured to exchange heat with one battery module 115. The thermal component 210 may be disposed or thermally coupled between the top submodule 300 and the bottom submodule 305. One thermal component 210 may also be thermally coupled to more than one battery module 115 (or more than two submodules 300, 305). The thermal components 210 shown as being adjacent to each other may be combined into a single thermal component 210 that spans the size of one or more submodules 300 or 305. The thermal component 210 may be positioned below the submodule 300 and above the submodule 305, between the submodules 300 and 305, on one or more sides of the submodules 300, 305, and other possibilities. The thermal component 210 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 300, 305 may together form a battery module 115. In some examples, each submodule 300, 305 may be considered a complete battery module 115 rather than a submodule.

[0033] The battery modules 115 may each include a plurality of battery cells 120. The battery modules 115 may be disposed within the housing 205 of the battery pack 110. For example, the battery modules 115 may include battery cells 120 that are cylindrical cells or prismatic cells. The battery modules 115 may operate as modular units of the battery cells 120. For example, the battery modules 115 may collect current or power from the battery cells 120 included in the battery modules 115, and may provide current or power as an output of the battery pack 110. The battery pack 110 may include any number of battery modules 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 modules 115 disposed in the housing 205. It should also be noted that each battery module 115 may include a top submodule 300 and a bottom submodule 305, and may have a thermal component 210 between the top submodule 300 and the bottom submodule 305. The battery pack 110 may include or define a plurality of areas for positioning the battery modules 115 and / or the battery cells 120. The battery modules 115 may be square, rectangular, circular, triangular, symmetrical, or asymmetrical. In some examples, the battery modules 115 may be of different shapes, such that some battery modules 115 are rectangular, while other battery modules 115 are square, as well as other possibilities. The battery module 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 submodules 300 and 305. The battery cells 120 may be arranged in the battery pack 110 in a battery cell-battery pack configuration without the submodules 300 and 305, as well as other possibilities.

[0034] like Figure 4 and Figure 5 As depicted, the battery pack 110 may include a busbar assembly 400, etc. The busbar assembly 400 may include at least one busbar 405 (e.g., a conductive member 405). The busbar 405 may be a conductive member capable of conducting electricity. For example, the busbar 405 may be coupled to the battery cells 120 of the battery pack 110. The battery pack 110 may include submodules 300 and submodules 305 housed in a battery carrier 430 (e.g., a shipping box 430, a battery shipping box 430, a battery module shipping box 430). The battery pack 110 may include a busbar 405 coupled to each of the submodules 300 or the submodules 305. The battery pack 110 may include at least one busbar 405 electrically coupled to the first submodule 300 and a second busbar 405 electrically coupled to the second submodule 305. For example, as Figure 4As depicted, the battery pack 110 may include a first bus bar 405 coupled to the submodule 300 (eg, the first module) and a second bus bar 405 coupled to the submodule 305 (eg, the second module). Figure 5 As depicted, battery pack 110 may include a single bus bar 405 or the like that is electrically coupled to both submodule 300 and submodule 305 .

[0035] The busbar 405 may be electrically coupled to the battery cell 120 of the submodule 300 or the battery cell of the submodule 305. For example, the busbar 405 may be electrically coupled to the current collector 465. The current collector 465 may be coupled to the battery cell 120 (e.g., a plurality of battery cells 120) of the submodule 300 or the submodule 305. For example, the current collector 465 may include a conductive material to electrically couple each of the battery cells 120 within the submodule 300 or the submodule 305. The busbar 405 may be electrically coupled to the current collector 465 so that the busbar 405 may be electrically coupled to one or more battery cells (e.g., all battery cells 120) of the battery cell 120 of the submodule 300 or the submodule 305. The busbar 405 may thus conduct the power provided by the battery cell 120 of the battery pack 110. The battery pack 110 may include a plurality of busbars 405 having different polarities. For example, one busbar 405 may have a positive polarity and may be coupled to the positive terminal of the battery cell 120. The bus bar 405 may include a negative polarity and may be coupled to a negative terminal of the battery cell 120. For example, the bus bar 405 (eg, Figure 5 The busbar 405 depicted in FIG. 1 may electrically couple the submodules 300 or submodules 305 in series to facilitate electrical coupling of the positive terminals of the battery cells 120 of one module with the negative terminals of the battery cells 120 of another module. Unless otherwise noted, it should be understood that the features of the busbar 405 discussed below apply to busbars 405 having positive polarity, negative polarity, or some other polarity.

[0036] The battery pack 110 may include a bus bar 405 coupled to a battery carrier 430. For example, the bus bar 405 may be mechanically coupled to the battery carrier 430. The bus bar 405 may be mechanically coupled to the battery carrier 430, wherein the bus bar 405 is also electrically coupled to the current collector 465. Figure 4 and Figure 5As depicted, the busbar assembly 400 may include a busbar 405 and a member 440 (e.g., an overmolded member 440), each of which may include one or more features to facilitate positioning and coupling of the busbar 405 relative to the battery carrier 430. For example, the busbar 405 may include at least a first opening. The first opening may be a reference locator opening, such as a first reference locator opening 410 or a second reference locator opening 415. For example, the busbar 405 may include a reference locator opening 410 and a reference locator opening 415. The reference locator opening 410 and the reference locator opening 415 may be openings (e.g., holes, orifices) defined by the busbar 405. The reference locator opening 410 and the reference locator opening 415 may be configured to receive at least one reference locator to position the busbar 405 relative to the battery carrier 430.

[0037] For example, the battery carrier 430 may include a first member. The first member may include a first reference locator 425 or a second reference locator 427. For example, the battery carrier 430 may include at least one first reference locator 425 and at least one second reference locator 427. The first reference locator 425 may engage with (e.g., be received in) the first reference locator opening 410. The second reference locator 427 may engage with (e.g., be received in) the second reference locator opening 415. For example, the first reference locator 425 may be a two-way reference locator that may positionally constrain the busbar 405 in two directions (e.g., left and right), wherein the first reference locator 425 engages with the first reference locator opening 410 of the busbar 405. The second reference locator 427 may be a four-way reference locator that may positionally constrain the busbar 405 in four directions (e.g., left, right, up, and down), wherein the second reference locator 427 engages with (e.g., be received in) the second reference locator opening 415 of the busbar 405. For example, bus bar 405 may be aligned or at least partially aligned with battery carrier 430, wherein first reference locator 425 engages first reference locator opening 410, and wherein second reference locator 427 engages second reference locator opening 415. Bus bar 405 may be aligned with battery carrier 430, wherein bus bar 405 is positioned such that bus bar 405 is aligned with battery carrier 430 once it is coupled (such as, for example, as described below with reference to FIG. 1 ). Figures 4 to 6 The busbar 405 may be aligned with the battery carrier 430, wherein a portion (e.g., one side, one edge) of the busbar 405 is at or within a position (e.g., within two inches in any direction) where the busbar 405 will reside once coupled to the battery carrier 430. The busbar 405 may be aligned with the battery carrier 430, wherein the busbar 405 is positioned to couple with the current collector 465, as described below with reference to Fig. 9and Fig.10 For example, the position of the busbar 405 on the battery carrier 430 can be a position where the busbar 405 can be coupled to the battery carrier 430 or electrically coupled to the current collector 465. For example, the busbar 405 can be electrically coupled to the current collector 465, wherein the busbar 405 is at least partially aligned with the battery carrier 430 via engagement of the first reference locator 425 within the first reference locator opening 410 and via engagement between the second reference locator 427 and the second reference locator opening 415.

[0038] The busbar 405 may include at least one second opening 420. For example, the second opening 420 may be a heat stake opening 420 that may receive a heat stake to couple the busbar 405 to the battery carrier 430. For example, the opening 420 may be an opening (e.g., a hole, an orifice) defined by the busbar 405. The opening 420 may engage with (e.g., receive) a protrusion 435 of the battery carrier 430. For example, the battery carrier 430 may include at least one protrusion 435 extending therefrom. The protrusion 435 may be a stake 435 (e.g., a heat stake 435). The protrusion 435 may expand when heated or otherwise exposed to heat. For example, the protrusion 435 may be configured to deform on the opening 420 of the busbar 405 when heated to couple the busbar 405 against the battery carrier 430. When the protrusion 435 is heated (e.g., exposed to heat by a heat gun or some other heat staking device), the protrusion may increase in diameter along at least a portion of the length of the protrusion. The initial diameter of the protrusion 435 can be selected so that the protrusion 435 can be received in the opening 420 of the bus bar 405. For example, the protrusion 435 (or more generally, the battery carrier 430) can be or include a polymer or composite material that can melt, deform, expand, or otherwise change its form when heated.

[0039] like Figure 6 As depicted, after protrusion 435 is exposed to heat (e.g., during a heat staking operation), protrusion 435 can have end portion 605. For example, end portion 605 of protrusion 435 can include diameter 610 after exposure to heat (e.g., a heat staking operation), which can be larger than the diameter of opening 420 of busbar 405. Diameter 610 can be larger than the diameter of opening 420 such that end portion 605 of protrusion 435 cannot pass through opening 420. For example, because protrusion 435 has not expanded prior to the heat staking operation, as shown in FIG. Figures 4 to 5etc., so the protrusion 435 can pass through the opening 420 before the heat staking operation. Then, with the protrusion 435 at least partially extending through the opening 420, heat can be applied to the protrusion 435 to deform (e.g., melt, deform, shape) the protrusion 435, thereby producing an end portion 605 having a diameter 610. The end portion 605 can be or include a disk member or a pie-shaped member that can have a diameter 610. Because the diameter 610 can be greater than the diameter of the opening 420, the end portion 605 of the protrusion 435 can prevent the bus bar 405 from being separated from the battery carrier 430. For example, the bus bar 405 can be coupled to the battery carrier 430, wherein the protrusion 435 of the shipping box extends through the opening 420 of the bus bar 405, and wherein the protrusion 435 is heat-staking (e.g., to produce the end portion 605 having a diameter 610).

[0040] The bus bar 405 may include a plurality of openings 420, and each opening 420 may receive a protrusion 435 of a battery carrier 430. Each protrusion 435 may expand when exposed to heat (e.g., a heat staking operation) such that the protrusion 435 forms an end portion 605 having a diameter 610. Each of the end portions 605 may couple the bus bar 405 against the battery carrier 430. For example, the bus bar 405 may be rigidly coupled against the battery carrier 430, wherein the protrusion 435 of the battery carrier 430 extends through the openings 420 of the bus bar 405 and is heat staking to create the end portions 605. By using at least one protrusion 435 engaged with at least one opening 420, the bus bar 405 may be coupled to the battery carrier 430 without requiring an adhesive between the bus bar 405 and the battery carrier 430 to couple the bus bar 405 to the battery carrier 430. For example, the bus bar 405 may be coupled with the battery carrier 430 without any adhesive positioned between the bus bar 405 and the battery carrier 430 .

[0041] like Figures 4 to 6As depicted, the busbar assembly 400 may include an overmolded component 440, among other things. The overmolded component 440 may be a polymer layer (e.g., a plastic layer) that may be coupled to at least one side of the busbar 405. For example, the overmolded component 440 may be a polymer component that may be molded (e.g., injection molded, compression molded, or otherwise molded) onto the busbar 405 such that the overmolded component 440 may be coupled to the busbar 405. The overmolded component 440 may generally conform to the form factor or shape of the busbar 405. The overmolded component 440 may have a certain shape or form factor that is different from the shape or form factor of the busbar 405. The overmolded component 440 may include at least one retaining arm 445 (e.g., a locating arm 445), at least one overmolded opening 450 (e.g., a heat stake opening 450), and at least one reference opening 480. The retaining arm 445 of the overmolded component 440 may engage with an opening 455 (e.g., a retaining arm opening 455) of the battery carrier 430. For example, the battery carrier 430 may define at least one opening 455. The opening 455 may be an opening (a hole, a channel, an orifice, a recess, a depression, a pit, or other feature) formed in the battery carrier 430. For example, the opening 455 may be a depression in the battery carrier 430 that may receive at least one retaining arm 445 of the overmolded component 440, as described below with reference to Figures 11 to 13 The reference opening 480 can correspond to (eg, be at least partially aligned with, at least partially concentric with) the first reference locator opening 410 or the second reference locator opening 415 of the busbar 405 .

[0042] The overmolded opening 450 can be an opening (e.g., an orifice, a hole, or some other opening) defined by the overmolded member 440. The overmolded opening 450 can be at least partially aligned with the opening 420 of the busbar 405. For example, the overmolded opening 450 can be coaxial with the opening 420 of the busbar 405. The overmolded opening 450 can include a diameter that is larger than the diameter of the opening 420. For example, the overmolded opening 450 can include a diameter that is two, three, four, or some other multiple larger than the diameter of the opening 420. At least a portion of the busbar 405 can be visible through the overmolded opening 450. For example, as shown in FIG. Figure 6As depicted, because the overmolding opening 450 may include a larger diameter than the diameter of the opening 420 of the busbar 405, a portion of the busbar 405 may be visible between an edge of the overmolding opening 450 and an edge of the opening 420 of the busbar 405. The overmolded member 440 may include an overmolding opening 450 having a diameter that is larger than a diameter 610 of an end portion 605 of the protrusion 435 after exposure to heat (e.g., a heat staking operation). For example, the protrusion 435 of the battery carrier 430 may extend at least partially through the opening 420 of the busbar 405 and at least partially through the overmolding opening 450. As described above, when exposed to heat (e.g., during a heat staking operation), the protrusion 435 may expand (e.g., deform, melt, change shape) such that the end portion 605 of the protrusion 435 may be formed. The end portion 605 of the protrusion 435 may include a diameter 610 that is larger than the diameter of the opening 420 to couple the bus bar 405 with the battery carrier 430. The end portion 605 may include a diameter 610 that is smaller than the diameter of the overmolded opening 450 so that the end portion 605 may be positioned against the bus bar 405 and within the overmolded opening 450. For example, the end portion 605 may be flush with the outer surface of the overmolded component 440 or recessed relative to the overmolded component 440. The end portion 605 may extend beyond the outer surface of the overmolded component 440.

[0043] like Figures 6 to 8 As depicted, the busbar assembly 400 may include a busbar 405 coupled to a terminal block 600. The terminal block 600 may be a conductive block extending from the busbar 405 (e.g., extending vertically from the busbar). For example, the terminal block 600 may be a metal component capable of conducting electricity so as to be electrically coupled to the busbar 405. The terminal block 600 may be a separate component capable of being coupled to the busbar 405. For example, the terminal block 600 may be welded to the busbar 405 (e.g., laser welded or welded via some other operation). The terminal block 600 may be a separate component coupled to the busbar 405, rather than being stamped or otherwise created to be integrally integrated with the busbar 405. The terminal block 600 may be electrically coupled to another object (e.g., another busbar, another busbar coupled to another module, or some other component). For example, the terminal block 600 may be electrically coupled to another battery module (e.g., a submodule 300 or a submodule 305) directly or indirectly. Thus, the terminal block 600 can facilitate the electrical connection of the busbar 405 to another component, such as another module (e.g., a submodule 300 or a submodule 305, or another busbar 405 coupled to another module). The terminal block 600 may include a surface 705 to facilitate the electrical connection of the terminal block 600 to some other object. The terminal block 600 may include at least one coupling feature 800. For example, Figure 8As depicted, the terminal block 600 may include a coupling feature 800 or the like as an opening (e.g., a hole, an aperture, a threaded opening, or some other opening) that may facilitate mechanical coupling (e.g., fastening) of the terminal block 600 to another object. The coupling feature 800 may be an opening formed completely through or partially through the terminal block 600.

[0044] like Figure 7 and Figure 8 As depicted, the terminal block 600 may be coupled to the busbar 405 at an interface 700. For example, the interface 700 may be an interface between a side of the terminal block 600 and an outer surface 725 of the busbar 405. The terminal block 600 and the busbar 405 may be electrically coupled via contact between the terminal block 600 and the busbar 405 at the interface 700. For example, the terminal block 600 may be welded (e.g., laser welded) to the busbar 405 to electrically couple the terminal block 600 to the busbar 405. For example, the terminal block 600 may be coupled at the interface 700 via a joint 715. The joint 715 may be a portion of the busbar 405 that is coupled to the terminal block 600 to mechanically couple the busbar 405 to the terminal block 600. The joint 715 may be an area of ​​the busbar 405 adjacent to the interface 700. For example, the joint 715 may be a welded joint 715. The welded joint 715 may be formed on or within an area of ​​the busbar 405 adjacent to the interface 700. For example, the weld joint 715 may include a portion of the busbar 405 and a portion of the terminal block 600 at the interface 700, which may be melted, fused, or otherwise combined. The busbar 405 may be coupled to the terminal block 600 via a welding operation to produce the weld joint 715. For example, the terminal block 600 may be laser welded to the busbar 405 to electrically and mechanically couple the terminal block 600 to the busbar 405. The laser welding device may emit (e.g., guide, emit, provide) a laser beam toward an area adjacent to the busbar 405 and the interface 700. For example, the laser welding device may emit a laser beam toward a surface 710 (e.g., an inner surface 710) of the busbar 405, wherein the laser beam may penetrate the terminal block 600 via the busbar 405 to produce the weld joint 715.

[0045] The terminal block 600 may include a terminal block material thickness 730 that may be greater than a material thickness 735 of the busbar 405. For example, because the terminal block 600 may be a separate component from the busbar 405, the busbar 405 and the terminal block 600 may be or include separate materials with separate thicknesses or specifications. For example, the terminal block 600 may include a terminal block material thickness 730 that may be greater (e.g., twice, three times, or some other multiple) than the material thickness 735 of the busbar 405. When the terminal block 600 or the busbar 405 is conducting, the greater terminal block material thickness 730 may provide improved thermal properties of the terminal block 600 or the busbar 405.

[0046] The greater terminal block material thickness 730 provides a larger weld joint 715 between the terminal block 600 and the bus bar 405. For example, the terminal block 600 may be coupled to the outer surface 725 of the bus bar 405 at the interface 700. Because the terminal block 600 includes a terminal block material thickness 730 that may be greater than the material thickness 735 of the bus bar 405, the weld joint 715 that joins the bus bar 405 to the terminal block 600 may also be larger. The increased thickness of the weld joint 715 may provide improved mechanical integrity to the weld joint 715. The increased thickness of the weld joint 715 may provide improved thermal characteristics when the bus bar 405 is electrically coupled to the terminal block 600.

[0047] Terminal block 600 may include electroplating or may not include electroplating. Busbar 405 may include electroplating. For example, because busbar 405 and the terminal block may be independent components, the electroplating of terminal block 600 does not need to be the same as the electroplating of busbar 405. For example, busbar 405 may be subjected to electroplating operation to realize the first electroplating. The first electroplating may be aluminum electroplating, copper electroplating, nickel electroplating or some other electroplating. Busbar 405 may remain electroless (e.g., without any electroplating). For example, busbar 405 may not be subjected to any electroplating operation, so that busbar 405 is electroless. Busbar 405 may not include electroplating, so that busbar 405 is at least partially electroless. Terminal block 600 may be subjected to electroplating operation separated from the electroplating operation of busbar 405. For example, terminal block 600 may be subjected to electroplating operation to realize a second electroplating different from the first electroplating. The second electroplating layer may be a nickel electroplating layer, such as an electroless nickel electroplating layer or some other electroplating layer. The terminal block 600 may remain electroless. Because the terminal block 600 may include an electroplating layer (or an absence of an electroplating layer) that is different from the electroplating layer (or an absence of an electroplating layer) of the busbar 405, the electroplating layer of each of the terminal block 600 and the busbar 405 may be independently selected to optimize various parameters, such as conductivity, solder adhesion, thermal properties, or some other parameter.

[0048] The terminal block 600 can be coupled to the busbar 405 so as to form a corner 720. For example, the terminal block 600 and the busbar 405 can define a corner 720, wherein the corner 720 can be a sharp angle. The corner can be a 90° angle or a corner with some other angle (e.g., 80°, 70°, 60°, or some other angle). Because the busbar 405 and the terminal block 600 can be independent components, the terminal block 600 can be coupled to the busbar 405 at the interface 700. For example, one side of the terminal block 600 can abut against a surface 725 of the busbar 405 to produce an interface 700, wherein the abutment of the terminal block 600 and the busbar 405 forms a corner 720.

[0049] like Fig. 9 and Fig.10As depicted, the busbar 405 may be coupled to the current collector 465, etc. For example, the busbar 405 may be electrically coupled to the current collector 465. The current collector 465 may include a tab 920. The tab 920 may be a conductive member or portion of the current collector 465 that may extend over an edge 910 of the busbar 405. For example, and as described above, the busbar 405 may be coupled to the battery carrier 430. The busbar 405 may be specifically coupled to one side of the battery carrier 430 such that the edge 910 of the busbar 405 is positioned at or near (e.g., within one centimeter) the upper or lower plane of the battery carrier 430. The current collector 465 may be positioned at the top or bottom of the battery carrier 430 to electrically couple with each of the battery cells 120 within the submodule 300 or submodule 305 or within the battery carrier 430 (e.g., a shipping box, a battery shipping box, a battery module shipping box). For example, the current collector 465 may be positioned on or within an upper or lower plane of the battery carrier 430, wherein the busbar 405 is positioned on one side of the battery carrier 430, wherein the edge 910 of the busbar 405 is positioned at or near the same upper or lower plane of the battery carrier 430. The current collector 465 may include a tab 920 extending from the current collector 465 by a length 1000. For example, the tab 920 may extend from the edge 1010 of the current collector by a length 1000. The tab 920 may have a width 1005. The tab 920 may include a first portion 900 and a second portion 905. The first portion 900 may be a proximal portion of the tab 920 positioned near (e.g., at or within one inch of) the edge 1010 of the current collector 465. The second portion 905 may be a distal portion of the tab 920. For example, the second portion 905 may be the outermost portion of the tab 920. The length 1000 of the tab 920 and the width 1005 of the tab 920 may be dimensionally optimized to maximize the surface area of ​​the tab 920 that may be used to electrically couple the tab 920 to the bus bar 405 .

[0050] The tab 920 may extend from the current collector 465 by a length 1000 such that the tab 920 may contact the edge 910 of the bus bar 405. The edge 910 of the bus bar 405 may be an exposed portion of the bus bar 405 that may be electrically coupled to the tab 920 of the current collector 465. For example, the edge 910 of the bus bar 405 may be a portion of the bus bar 405 that is not overmolded with the overmolded component 440. Because the edge 910 is not overmolded with the overmolded component 440, the edge 910 may facilitate electrical coupling between the bus bar 405 and the tab 920 of the current collector 465. For example, the tab 920 may extend from the edge 1010 of the current collector 465 and extend over at least a portion of the edge 910 of the bus bar 405. The tab 920 may extend over (e.g., beyond) the edge 910 of the bus bar 405. The current collector 465 may be electrically coupled to the bus bar 405 via contact between the tab 920 and the edge 910 of the bus bar 405. For example, the current collector 465 may be electrically coupled to the bus bar 405 via contact between the first portion 900 of the tab 920 and the edge 910 of the bus bar 910. The first portion 900 of the tab 920 may be welded (e.g., laser welded) to the edge 910 of the bus bar 405 to electrically couple the bus bar 405 to the tab 920. For example, a laser welding device or some other laser emitting element may emit (e.g., direct, shoot, aim) a laser beam onto the first portion 900 in a direction 915 (e.g., a downward direction), wherein the first portion 900 is positioned on the edge 910 of the bus bar 405. The laser welding device may, for example, emit a laser beam in a direction 915 such that at least a portion of the tab 920 (e.g., the first portion 900) and at least a portion of the bus bar 405 (e.g., the edge 910) melt, fuse, or otherwise combine. For example, the laser welding device may emit a laser beam along direction 915 to generate a weld joint between the tab 920 and the bus bar 405, thereby electrically connecting the tab 920 to the bus bar 405. Fig. 9 and Fig.10 As depicted, current collector 465 may include a plurality of tabs 920, etc., each of which may be coupled to edge 910 of bus bar 405 (e.g., by a laser welding operation) to electrically couple current collector 465 to bus bar 405. Tabs 920 may be coupled to edge 910 of bus bar 405 via some other operation (e.g., such as ultrasonic welding, friction welding, a conductive adhesive, or some other bonding operation).

[0051] The current collector 465 may include a tab 920 to be folded over the edge 910 of the bus bar 405. For example, the current collector 465 may include a tab 920 extending a length 1000 so that the tab 920 extends beyond the edge 910 of the bus bar 405. The tab 920 may extend beyond the edge 910 of the bus bar 405 so that the tab 920 may extend a length 930 along a face 935 of the bus bar 405. For example, a second portion 905 of the tab 920 may be folded over the edge 910 and along the face 935 of the bus bar 405. The face 935 of the bus bar 405 may be an exposed portion of the outer surface 725 of the bus bar 405 (e.g., not overmolded with the overmolded component 440). For example, the face 935 of the bus bar 405 may be an exposed conductive portion of the bus bar 405. The face 935 may include a height 925. The height 925 may be the distance from the overmolded component 440 to the edge 910 of the bus bar 405. For example, the height 925 can be the height of the busbar 405 that is not overmolded with the overmolded component 440. The tab 920 (e.g., the second portion 905 of the tab 920) can extend a length 930 along a face 935 of the busbar 405, wherein the tab 920 is folded over an edge 910 of the busbar 405. For example, the tab 920 can extend a length 930 along the face 935 of the busbar, wherein the length 930 is at least 50% of the height 925 of the face 935. The tab 920 can be folded over the edge 910 and extend a length 930 along the face 935, wherein the tab 920 is electrically coupled to the edge 910 of the busbar. The second portion 905 of the tab 920 can be electrically coupled to the face 935 of the busbar 405. For example, the second portion 905 can be welded or otherwise bonded to the face 935. Second portion 905 may be folded over edge 910 and along face 935 without being mechanically or electrically coupled to face 935. For example, second portion 905 may be folded over edge 910 or capable of being folded over edge 910 but may remain uncoupled from face 935. The length 930 that tab 920 extends along face 935 may be the length 930 that tab 920 would extend along face 935 if tab 920 (e.g., second portion 905) were positioned against (e.g., abutting) face 935.

[0052] The current collector 465 may include a tab edge 940 positioned a distance 945 from the side 950 of the busbar 405. For example, the current collector 465 may include an outermost tab 920. The outermost tab 920 may be the tab 920 (among the various tabs 920 of the current collector 465) positioned closest to the side 950 of the busbar 405. The outermost tab 920 may include a tab edge 940 positioned parallel or at least partially parallel to the side 950 of the busbar 405. For example, the side 950 of the busbar 405 may be a surface of the busbar 405 positioned perpendicular or at least partially perpendicular to the face 935 of the busbar 405. The tab edge 940 of the outermost tab 920 may be positioned at a distance 945 from the side 950 of the busbar 405, wherein the distance 945 may be less than 1 centimeter, less than 8 millimeters, 7.4 millimeters, or some other distance. For example, distance 945 can be a relatively small distance (e.g., less than thirty millimeters) because tab 920 can include a width 1005 that is sufficient to cover a substantial portion (e.g., greater than 80%) of the surface area of ​​edge 910 of busbar 405. Distance 945 can be 7.4 millimeters, less than 7.4 millimeters, or greater than 7.4 millimeters.

[0053] like Figures 11 to 13 As depicted, the overmolded member 440 may include a retaining arm 445 (e.g., a positioning arm 445) to engage with the battery carrier 430 to couple the bus bar 405 with the battery carrier 430. For example, the bus bar 405 may be coupled with the overmolded member 440, and the retaining arm 445 of the overmolded member 440 may engage with the battery carrier 430 to couple the bus bar 405 and the overmolded member 440 to the battery carrier 430. The retaining arm 445 may include a tip 1100 (e.g., an end 1100, a distal end 1100) that may be inserted into the opening 455 of the battery carrier 430. For example, the retaining arm 445 may extend from the overmolded member 440 toward the battery carrier 430, wherein the bus bar 405 is positioned between the overmolded member 440 and the battery carrier 430. The retaining arm 445 may extend around the bus bar 405 (e.g., around the outside thereof). The retaining arm 445 can extend through the opening 1105 (eg, the retaining arm opening 1105) of the busbar 405. For example, Fig.12As depicted, the retaining arm 445 may include a tip 1100 that extends through the opening 1105 of the busbar 405 before ultimately engaging the opening 455 of the battery carrier 430. The retaining arm 445 may include a first portion 1200 (e.g., a proximal end 1200). The first portion 1200 may extend from the overmolded member 440 in a direction opposite or different from the direction in which the tip 1100 extends. For example, the first portion 1200 may extend from the overmolded member 440 away from the battery carrier 430 or away from the busbar 405, wherein the busbar 405 is positioned between the overmolded member 440 and the battery carrier 430. The first portion 1200 may be an annular or curved portion of the retaining arm 445 that extends from the outer surface of the overmolded member 440.

[0054] The retaining arm 445 may include a retaining portion 1110. The retaining portion 1110 may be a protrusion, sharp edge, raised edge, or other feature extending from the retaining arm 445 that is close to (e.g., within one inch, within one centimeter, or some other length) the tip 1100. The retaining portion 1110 may be tapered. For example, the retaining portion 1110 may taper toward the tip 1100 of the retaining arm 445. The retaining portion 1110 may extend from the retaining arm 445 to engage with a wall 1400 of the battery carrier 430. For example, the wall 1400 may be a wall that at least partially defines the opening 455 of the battery carrier 430. As shown in FIG. Fig.13 As depicted, a retaining portion 1110 may extend from the retaining arm 445 to engage with the rear surface 1305 of the wall 1300. The engagement (e.g., contact) between the retaining portion 1110 and the wall 1300 may at least partially prevent the retaining arm 445 from being removed from or disengaged from the opening 455 of the battery carrier 430. For example, the engagement between the retaining portion and the wall 1300 may at least partially prevent the overmolded component 440 from being separated from the battery carrier 430. The retaining portion 1110 of the retaining arm 445 of the overmolded component 440 may engage with the opening 455 of the battery carrier 430, wherein the bus bar 405 is at least partially positioned between the overmolded component 440 and the battery carrier 430. For example, the retaining portion 1110 of the retaining arm 445 of the overmolded component 440 may engage with the opening 455 of the battery carrier 430 to retain the bus bar 405 and the overmolded component 440 to (e.g., against) the battery carrier 430.

[0055] The retaining arm 445 can be flexible or can include at least a certain amount of elasticity. For example, the retaining arm 445 can be or include a polymer material (e.g., a polymer material used to mold the entire overmolded member 440). The retaining arm 445 can be slightly bent to facilitate the engagement or disengagement of the retaining arm 445 with the opening 455 of the battery carrier 430. For example, the retaining arm 445 can be bent or flexed to allow the retaining arm 445 to pass into or out of the opening 455 in a substantially uninhibited (e.g., at least 50% uninhibited) or substantially unhindered (e.g., at least 50% unhindered) manner through the engagement between the retaining portion 1110 and the wall 1400 of the opening 455. The retaining arm 445 can flex when the tip 1100 is inserted into the opening 455. Once the retaining portion 1110 moves past the wall 1400, the retaining member can spring outward (e.g., in a direction toward the wall 1400). The retaining arm 445 may be recessed or flexed inwardly (e.g., away from the wall 1400) to disengage the retaining portion 1110 from the wall 1400, thereby allowing the retaining portion 1110 and the tip 1100 to pass through the opening 455. For example, the retaining arm 445 may be flexed to disengage the retaining arm 445 from the opening 455 of the battery carrier 430.

[0056] The retaining arms 445 can removably couple the busbar 405 and the overmolded component 440 with the battery carrier 430. For example, the retaining arms 445 can engage the openings 455 of the battery carrier 430 to position the busbar 405 and the overmolded component 440 relative to the battery carrier 430. The protrusions 435 of the battery carrier 430 can be subjected to a heat staking operation (e.g., subjected to localized heat) to form end portions 605 on the protrusions 435, thereby rigidly coupling the busbar 405 and the overmolded component 440 with the battery carrier 430. For example, the retaining arms 445 can engage the openings 455 of the battery carrier 430 while the first reference locator 425 engages the first reference locator opening 410 and while the second reference locator 427 engages the second reference locator opening 415 to removably (e.g., temporarily) position the busbar 405 and the overmolded component 440 against the battery carrier 430. The protrusion 435 of the battery carrier 430 can be subjected to a heat staking operation (e.g., subjected to localized heat) to form an end portion 605 on the protrusion 435, thereby rigidly coupling the bus bar 405 and the overmolded component 440 with the battery carrier 430, wherein the retaining arm 445 engages with the opening 455 of the battery carrier 430, the first datum locator 425 engages with the first datum locator opening 410, and the second datum locator 427 engages with the second datum locator opening 415. The retaining arm 445 (e.g., the positioning arm 445) can facilitate the proper positioning of the overmolded component 440 and the bus bar 405 against the battery carrier 430. For example, the engagement of the retaining arm 445 with the opening 455 of the battery carrier 430 can at least partially align the bus bar 405 and the overmolded component 440 against the battery carrier 430 even without the presence of the first datum locator 425 or the second datum locator 427. At least partially aligning the busbar 405 and the overmolded component 440 with the battery carrier 430 may include, for example, aligning an edge 910 of the busbar 405 with a tab 920 of the current collector 465. At least partially aligning the busbar 405 and the overmolded component 440 with the battery carrier 430 may include aligning a protrusion 435 of the battery carrier 430 with an opening 420 of the busbar 405 to facilitate heat staking or coupling the busbar 405 with the battery carrier 430.

[0057] like Figure 4 as depicted, and as Fig.14 and Fig.15 As shown in detail, the busbar assembly 400 may include a retaining fixture 460. The retaining fixture 460 may be integrally formed with the overmolded component 440. For example, the retaining fixture 460 may be a part of the overmolded component 440 or molded integrally with the overmolded component. The retaining fixture 460 may be a separate component coupled to the overmolded component 440. The retaining fixture may retain a cable 475, such as a ribbon cable 475. The cable 475 may include a connector 470. The connector 470 may facilitate connection of the cable 475 to another object, such as a Fig.14470)). For example, cable 475 may be a cable associated with a voltage monitor, such as a voltage sensing harness (VSH) that may monitor the voltage of a submodule 300 or a submodule 305. For example, the VSH may be coupled to a current collector 465 and may include at least one voltage sensor to measure the voltage of the current collector 465, wherein the current collector 465 is coupled to the battery cell 120. BVT 1410 may be a monitor, a module, a controller, or other device. BVT 1410 may be coupled to a battery carrier 430, a busbar assembly 400, or some other component of the battery pack 110. For example, BVT 1410 may monitor the voltage of a submodule 300, a submodule 305, or both a submodule 300 and a submodule 305 via a VSH coupled to an associated current collector 465. BVT 1410 may monitor the voltage based on data or information provided by the VSH via cable 475 and connector 470.

[0058] like Fig.15 As depicted, the overmolded member 440 may include a retaining fixture 460 to retain the cable 475 against the overmolded member 440. For example, the retaining fixture 460 may include a first end 1500 and a second end 1505. The first end 1500 may be a free end 1500 that may be disconnected from the overmolded member 440 or may be selectively engageable with the overmolded member 440. For example, the first end 1500 may contact the overmolded member 440 via a spring force of the retaining fixture 460 (e.g., a biasing force that retains the first end 1500 against the overmolded member 440). The first end 1500 may be selectively detachable from the overmolded member 440 to allow an object (such as the cable 475) to pass between the first end 1500 and the overmolded member 440. The first end 1500 may be fixed against the overmolded member 440. For example, the first end 1500 may be fastened, clamped, or otherwise coupled to the overmolded member 440. The first end 1500 may then be unclamped, unclamped, or released from the overmolded member 440 to allow an object, such as a cable 475, to pass between the first end 1500 and the overmolded member 440. The second end 1505 of the retaining fixture 1505 may be coupled to the overmolded member 440. For example, the second end 1505 may be integrally molded with the overmolded member 440. The second end 1505 may be rigidly coupled to the overmolded member 440. The second end 1505 may be pivotally coupled to the overmolded member 440 such that the retaining fixture 460 may rotate about the second end 1505 to allow an object, such as a cable 475, to pass between the retaining fixture 460 and the overmolded member 440.

[0059] The retaining clamp 460 may retain the cable 475 against the overmolded component 440. For example, the retaining clamp 460 may include a first end 1500 and a second end 1505 of the retaining clamp 460 to apply a force to the cable 475 so that the cable 475 is pressed against the overmolded component 440. The retaining clamp 460 may include a first end 1500 and a second end 1505 of the retaining clamp 460 to prevent the cable 475 from separating from the overmolded component 440. For example, the retaining clamp 460 may include a first end 1500 and a second end 1505 of the retaining clamp 460 to prevent the cable 475 from separating from the overmolded component 440 by more than a certain distance (e.g., one centimeter, one inch).

[0060] BVT 1410 may monitor the temperature of submodule 300, submodule 305, both submodule 300 and submodule 305, or some other component of battery pack 110. For example, Fig.14 As depicted, cable 1405 may be coupled to BVT 1410 to provide data or information regarding temperature measurements to BVT 1410. Cable 1405 may be a thermistor cable 1405. Figure 4 , Fig.14 and Fig.16 As depicted, the busbar assembly 400 may include at least one retaining member 1400 coupled to a mounting feature 485 of the overmolded component 440. The overmolded component 440 may include a mounting feature 485 to which the retaining member 1400 may be coupled. For example, the mounting feature 485 may be a protrusion, a boss, or an elevated surface of the overmolded component 440. The mounting feature 485 may be a groove, a recess, or a recessed surface of the overmolded component 440. The mounting feature 485 may be or include one or more elevated edges. The mounting feature 485 may include at least one opening (e.g., an orifice, a groove, a hole, a threaded hole, or other feature). For example, the mounting feature 485 may include a threaded hole or a threaded post to which the retaining member 1400 may be coupled. The mounting feature 485 may be integrally molded with the overmolded component 440. The mounting feature 485 may be a separate component coupled to the overmolded component 440.

[0061] Retention member 1400 may be a clamp, loop, clasp, or other retention feature capable of retaining cable 1405. For example, overmolded member 440 may be coupled to retention member 1400 such that retention member 1400 may retain cable 1405 against overmolded member 440. Fig.16As depicted, the retaining member 1400 can be a clamp or collar that can define an opening 1600. The cable 1405 can be received in the opening 1600. For example, the cable 1405 can be received in the opening 1600 such that the retaining member 1400 at least partially surrounds the cable 1405. The retaining member 1400 can completely surround the cable 1405, wherein the cable 1405 is positioned within the opening 1600. The cable 1405 can be held against the overmolded member 440, wherein the cable 1405 is within the opening 1600 of the retaining member 1400. For example, the cable 1405 can be prevented or substantially prevented (e.g., at least 95% prevented) from separating from the overmolded member 440 or the busbar assembly 400. The cable 1405 can be passed through the opening 1600 to hold the cable 1405 against the overmolded member 440 so that the cable 1405 is less likely to be stuck, pulled, dragged, or otherwise damaged. The retaining member 1400 may be integrally formed with the overmolded member 440 , or may be a separate component that may be coupled with the overmolded member 440 .

[0062] like Figures 17 to 19 As depicted, the battery cell 120 may have a variety of form factors, shapes, or sizes. For example, the battery cell 120 may have a cylindrical, rectangular, square, cubic, flat, pouch-shaped, elongated, or prismatic form factor. Fig.17 As depicted, for example, battery cell 120 may be cylindrical. Fig.18 As depicted, for example, battery cell 120 may be prismatic. Fig.19As 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 1700. 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 1700 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 an electrode to at least some of the electrolyte material may be formed at two points or regions of the battery cell 120, for example to form a first polarity terminal 1705 (e.g., a positive terminal or anode terminal) and a second polarity terminal 1710 (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.

[0063] 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 zIn 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.

[0064] The battery cell 120 may be included in the battery module 115 of the battery pack 110 to power components of the electric vehicle 105. The battery cell housing 1700 may be disposed in the battery module 115, the battery pack 110, or a battery array installed in the electric vehicle 105. The housing 1700 may have any shape, such as a circular shape (e.g., particularly Fig.17 The shape of the housing 1700 may also be a prism with a polygonal base, especially as shown in FIG. Fig.18 In particular, Fig.19 As shown, the housing 1700 may include a pouch-like form factor. The housing 1700 may include other form factors, such as triangles, squares, rectangles, pentagons, and hexagons. In some embodiments, the battery pack may not include a module (e.g., no module). For example, the battery pack may have a module-free or cell-cell configuration, in which the cells are directly arranged in the battery pack without being assembled into a module.

[0065] The housing 1700 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 used for the housing 1700 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 used for the housing 1700 of the battery cell 120 may include ceramic materials (e.g., silicon nitride, silicon carbide, titanium carbide, zirconium dioxide, beryllium oxide, etc.) and thermoplastic materials (e.g., polyethylene, polypropylene, polystyrene, polyvinyl chloride or nylon), etc. In the case where the housing 1700 of the battery cell 120 is prismatic (e.g., especially as Fig.18 as depicted) or cylindrical (e.g., especially as Fig.17In the example depicted in FIG. 17A , the housing 1700 may include a rigid or semi-rigid material such that the housing 1700 is rigid or semi-rigid (e.g., not easily deformed or manipulated into another shape or form factor). In the example depicted in FIG. 17B , the housing 1700 may include a rigid or semi-rigid material such that the housing 1700 is rigid or semi-rigid (e.g., not easily deformed or manipulated into another shape or form factor). Fig.19 In the example depicted), the housing 1700 may include a flexible, stretchable, or non-rigid material such that the housing 1700 can be bent, deformed, manipulated into another form factor or shape.

[0066] The battery cell 120 may include at least one anode layer 1715, which may be disposed within a cavity 1720 defined by the housing 1700. The anode layer 1715 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 1715 may receive current into the battery cell 120 and output electrons. The anode layer 1715 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.

[0067] The battery cell 120 may include at least one cathode layer 1725 (e.g., a composite cathode layer, a compound cathode layer, a compound cathode, a composite cathode, or a cathode). The cathode layer 1725 may include a second redox potential that may be different from the first redox potential of the anode layer 1715. The cathode layer 1725 may be disposed within the cavity 1720. During the discharge of the battery cell 120, the cathode layer 1725 may output current from the battery cell 120 and may receive electrons. During the discharge of the battery cell 120, the cathode layer 1725 may also receive lithium ions. Conversely, during the charging of the battery cell 120, the cathode layer 1725 may receive current into the battery cell 120 and may output electrons. During the charging of the battery cell 120, the cathode layer 1725 may release lithium ions.

[0068] The battery cell 120 may include a layer 1730 disposed within the cavity 1720. The layer 1730 may include a solid electrolyte layer. The layer 1730 may include a separator wetted by a liquid electrolyte. The layer 1730 may include a polymer material. The layer 1730 may include a polymer separator. The layer 1730 may be disposed between the anode layer 1715 and the cathode layer 1725 to separate the anode layer 1715 from the cathode layer 1725. 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 1715. The liquid electrolyte may diffuse into the cathode layer 1725. The layer 1730 may facilitate the transfer of ions (e.g., Li ions) between the anode layer 1715 and the cathode layer 1725. + ions). Layer 1730 may transfer Li + Cations are transferred from anode layer 1715 to cathode layer 1725. Layer 1730 may transfer lithium ions from cathode layer 1725 to anode layer 1715 during a charging operation of battery cell 120.

[0069] The redox potential of a layer (e.g., the first redox potential of anode layer 1715 or the second redox potential of cathode layer 1725) may vary based on the chemistry of the corresponding layer or the chemistry of 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 a cathode layer (e.g., cathode layer 1725). A lithium-ion battery may include graphite chemistry, silicon-graphite chemistry, or lithium metal chemistry for an anode layer (e.g., anode layer 1715).

[0070] 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 (LiMn1.5 Ni 0.5 O4), disordered rock salt, fluorophosphate Li2FePO4F (M = Fe, Co, Ni) and fluorosulfate LiMSO4F (M = Co, Ni, Mn) (e.g., cathode layer 1725). Lithium-ion batteries may include graphite chemistry, silicon-graphite chemistry, or lithium metal chemistry for the anode layer (e.g., anode layer 1715). 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.

[0071] 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 1725) 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 21715) may include conductive carbon materials 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.

[0072] 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.

[0073] 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.

[0074] Layer 1730 may include a liquid electrolyte material or be made of a liquid electrolyte material. For example, layer 1730 may be or may include at least one layer of a polymer material (e.g., polypropylene, polyethylene, or other material) that includes a hole that is wetted by a liquid electrolyte substance (e.g., saturated with a liquid electrolyte substance, soaked with a liquid electrolyte substance, received, filled with a liquid electrolyte substance) 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 1730 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 1730, but the liquid electrolyte can fill the battery cell 120 in many different ways. Layer 1730 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.

[0075] 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.

[0076] In an example where layer 1730 includes a liquid electrolyte material, layer 1730 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 1730 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 1730 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 1730 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.

[0077] Fig. 20 In particular, method 2000 is depicted. For example, method 2000 can be a method of mounting busbar assembly 400 on battery carrier 430. Method 2000 can include one or more of actions 2005 to 2030. Method 2000 can include providing a busbar assembly at action 2005. The busbar assembly can be busbar assembly 400 as described herein. Busbar assembly 400 can include busbar 405 and overmolded component 440. For example, busbar 405 can be a conductive component defining at least one opening 420. Busbar 405 can include at least one first reference locator opening 410 and at least one second reference locator opening 415. Overmolded component 440 can be a polymer component overmolded onto busbar 405. Overmolded component 440 can include at least one retaining arm 445 and at least one opening 450. The opening 450 of overmolded component 440 can correspond to the opening 420 of busbar 405. The overmolded component 440 may include at least one opening 480 (eg, hole, channel, orifice) corresponding to each of the first datum locator openings 410 and each of the second datum locator openings 415 of the busbar 405 .

[0078] The method 2000 may include engaging the locators at act 2010. For example, the method 2000 may include engaging at least one first reference locator 425 and at least one second reference locator 427 of the battery carrier 430 with the first reference locator opening 410 and the second reference locator opening 415 of the bus bar 405, respectively. The battery carrier 430 may include one or more first reference locators 425 that may engage with (e.g., be received therein, be at least partially received therethrough) the first reference locator opening 410 of the bus bar 405. The engagement of the first reference locator 425 of the battery carrier 430 with the first reference locator opening 410 of the bus bar 405 may at least partially align the bus bar 405 with the battery carrier 430. For example, the engagement of the first reference locator 425 of the battery carrier 430 with the first reference locator opening 410 of the bus bar 405 may constrain the movement of the bus bar 405 relative to the battery carrier 430 in at least two directions (e.g., left and right). The battery carrier 430 may include one or more second reference locators 427 that may engage with (e.g., be received therein, at least partially received therethrough) the second reference locator openings 415 of the bus bar 405. The engagement of the second reference locators 427 of the battery carrier 430 with the second reference locator openings 415 of the bus bar 405 may at least partially align the bus bar 405 with the battery carrier 430. For example, the engagement of the second reference locators 427 of the battery carrier 430 with the second reference locator openings 415 of the bus bar 405 may constrain the movement of the bus bar 405 relative to the battery carrier 430 in at least four directions (e.g., left, right, up, and down).

[0079] The method 2000 may include engaging the retaining arms at act 2015. For example, the method 2000 may include engaging the retaining arms 445 of the overmolded component 440 with at least one opening 455 of the battery carrier 430. The opening 455 of the battery carrier 430 may be configured to receive the tip 1100 of the retaining arm 445. For example, the tip 1100 of the retaining arm 445 may be inserted into the opening 455 so that the retaining feature 1110 of the retaining arm 445 may engage with the wall 1300 of the battery carrier 430. The engagement between the retaining arm 445 and the wall 1300 of the battery carrier 430 may couple the overmolded component 440 with the battery carrier 430. For example, the overmolded component 440 may be removably coupled to the battery carrier 430, wherein the retaining arms 445 of the overmolded component 440 engage with the opening 455 of the battery carrier 430. The retaining arms 445 may be coupled to the battery carrier 430 , with the bus bar 405 at least partially positioned between the overmolded component 440 and the battery carrier 430 .

[0080] Method 2000 may include engaging a heat stake at act 2020. For example, method 2000 may include engaging a protrusion 435 (e.g., heat stake 435) of battery carrier 430 with opening 420 of busbar 405. Protrusion 435 may extend outward from battery carrier 430 and may engage (e.g., be received therein) with opening 420 of the busbar. Protrusion 435 may be or include a polymer material such that the protrusion may be configured to expand, deform, or otherwise change shape when heated. Acts 2010 to 2020 may be performed simultaneously or substantially simultaneously. For example, while retaining arm 445 may engage opening 420, first reference locator 425 may be received in first reference locator opening 410, and second reference locator 427 may be received in second reference locator opening 415, which may further occur while protrusion 435 may engage opening 455.

[0081] Method 2000 may include applying heat at action 2025. For example, method 2000 may include applying heat to protrusion 435 of battery carrier 430 at action 2025. Heat may be applied to protrusion 435 at action 2025 to expand, deform, or otherwise change the shape of protrusion 435. For example, heat may be applied to protrusion 435 while protrusion 435 extends through opening 420. Heat may be applied locally to protrusion 435 (e.g., via a heat gun, iron, or some other device, such as during a heat staking operation). Protrusion 435 may expand or be deformed to couple busbar 405 to battery carrier 430. For example, applying heat to protrusion 435 may result in the formation of an end portion 605 of the protrusion, wherein end portion 605 may include diameter 610. Diameter 610 may be greater than the diameter of opening 420. Because the diameter 610 of the end portion 605 may be larger than the diameter of the opening 420 , the end portion 605 may prevent the bus bar 405 from being separated from the battery carrier 430 .

[0082] Method 2000 may include coupling a current collector at action 2030. For example, method 2000 may include coupling current collector 465 to busbar 405. For example, busbar 405 may be positioned against battery carrier 430, and current collector 465 may be positioned on top of or along a bottom surface of submodule 300 or submodule 305. Current collector 465 may include at least one tab 920 extending over edge 910 of busbar 405. For example, tab 920 may extend beyond edge 910 and fold over busbar 405. Tab 920 of current collector 465 may be electrically coupled to busbar 405. Tab 920 of current collector 465 may be mechanically coupled to busbar 405. Tab 920 of current collector 465 may be welded to busbar 405. For example, a laser welding device or some other device may emit (e.g., direct, direct) a laser beam in a direction 915 to weld a first portion 900 of a tab 920 to an edge 910 of a bus bar 405. The bus bar 405 may be electrically coupled to a submodule 300 or a battery cell 120 of the submodule 305 via the electrical coupling of the tab 920 of the current collector 465 to the edge 910 of the bus bar 405.

[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 other implementations or similar roles in the implementation.

[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 description of positive and negative electrical characteristics can be reversed. For example, busbar 405 can be a negative busbar or a positive busbar. An element described as a negative element can be configured as a positive element, while an element described as a positive element can be configured as a negative element. For example, an element described as having a first polarity can have a second polarity, while an element described as having a second polarity can 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 can 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 device, comprising: a conductive member having a first opening and a second opening; The first opening is configured to engage a first member of a battery carrier such that the conductive member is at least partially aligned with the battery carrier; and The second opening is configured to engage a second member of the battery carrier for coupling the conductive member to the battery carrier.

2. The device according to claim 1, comprising: An edge is configured to electrically couple the conductive member to a tab of a current collector, the tab being adapted to be folded over the edge, wherein the conductive member is coupled to the current collector.

3. The device according to claim 1, comprising: An edge configured to electrically couple the conductive member to a tab of a current collector, the tab being configured to be folded over the edge, wherein the conductive member is coupled to the current collector, wherein one side of the conductive member is positioned less than 1 cm from a tab edge of the tab.

4. The device according to claim 1, comprising: The conductive member is coupled to an overmolded member, the overmolded member including a retaining member configured to retain a cable against the overmolded member.

5. The device according to claim 1, comprising: The conductive member is coupled to an overmolded member, the overmolded member including a retaining member configured to retain a cable against the overmolded member and a retaining clamp configured to retain a ribbon cable against the overmolded member.

6. The device according to claim 1, comprising: The second member of the battery carrier includes a heat stake configured to expand when heated to couple the conductive member with the battery carrier.

7. The device according to claim 1, comprising: The second member of the battery carrier includes a heat stake configured to deform over the second opening when heated to couple the conductive member against the battery carrier.

8. The device according to claim 1, comprising: the conductive member being coupled to an overmolded member, the overmolded member including an overmolded opening that is at least partially aligned with the second opening of the conductive member; The second member of the battery carrier includes a heat stake configured to expand within the overmolded opening when heated to couple the conductive member with the battery carrier.

9. The device according to claim 1, comprising: The conductive member is coupled to an overmolded member, the overmolded member including a retaining arm configured to engage with a battery carrier opening of the battery carrier to couple the overmolded member to the battery carrier, the conductive member being at least partially positioned between the overmolded member and the battery carrier, wherein the retaining arm engages with the battery carrier opening.

10. The device according to claim 1, comprising: the conductive member being coupled to an overmolded member, the overmolded member comprising a retaining arm and an overmolded opening, the retaining arm being configured to engage with the battery carrier opening of the battery carrier to couple the overmolded member to the battery carrier, the conductive member being at least partially positioned between the overmolded member and the battery carrier, wherein the retaining arm engages with the battery carrier opening; The second member of the battery carrier includes a heat stake configured to expand within the overmolded opening when heated to couple the conductive member with the carrier.

11. The device according to claim 1, comprising: The conductive member is configured to couple with a terminal block having a terminal block material thickness greater than a material thickness of the conductive member.

12. The device according to claim 1, comprising: The conductive member is configured to be coupled to a terminal block having a terminal block material thickness greater than a material thickness of the conductive member, the terminal block having a plating layer different from a plating layer of the conductive member.

13. The device according to claim 1, comprising: The conductive member is configured to couple with a terminal block having a terminal block material thickness greater than a material thickness of the conductive member, wherein a corner is defined by the conductive member and the terminal block, wherein the conductive member is coupled with the terminal block.

14. The apparatus of claim 1, wherein the conductive member is a bus bar for a battery module, and wherein the battery carrier is a shipping box for the battery module.

15. A system, comprising: Busbar; a battery carrier, the battery carrier comprising a battery carrier opening; and a member including a retaining arm and a member opening, the retaining arm being configured to engage the battery carrier opening to couple the member to the battery carrier; and The member opening is configured to receive a protrusion of the battery carrier, and the protrusion is configured to expand within the member opening to couple the bus bar with the battery carrier.

16. The device according to claim 15, comprising: The battery carrier includes at least one locating member for engaging with at least one locating opening of the bus bar to at least partially align the bus bar and the member with the battery carrier.

17. The device according to claim 15, comprising: The member includes a retaining member configured to retain a cable against the overmolded member and a retaining clamp configured to retain a ribbon cable against the overmolded member.

18. A method comprising: engaging a locator of a battery carrier with a locating opening of a bus bar, the locator being used to at least partially align the bus bar with the battery carrier; The heat stakes of the battery carrier are engaged with the heat stake openings of the busbar, the heat stakes being used to couple the busbar to the battery carrier.

19. The method according to claim 18, comprising: Engaging a retention arm of the overmolded component with a battery carrier opening of the battery carrier to couple the overmolded component with the battery carrier, wherein the bus bar is at least partially positioned between the overmolded component and the battery carrier.

20. The method according to claim 18, comprising: Heat is applied to the heat stake of the battery carrier, the heat stake engaging the opening of the bus bar, the heat stake being adapted to expand when heated to couple the bus bar to the battery carrier.

Images