Busbar available for intermediate battery pack

Abstract

The present solution relates to systems and methods for electrically disconnecting at least a portion of a battery pack using busbars. The solution may include a bus bar electrically coupled with a battery pack between two sets of battery cells of the battery pack. The bus bar may be disposed at an opening of a housing of the battery pack. The bus can be exposed through the access cover. The bus bar may include a jumper connector that electrically couples one body of the bus bar that is electrically coupled with a first set of battery cells of the battery pack and another body of the bus bar that is electrically coupled with a second set of battery cells of the battery pack. The jumper connector is accessible through the opening below the access cover to allow the first or second set of battery cells to be electrically disconnected.

Description

[0001] introduction

[0002] Electric vehicles (EVs) can be powered using batteries that store energy that can be used to power and move the vehicle. Batteries can include different components that facilitate energy storage and distribution. Summary of the invention

[0003] The present solution provides an on-board available busbar that can be used to divide the voltage of a battery pack (e.g., into two halves of approximately 50% of the battery pack voltage), thereby allowing convenient on-board maintenance, maintenance, and repair at a reduced voltage level. The busbar can allow a maintenance technician to disconnect the high voltage within the battery pack from the rest of the vehicle without removing the battery pack from the vehicle. The busbar can also allow one battery pack to be disconnected from the high voltage distribution box of the EV or from another battery pack to allow maintenance of one of the battery packs inside or outside the vehicle, and to allow cross-compatible battery packs to be used in the same vehicle. The busbar may include a first busbar electrically connected to a first portion of the battery pack (e.g., or a first battery pack) and a second busbar connected to a second portion of the battery pack (e.g., or a second battery pack). Each of the first busbar and the second busbar may include a corresponding first jumper and a second jumper, which are bent relative to the body of a corresponding one of the first busbar and the second busbar (e.g., arced downward at an angle of 90%). A connector jumper can be used to electrically connect the first jumper and the second jumper. To disconnect the busbars, the connector jumper can be removed, thereby disconnecting the first jumper and the second jumper and electrically separating the first portion of the battery pack (or the first battery pack) from the second portion of the battery pack (or the second battery pack). A cover made of an electrically insulating material can be used to insulate, shield or cover the connector jumper, the first jumper and the second jumper of the first busbar and the second busbar, and the body.

[0004] At least one aspect relates to a system. The system may include a busbar electrically connected to the battery pack between two groups of battery cells of the battery pack. The busbar may be disposed at an opening of a housing of the battery pack. The busbar may be exposed through an access cover.

[0005] At least one aspect relates to a method for electrically disconnecting at least a portion of a battery pack. The method may include electrically connecting a busbar to two groups of battery cells of the battery pack. The method may include positioning the busbar at an opening of a housing of the battery pack. The method may include exposing the busbar for access through an access cover.

[0006] At least one aspect relates to a battery system for an electric vehicle. The battery system may include a busbar electrically connected to the battery pack between two groups of battery cells in the battery pack. The busbar may be disposed at an opening of a housing of the battery pack. The busbar may be exposed through an inspection cover. The battery system may include a jumper connector electrically connecting a first body of the busbar to a second body of the busbar, the jumper connector being removable via an inspection cover on an end plate of the housing to disconnect a first group of battery cells electrically connected to the first body of the two groups of battery cells and a second group of battery cells electrically connected to the second body of the two groups of battery cells.

[0007] These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of the various aspects and implementations, and provide an overview or framework for understanding the nature and characteristics of the claimed aspects and implementations. The accompanying drawings provide illustration and further understanding of the 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 construed as limiting. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0009] Figure 1 An exemplary electric vehicle is depicted.

[0010] Figure 2A An example of a battery pack is depicted.

[0011] Figure 2B An example of a battery pack having a battery subassembly is depicted.

[0012] Figure 2C A cross-sectional view of a battery cell is depicted.

[0013] Figure 2D A cross-sectional view of a battery cell is depicted.

[0014] Figure 2E A cross-sectional view of a battery cell is depicted.

[0015] Figure 3 An example of a battery system including an access cover for accessing bus bars of a battery pack is shown.

[0016] Figure 4 An example of a battery system having a bus bar for reducing the voltage of a battery pack is shown.

[0017] Figure 5 An example of a cross-sectional view of a bus bar used to step down the voltage of a battery system is shown.

[0018] Figure 6 An example of an access opening for accessing the busbars to reduce the voltage of the battery pack is shown.

[0019] Figure 7 An example of a top view of an access opening and bus bars in a battery pack is shown.

[0020] Figure 8 A flow chart of an exemplary method for electrically disconnecting at least a portion of a battery pack using a bus bar is shown. DETAILED DESCRIPTION

[0021] The following is a more detailed description of various concepts and implementations related to methods, apparatus, and systems for electrically disconnecting at least a portion of a battery pack using a busbar.The various concepts introduced above and discussed in more detail below can be implemented in any of numerous ways.

[0022] The present disclosure generally relates to a system including an on-vehicle serviceable busbar for a battery pack. The busbar can be positioned at an intermediate section, intermediate node, or middle of a battery pack (e.g., a battery pack subassembly) and divides the voltage of the battery pack by approximately 50% (e.g., between two groups of battery cells). For example, from an electrical architecture perspective, the busbar 310 can be deployed and connected to the battery cells 120 of the battery pack 110 so that it provides availability by, for example, halving the voltage of the battery pack 110 at an intermediate battery pack (e.g., providing two halves of the voltage of the battery pack). The busbar allows convenient on-vehicle service, maintenance, and repair of the battery pack and any components connected thereto. For example, the system described herein allows the high voltage within the battery pack to be disconnected from the rest of the vehicle from outside the battery pack while the battery pack remains within the vehicle. Thus, a maintenance technician can repair and replace components within the battery pack and the rest of the vehicle while the battery pack remains within the vehicle. In addition, the battery pack may include two battery packs, one battery pack being available when outside the vehicle and the other battery pack being available when maintained inside the vehicle, the system described herein allows the busbar to be disconnected when both battery packs are inside the vehicle, thereby allowing cross-compatible battery packs to be used in the same vehicle.

[0023] The busbar connects the battery pack (e.g., the battery cells therein) to various components, such as a high voltage distribution box (HVDB), fuses, current sensors, contactors, battery management systems (BMS), battery voltage temperature monitors (BVT), etc. The busbar can be electrically connected to a collector assembly (CCA) busbar, which is connected to the terminals of the battery cells. After the busbar is disconnected in the manner described, such components can be repaired, maintained, inspected, monitored, or evaluated. For example, after the busbar is disconnected, the voltage at the HVDB is 0V, and the current sensed by the current sensor is 0 amperes.

[0024] The busbar may include a first busbar coupled to a first portion of the battery pack and a second busbar coupled to a second portion of the battery pack. Each of the first busbar and the second busbar includes a corresponding first jumper and a second jumper, which are bent relative to the body of a corresponding one of the first busbar and the second busbar (e.g., arced downward at an angle of 90%, etc.). The busbar may include a connecting jumper to connect the first jumper and the second jumper. In order to disconnect the busbar (e.g., to disconnect the high voltage in the battery pack from the high voltage distribution box), the connecting jumper can be removed, thereby disconnecting the first jumper and the second jumper. A cover made of an insulating material (e.g., a plastic material) may be provided to cover the body of the first busbar and the body of the second busbar. In one aspect, the present solution may include a busbar available from outside the battery pack, which may be configured as a modular addition to a module or subassembly within the battery pack. This may allow, for example, two variants of a battery pack to be manufactured with the same module or subassembly. One variant may include a usable busbar subassembly and thus allow for servicing accessible via the busbar while the battery pack remains within the vehicle, while another battery pack variant may, for example, not include that subassembly. The battery pack variant may then be selected based on the configuration of the vehicle. The present solution may involve a "mid-pack" electrical architecture where the busbar may provide a usable feature at an intermediate node of the battery pack to reduce the voltage of the battery pack such that the maximum voltage present in the system is reduced to facilitate usability.

[0025] 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 subassembly 115, or a battery cell 120 to power the electric vehicle. The electric vehicle 105 may include a chassis 125 (e.g., a frame, an internal frame, or a support structure). The chassis 125 may support various components of the electric vehicle 105. The chassis 125 may span a front portion 130 (e.g., a hood or lid portion), a body portion 135, and a rear portion 140 (e.g., a luggage compartment, 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 body portion 135, or the rear portion 140 on the chassis 125 of the electric vehicle 105. The battery pack 110 may include or be connected to at least one bus bar, such as a collector element. For example, the first bus bar 145 and the second bus bar 150 may include conductive materials to connect or otherwise electrically couple the battery 115, the battery subassembly 115, or the battery cell 120 to other electrical components of the electric vehicle 105, thereby powering various systems or components of the electric vehicle 105.

[0026] Figure 2A An exemplary battery pack 110 is depicted. Figure 2A, among other things, the battery pack 110 may 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 205. The housing 205 may include at least one battery subassembly 115 or at least one battery cell 120, as well as other battery pack components. The battery subassembly 115 may be or may include one or more groups of prismatic battery cells, cylindrical battery cells, pouch battery cells, or other form factor battery cells 120. The housing 205 may include a shield on or below the bottom of the battery subassembly 115 to protect the battery subassembly 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 210 that distributes 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) 215. The thermal component 215 may be located relative to the top submodule and the bottom submodule, such as between the top submodule and the bottom submodule, among other possibilities. The battery pack 110 may include any number of thermal components 215. For example, there may be one or more thermal components 215 per battery pack 110 or per battery subassembly 115. The at least one cooling line 210 may be coupled to, partially coupled to, or independent of the thermal component 215.

[0027] Figure 2B An exemplary battery subassembly 115 is depicted, and Figure 2C , Figure 2D and Figure 2EAn exemplary cross-sectional view of a battery cell 120 is depicted. The battery subassembly 115 may include at least one submodule. For example, the battery subassembly 115 may include at least one first (e.g., top) submodule 220 or at least one second (e.g., bottom) submodule 225. At least one thermal component 215 may be disposed between the top submodule 220 and the bottom submodule 225. For example, one thermal component 215 may be configured to exchange heat with one battery subassembly 115. The thermal component 215 may be disposed or thermally coupled between the top submodule 220 and the bottom submodule 225. One thermal component 215 may also be thermally coupled to more than one battery subassembly 115 (or more than two submodules 220, 225). The thermal components 215 shown as being adjacent to each other may be combined into a single thermal component 215 that spans the size of one or more submodules 220 or 225. The thermal member 215 may be positioned below the submodule 220 and above the submodule 225, between the submodules 220 and 225, on one or more sides of the submodules 220, 225, and other possibilities. The thermal member 215 may be disposed in a sidewall, a cross member, a structural beam, among various other components of a battery pack, such as the battery pack 110 described above. The battery submodules 220, 225 may collectively form a battery subassembly 115. In some examples, each submodule 220, 225 may be considered a complete battery subassembly 115, rather than a submodule.

[0028] The battery subassemblies 115 may each include a plurality of battery cells 120. The battery subassemblies 115 may be disposed within the housing 205 of the battery pack 110. For example, the battery subassemblies 115 may include battery cells 120 that are cylindrical battery cells or prismatic battery cells. The battery subassemblies 115 may operate as modular units of battery cells 120. For example, the battery subassemblies 115 may collect current or power from the battery cells 120 included in the battery subassemblies 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 subassemblies 115. For example, the battery pack may have one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, or other number of battery subassemblies 115 disposed in the housing 205. It should also be noted that each battery subassembly 115 may include a top submodule 220 and a bottom submodule 225, and may have a thermal component 215 between the top submodule 220 and the bottom submodule 225. The battery pack 110 may include or define a plurality of areas for positioning the battery subassemblies 115 and / or the battery cells 120. The battery subassemblies 115 may be square, rectangular, circular, triangular, symmetrical, or asymmetrical. In some examples, the battery subassemblies 115 may be of different shapes, such that some battery subassemblies 115 are rectangular, while other battery subassemblies 115 are square, as well as other possibilities. The battery subassembly 115 may include or define a plurality of slots, holders, or containers for a plurality of battery cells 120. It should be noted that the illustrations and descriptions herein are provided for exemplary purposes and should not be construed as limiting. For example, the battery cells 120 may be inserted into the battery pack 110 without the battery submodules 220 and 225. The battery cells 120 may be arranged in the battery pack 110 in a battery cell-battery pack configuration without the submodules 220 and 225, as well as other possibilities.

[0029] The battery cell 120 has a variety of form factors, shapes, or sizes. For example, the battery cell 120 can have a cylindrical, rectangular, square, cubic, flat, pouch-shaped, elongated, or prismatic form factor. Figure 2C As depicted, for example, battery cell 120 may be cylindrical. Figure 2D As depicted, for example, battery cell 120 may be prismatic. Figure 2EAs depicted, for example, the battery cell 120 may include a pouch form factor. The battery cell 120 may be assembled, for example, by inserting a wound or stacked electrode roll (e.g., a jelly roll) including an electrolyte material into at least one battery cell housing 230. An electrolyte material such as an ion conductive fluid or another material may support an electrochemical reaction at the electrode to generate, store, or provide power for the battery cell by allowing ion conduction between the positive electrode and the negative electrode. The battery cell 120 may include an electrolyte layer, wherein the electrolyte layer may be or include a solid electrolyte material that can conduct ions. For example, a solid electrolyte layer may conduct ions without receiving a separate liquid electrolyte material. An electrolyte material such as an ion conductive fluid or another material may support ion conduction between electrodes, thereby generating or providing power for the battery cell 120. The housing 230 may have a variety of shapes, including, for example, a cylindrical or rectangular shape. An electrical connection may be formed between the electrolyte material and the components of the battery cell 120. For example, an electrical connection of the electrode to at least some of the electrolyte material may be formed at two points or areas of the battery cell 120, for example to form a first polarity terminal 235 (e.g., a positive terminal or anode terminal) and a second polarity terminal 240 (e.g., a negative terminal or cathode terminal). The polarity terminals may be made of a conductive material to carry current from the battery cell 120 to an electrical load, such as a component or system of the electric vehicle 105.

[0030] 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 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. An 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 solid electrodes and solid electrolytes. The solid electrode or electrolyte may be or include an organic 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., a lithium superionic conductor (LISICON), a sodium superionic conductor (NASICON), a material having the formula ABO 3 (A = Li, Ca, Sr, La and B = Al, Ti) perovskite having formula A 3 B 2 (XO 4 ) 3 Garnet type (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., Li 3 PS 4 , Li 7 P 3 S 11 , Li 2 SP 2 S 5 , Li 2 SB 2 S 3 、SnS-P 2 S 5 , Li 2 S–SiS 2 , Li 2 S–P 2 S 5 , Li 2 S-GeS 2 , Li 10 G 2 S 12 ) and / or having the formula Li 6 PS 5 X (X = Cl, Br) sulfide-based lithium argyrodite (such as Li 6 PS 5 Cl). 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.

[0031] The battery cell 120 may be included in the battery subassembly 115 of the battery pack 110 to power components of the electric vehicle 105. The battery cell housing 230 may be disposed in the battery subassembly 115, the battery pack 110, or a battery array installed in the battery vehicle 105. The housing 230 may have any shape, such as a circular shape (e.g., particularly Figure 2C The shape of the housing 230 may also be a prism with a polygonal base, especially as shown in FIG. Figure 2D In particular, Figure 2E As shown, the housing 230 may include a pouch factor. The housing 230 may include other form factors, such as triangles, squares, rectangles, pentagons, and hexagons. In some embodiments, the battery pack may not include subassemblies (e.g., no subassemblies). For example, the battery pack may have a no-subassembly or battery cell-battery pack configuration, in which the battery cells are directly arranged in the battery pack without being assembled into subassemblies.

[0032] The housing 230 of the battery cell 120 may include one or more materials or combinations thereof having various electrical or thermal conductivities. The electrically conductive and thermally conductive materials for the housing 230 of the battery cell 120 may include metal materials such as aluminum, alloys of aluminum with copper, silicon, tin, magnesium, manganese or zinc (e.g., aluminum 1000, 4000 or 5000 series), iron, iron-carbon alloys (e.g., steel), silver, nickel, copper and copper alloys, etc. The electrically insulating and thermally conductive materials for the housing 230 of the battery cell 120 may include ceramic materials (e.g., silicon nitride, silicon carbide, titanium carbide, zirconium dioxide, beryllium oxide, etc.) and thermoplastic materials (e.g., polyethylene, polypropylene, polystyrene, polyvinyl chloride or nylon), etc. In the case where the housing 230 of the battery cell 120 is prismatic (e.g., especially as Figure 2D as depicted) or cylindrical (e.g., especially as Figure 2C In the example depicted in FIG. 20 , the housing 230 may include a rigid or semi-rigid material such that the housing 230 is rigid or semi-rigid (e.g., not easily deformed or manipulated into another shape or form factor). ... Figure 2E In the example depicted), the housing 230 may include a flexible, stretchable, or non-rigid material such that the housing 230 can be bent, deformed, manipulated into another form factor or shape.

[0033] The battery cell 120 may include at least one anode layer 245, which may be disposed within a cavity 250 defined by the housing 230. The anode layer 245 may include a first redox potential. During operation of the battery cell 120 (e.g., charging or discharging of the battery cell 120), the anode layer 245 may receive current into the battery cell 120 and output electrons. The anode layer 245 may include an active material. The active material may include, for example, activated carbon or a material infused with a conductive material (e.g., artificial or natural graphite or a mixture), lithium titanate (Li 4 Ti 5 O 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 2Hybrid 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 include an anode active material in an uncharged state.

[0034] The battery cell 120 may include at least one cathode layer 255 (e.g., a composite cathode layer, a compound cathode layer, a compound cathode, a composite cathode, or a cathode). The cathode layer 255 may include a second redox potential that may be different from the first redox potential of the anode layer 245. The cathode layer 255 may be disposed within the cavity 250. During the discharge of the battery cell 120, the cathode layer 255 may output current from the battery cell 120 and may receive electrons. During the discharge of the battery cell 120, the cathode layer 255 may also receive lithium ions. Conversely, during the charging of the battery cell 120, the cathode layer 255 may receive current into the battery cell 120 and may output electrons. During the charging of the battery cell 120, the cathode layer 255 may release lithium ions.

[0035] The battery cell 120 may include a layer 260 disposed within the cavity 250. The layer 260 may include a solid electrolyte layer. The layer 260 may include a separator wetted by a liquid electrolyte. The layer 260 may include a polymer material. The layer 260 may include a polymer separator. The layer 260 may be disposed between the anode layer 245 and the cathode layer 255 to separate the anode layer 245 from the cathode layer 255. The polymer separator may physically separate the anode and cathode from the battery cell short circuit. The separator may be wetted with a liquid electrolyte. The liquid electrolyte may diffuse into the anode layer 245. The liquid electrolyte may diffuse into the cathode layer 255. The layer 260 may facilitate the transfer of ions (e.g., Li+) between the anode layer 245 and the cathode layer 255. + ions). Layer 260 may transfer Li + The cations are transferred from the anode layer 245 to the cathode layer 255. Layer 260 can transfer lithium ions from the cathode layer 255 to the anode layer 245 during a charging operation of the battery cell 120.

[0036] The redox potential of the layer (e.g., the first redox potential of the anode layer 245 or the second redox potential of the cathode layer 255) may vary based on the chemistry of the corresponding layer or the chemistry of the battery cell 120. For example, a lithium-ion battery may include LFP (lithium iron phosphate) chemistry, LMFP (lithium iron manganese phosphate) chemistry, NMC (nickel manganese cobalt) chemistry, NCA (nickel cobalt aluminum) chemistry, OLO (overlithiated oxide) chemistry, or LCO (lithium cobalt oxide) chemistry for the cathode layer (e.g., cathode layer 255). A lithium-ion battery may include graphite chemistry, silicon-graphite chemistry, or lithium metal chemistry for the anode layer (e.g., anode layer 245).

[0037] For example, lithium-ion batteries may include olivine phosphate (LiMPO 4 , M=Fe and / or Co and / or Mn and / or Ni)) chemical substances, LISICON type or NASICON type phosphate (Li 3 M 2 (PO 4 ) 3 and LiMPO 4 O x , M=Ti, V, Mn, Cr and Zr), such as lithium iron phosphate (LFP), lithium iron manganese phosphate (LMFP), layered oxide (LiMO 2 , 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 O 2 )(Ni, and / or Mn, and / or Co), (OLO or LMR), spinel (LiMn 2 O 4 ) and high pressure spinel (LiMn 1.5 Ni 0.5 O 4 ), disordered rock salt, fluorophosphate Li 2 FePO 4 F (M = Fe, Co, Ni) and fluorosulfate LiMSO 4 F (M = Co, Ni, Mn) (e.g., cathode layer 255). The lithium-ion battery may include a graphite chemistry, a silicon-graphite chemistry, or a lithium metal chemistry for the anode layer (e.g., anode layer 245). For example, a cathode layer with LFP chemistry may have a 3.4 V vs. Li / Li + The redox potential of the anode layer with graphite chemistry can be 0.2 V vs. Li / Li + Redox potential.

[0038] Typically, in addition to conductive carbon materials, binders or other additives, the electrode layer may also include an anode active material or a cathode active material as a coating on the collector (metal foil). The chemical composition of the electrode layer can affect the redox potential of the electrode layer. For example, the cathode layer (e.g., cathode layer 255) may include a lithium transition metal oxide with a medium to high nickel content (50% to 80% or equal to 80% Ni), such as granular lithium nickel manganese cobalt oxide ("LiNMC"), lithium nickel cobalt aluminum oxide ("LiNCA"), lithium nickel manganese cobalt aluminum oxide ("LiNMCA") or lithium metal phosphates, such as lithium iron phosphate ("LFP") and lithium iron manganese phosphate ("LMFP"). The anode layer (e.g., anode layer 245) may include a conductive carbon material such as graphite, carbon black, carbon nanotubes, etc. The anode layer may include, for example, Super P carbon black material, Ketjen Black, acetylene black, SWCNT, MWCNT, graphite, carbon nanofibers or graphene.

[0039] 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.

[0040] 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.

[0041] Layer 260 may include or be made of a liquid electrolyte material. For example, layer 260 may be or may include at least one layer of a polymer material (e.g., polypropylene, polyethylene, or other material) that includes pores that are wetted (e.g., saturated with, soaked with, receiving, filled with) a liquid electrolyte substance to enable ions to move between the electrodes. The liquid electrolyte material may include a lithium salt dissolved in a solvent. The lithium salt for the liquid electrolyte material of layer 260 may include, for example, lithium tetrafluoroborate (LiBF 4 ), lithium hexafluorophosphate (LiPF 6 ) and lithium perchlorate (LiClO 4 ) and the like. The solvent may include, for example, dimethyl carbonate (DMC), ethylene carbonate (EC), and diethyl carbonate (DEC), etc. The liquid electrolyte need not be disposed near layer 260, but the liquid electrolyte may fill the battery cell 120 in many different ways. Layer 260 may include or be made of a solid electrolyte material, such as a ceramic electrolyte material, a polymer electrolyte material, or a glass electrolyte material, etc., or any combination thereof.

[0042] 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 3 (A = Li, Ca, Sr, La and B = Al, Ti) perovskite having formula A 3 B 2 (XO 4 ) 3 Garnet type (A = Ca, Sr, Ba and X = Nb, Ta), lithium phosphorus oxynitride (Li x PO y Nz In some embodiments, the solid electrolyte layer may include a glassy, ​​ceramic, and / or crystalline sulfide-based electrolyte (e.g., Li 3 PS 4 , Li 7 P 3 S 11 , Li 2 SP 2 S 5 , Li 2 SB 2 S 3 、SnS-P 2 S 5 , Li 2 S–SiS 2 , Li 2 S–P 2 S 5 , Li 2 S-GeS 2 , Li 10 G 2 S 12 ) and / or having the formula Li 6 PS 5 X (X = Cl, Br) sulfide-based lithium argyrodite (such as Li 6 PS 5 Cl). 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.

[0043] In an example where layer 260 includes a liquid electrolyte material, layer 260 may include a non-aqueous polar solvent. The non-aqueous polar solvent may include a carbonate, such as ethylene carbonate, propylene carbonate, diethyl carbonate, ethyl methyl carbonate, dimethyl carbonate, or a mixture of any two or more thereof. Layer 260 may include at least one additive. The additive may be or include vinylene carbonate, fluoroethylene carbonate, ethyl propionate, methyl propionate, methyl acetate, ethyl acetate, or a mixture of any two or more thereof. Layer 260 may include a lithium salt material. For example, the lithium salt may be lithium perchlorate, lithium hexafluorophosphate, lithium bis(fluorosulfonyl)imide, lithium bis(trifluorosulfonyl)imide, or a mixture of any two or more thereof. The lithium salt may be present in layer 260 at a concentration greater than 0 M to about 1.5 M. Once provided to the battery cell 120, the liquid electrolyte may be present and contact the battery subcomponents present in the battery cell 120. The battery subcomponents may include a cathode, an anode, a separator, a current collector, and the like.

[0044] Figure 3An exemplary block diagram of an exemplary battery system 300 (also referred to as system 300) is depicted, the exemplary battery system having a battery pack 110 including an access cover 340 for accessing the busbar 310 to reduce the voltage of the battery pack. The battery system 300 may include one or more battery packs 110. Each battery pack 110 may include a housing 344. The battery pack 110 may include one or more battery subassemblies 115. Each battery subassembly in the battery subassembly 115 may include one or more battery cells 120. In some embodiments, the battery pack 110 may include a plurality (e.g., a group) of battery cells 120.

[0045] The battery pack 110 may include an access cover 340. The access cover 340 may include any access member or component that protects or exposes the access to the busbar 310. The access cover 340 may be a portion of an end plate 342, which may be a portion of a housing 344. The access cover 340 may provide access to the busbar 310 included below the access cover 340 (e.g., on the other side thereof) for maintenance or inspection. The access cover 340 may include an electrically insulating material (e.g., plastic) to protect the busbar 310 within the battery pack 110 from environmental factors (such as dust or moisture). The access cover 340 may allow a user (e.g., a maintenance technician or mechanic) to access the busbar 310, troubleshoot a problem, replace a faulty part, perform a routine inspection, or remove a portion of the busbar 310 to reduce the voltage from the battery pack 110 (e.g., to two or more portions of the battery pack 110).

[0046] Figure 4 An example of a battery system 300 having a busbar 310 for reducing the voltage of a battery pack 110 is shown. The busbar 310 may include a plurality of (e.g., two or more) bodies 312 that may electrically connect any number of battery cells 120, such as a group of battery cells 120 in one or more battery subassemblies 115. Each body 312 may be electrically connected to a jumper 314. Each jumper 314 may be bent downward or otherwise shaped to interface or connect with a jumper connector 318 (also referred to as an intermediate battery pack busbar 318). A jumper connector 318 (e.g., an intermediate battery pack busbar) may electrically connect two or more jumpers 314 so that the bodies 312 of the busbar 310 are electrically connected to each other. An access opening 350 that may be covered by an access cover 340 may provide a user (such as a technician or mechanic) with access to the jumper connector 318, the jumper 314, and the body 312 of the busbar 310.

[0047] The busbar 310 may include any one or more conductive components for electrically connecting or disconnecting the grouped battery cells 120 of the battery pack 110. The busbar 310 may include one or more conductive parts (e.g., a busbar body 312, a jumper 314, and / or a jumper connector) for creating electrical continuity between different groups of battery cells 120 (e.g., one or more battery subassemblies 115). The busbar 310 may include conductive components (e.g., metal components) that are interconnected to each other and allow a sufficient amount of conductivity for high voltage and high current applications (e.g., about 150 kWh to 200 kWh or about 50 amps to 70 amps of current) for electric vehicle batteries. The busbar 310 may be configured, deployed, or arranged to be accessible by a user (e.g., a mechanic or technician) via an access opening 350. The busbar 310 may be configured or arranged to allow a user to electrically connect or disconnect two or more battery cells 120, groups of battery cells 120, two or more battery subassemblies 115, groups of battery subassemblies 115, two or more battery packs 110, or groups of battery packs 110.

[0048] The groups of battery cells 120 may be connected to each other in series, in parallel, or in any combination of series and parallel configurations. A group of battery cells 120 may include any number or ratio of battery cells 120 of the battery pack 110. For example, a group of battery cells 120 may include half of all battery cells in the battery pack 110, one-third of the battery cells 120 in the battery pack, one-quarter of the battery cells, or any other ratio or proportion of battery cells 120 in the battery pack 110, such as 1 / 5, 1 / 6, 1 / 7, 1 / 8, 1 / 10, 1 / 12, 1 / 16, 1 / 20, or any other fraction. Each group of battery cells in the group of battery cells 120 may be electrically coupled to at least one of the bodies 312 of the battery pack 110.

[0049] The body 312 may include any one or more conductive parts or components for providing electrical continuity between the jumper 314 or jumper connector 318 and one or more battery cells 120, battery subassemblies 115, or battery pack 110. The body 312 may include a metal component (e.g., a strip or wire) that electrically couples the battery cell 120, subassembly 115, or battery pack 110 to the jumper connector 318. The body 312 may include a metal strip between the jumper connector 318 disposed at the end of the battery pack 110 and the battery cell 120 or subassembly 115 in the interior of the battery pack 110. The body 312 may be covered by an electrically insulating cover 330. The cover 330 may be a portion of the housing 344 that surrounds or provides an outer surface of the battery pack 110.

[0050] The body 312 of the bus bar 310 may be routed through the battery pack 110 to any number of grouped battery cells 120. For example, the bus bar 310 may include a first component (e.g., a first body 312) coupled to a first half of the battery pack 110 (e.g., one or more battery subassemblies 115 having a group of battery cells 120) and a second component (e.g., a second body 312) coupled to a second half of the battery pack 110. For example, the bus bar 310 may include a first body 312 coupled to a first quarter of the battery pack 110 (e.g., one or more battery subassemblies 115 having a first group of battery cells 120), a second body 312 coupled to a second quarter of the battery pack 110, a third body 312 coupled to a third quarter of the battery pack 110, and a fourth body 312 coupled to a fourth quarter of the battery pack. Each of the bodies 312 may be electrically insulated from each other (e.g., via an air gap or an electrically insulating material) and may be electrically coupled to each other only via the jumper connector 318.

[0051] The jumper 314 may include a component configured to connect, couple, or interface with a jumper connector 318. The jumper 314 may include an end of the body 312. The jumper 314 may be bent at a 90 degree angle relative to the rest of the body 312 (e.g., a bar or rod). The jumper 314 may be bent, shaped, curved, or otherwise configured to provide a straight, aligned, or otherwise equidistant termination surface for connection to the jumper connector 318. The jumper 314 may be a part of the body 312 or a component connected or coupled to the body 312. The jumper 314 may be shaped or formed to provide electrical contact suitable for high current electric vehicle applications (e.g., currents up to 100A).

[0052] The jumper connector 318 (also referred to as the intermediate battery pack bus bar 318) may include any conductive component for electrically shorting or coupling two or more bodies 312 of the bus bar 310. For example, the jumper connector 318 may include a plate for connecting or coupling with a plurality of jumpers 314, each of which is coupled with its own body 312, with its own group of battery cells 120. The jumper connector 318 may include a flat surface plate, a curved surface plate, or any component for receiving, attaching, coupling, or otherwise connecting to one or more jumpers 314 or the body 312. The jumper connector 318 may include screw holes for allowing the jumper connector 318 to be screwed onto or fastened to the jumpers 314 and / or the body 312.

[0053] The housing 344 may include any structure or component for enclosing, covering, or protecting any portion of the battery pack 110. The housing 344 may include a plate or cover on the outer surface of the battery pack 110, such as an end plate 342. The housing 344 may include or be connected to an electrically insulating component, such as a cover 330 covering the top side of the body 312. The end plate 342 may include a sheet or plate of a material such as metal or plastic, and may serve as a portion of the housing 344 located on one side of the battery pack 110.

[0054] The access opening 350 may include any opening through the housing 344 (e.g., the end plate 342) to provide access for servicing the busbar 310. The access opening 350 may be covered by a removable access cover 340 that a user (e.g., a technician or mechanic) may move aside or remove to access the jumper connectors 318 of the busbar 310. The user may remove the jumper connectors 318 to electrically disconnect the body 312 electrically coupled to their respective group of battery cells 120, thereby causing the voltage output from each group of battery cells in the disconnected group of battery cells 120 to be reduced. For example, the user may loosen the screws of the jumper connector 318 to disconnect the jumper connector 318 from the jumper 314 of the body 312. In doing so, the user may electrically separate the group of battery cells 120 coupled to the body 312, thereby reducing the voltage and / or current output of the battery pack 110. This may be useful, for example, when a lower current and / or voltage output is desired during maintenance or repair of the battery pack 110 .

[0055] Figure 5 An example of a cross-sectional view of a bus bar 310 for reducing the voltage of a battery system 300 is shown. Figure 5 As shown, the battery system 300 may include a body 312 of a bus bar 310 that may be coupled at its inner end to a battery subassembly 115 (e.g., or any other portion of a battery pack 110). The outer end of the body 312 may include a jumper 314 that may be bent, curved, shaped, or formed downward to align with a flat surface of a jumper connector 318. Covering the jumper connector 318 may be an access cover 340 that may be used to cover an access opening 350 in an end plate 342. The body 312 of the bus bar 310 may be electrically coupled to one or more battery subassemblies 115 or any number of battery cells 120 within a battery pack via fasteners (e.g., screws or clips), which may be electrically connected to each other and to the body 312.

[0056] Figure 6An example of an access opening is shown for accessing the busbar to reduce the voltage of the battery pack 110. The access opening 350 may include an opening, through-hole, or passage through the end plate 342 or any other portion of the housing 344 to view, access, reach, and work on the jumper connector 318 of the busbar 310. The access opening 350 may expose screws or fasteners used to couple the jumper connector 318 to the jumper 314 and / or the body 312 of the busbar 310 to the user.

[0057] Figure 7 An example of a top view of an access opening and busbars in a battery pack is shown. Figure 7 As shown, the body 312 of the busbar 310 can be accessed by removing the cover 330 on the top surface of the battery pack 110. When the cover 330 is removed, the user can access the screws or fasteners that connect the inner ends of the body 312 to the portion of the battery pack 110 that is connected to each of the bodies 312 (e.g., the grouped battery cells 120). However, access to the jumper connector 318 through the access opening 350 allows the user to disconnect the bodies 312 from each other (e.g., thereby reducing the battery pack voltage and current) without removing the cover 330 or removing the battery pack 110 from the EV 105. Therefore, the access opening 350 can allow the user to remove the jumper connector 318 and disconnect the sections of the battery pack 110 that are connected to different bodies 312 without removing the battery pack 110 or the subassembly 115.

[0058] In some aspects, the present solution relates to a battery system 300. The battery system 300 may include a bus bar 310 electrically coupled to a battery pack 110. The bus bar 310 may be electrically coupled between and electrically coupled to two groups of battery cells 120 of the battery pack 110. For example, the bus bar 310 may include a first body 312 electrically coupled to a first group of battery cells 120 of the two groups of battery cells 120 and a second body 312 electrically coupled to a second group of battery cells 120 of the two groups of battery cells 120. The battery system 300 may include the bus bar 310 to be disposed at an opening of a housing 344 of the battery pack 110. The bus bar 310 may be exposed through an access cover 340. For example, the access cover 340 may shield or cover an access opening 350 configured to allow a user (e.g., a technician or mechanic) to attach a jumper connector 318 to the body 312 of the bus bar 310, thereby electrically coupling the body 312 and their respective groups of battery cells 120. Similarly, the access opening 350 may allow a user (eg, a technician or mechanic) to remove the jumper connector 318 from the body 312 of the bus bar 310 , thereby electrically disconnecting the body 312 and their respective group of battery cells 120 .

[0059] The battery system 300 may include a busbar 310 to include one or more bodies 312. Each of the bodies 312 may be electrically coupled to one or more jumpers 314. The jumper 314 may include a conductive (e.g., metal) component. The jumper 314 may be shaped, formed, or configured to provide a tight physical and electrical connection to the jumper connector 318 and / or the body 312. The jumper 314 may be an integral component or portion (e.g., an end) of the body 312. The jumper 314 may be bent relative to the body 312. For example, the jumper 314 may be bent 90 degrees relative to the body (e.g., forming a right angle with the body 312). The jumper 314 may be located within the housing 344 and may be exposed (e.g., for inspection, troubleshooting, fixing, or adjustment) by removing the access cover 340.

[0060] The battery system 300 may include a bus bar 310 including a body 312 and a jumper 314. For example, the bus bar 310 may include one or more bodies 312. Each of the bodies 312 may be electrically insulated from the other bodies 312 of the bus bar 310 except via a jumper connector 318. The jumper connector 318 may electrically couple the bodies 312 of the bus bar 310 into a single conductive component. The cover 330 may include an electrically insulating material and may be disposed over one or more bodies 312. The cover 330 may cover a portion of the body 312 or the entire body 312.

[0061] The battery system 300 may include a bus bar 310 that may be coupled to the battery pack 110 at a mid-position between two groups of battery cells 120. For example, the bus bar 310 may be located on or near a surface (e.g., a top surface or a bottom surface) of the battery pack 110. The bus bar 310 may include a first body 312 that is electrically coupled to one half of the battery cells 120 (e.g., the left side of the battery pack 110 having one or more battery subassemblies 115 filled with battery cells 120). The bus bar 310 may include a second body 312 that is electrically coupled to a second half of the battery cells 120 (e.g., the right side of the battery pack 110 having one or more battery subassemblies 115 filled with battery cells 120). In doing so, the bus bar 310 may allow the battery cells 120 of the two halves of the battery pack 110 to be connected to each other (e.g., connected in series to provide a maximum voltage) via a jumper connector 318. Once the jumper connector 318 is removed, the two halves of the battery pack 110 may provide half of their maximum voltage output when they are connected via the jumper connector 318 .

[0062] The battery system 300 may include a first body 312 of a bus bar 310 electrically coupled to a first group of battery cells in the two groups of battery cells 120 and a second body 312 of a bus bar 312 electrically coupled to a second group of battery cells in the two groups of battery cells 120. The first group of battery cells 120 may include half of the battery cells 120 of the battery pack 110 (e.g., when the bus bar 310 includes two bodies 312), one-third of the battery cells 120 of the battery pack 110 (e.g., when the bus bar 310 includes three bodies 312), one-quarter of the battery cells 120 (e.g., when the bus bar 310 includes four bodies 312), and the like. The remaining bodies 312 (such as the second body 312) may be connected to the second group of battery cells 120. For example, the third body 312 may be connected to the third group of battery cells 120. For example, the fourth body 312 may be connected to the fourth group of battery cells 120.

[0063] The battery system 300 may include a bus bar 310 to be disposed at an end plate 342 of a housing 344. The bus bar 310 may be disposed near the end plate 342 of the housing 344. For example, a jumper connector 318 may be disposed near or within the end plate 342. For example, a jumper connector 318 of the bus bar 310 may be disposed, positioned, formed, or placed within an access opening 350 within the end plate 342. The jumper connector 318 of the bus bar 310 and the bus bar 310 may be positioned next to, adjacent to, abutting, or otherwise extending through any surface of the plate 342 or housing 344 (e.g., a top side or top surface of the housing 344, a bottom side or bottom surface of the housing 344, any of the side surfaces of the housing 344, a front surface or a rear surface of the housing 344).

[0064] The battery system 300 may include a jumper connector 318 that electrically couples a first body 312 of the bus bar 310 with a second body 312 of the bus bar 310. The jumper connector 318 may be removed via an access opening 350 of an access cover 340 on an end plate of the housing 344. Removing the jumper connector 318 may cause a first group of battery cells in two groups of battery cells 120 to be electrically disconnected from a second group of battery cells in two groups of battery cells 120. For example, when the bus bar 312 includes more than two bodies 312, each group of battery cells in a group of battery cells 120 coupled to each of the bodies 312 may be electrically disconnected by removing the jumper connector 318 and electrically coupled by placing, installing, or connecting the jumper connector 318 back together with the body 312 (e.g., or the jumper 314).

[0065] The battery system 300 may include a jumper connector 318 that electrically connects a first jumper 314 of a first body 312 of a bus bar 310 coupled to a first group of battery cells in the two groups of battery cells 120 and a second jumper 314 of a second body 312 of the bus bar 310 coupled to a second group of battery cells in the two groups of battery cells 312. The jumper connector 318 may be configured to electrically disconnect the first group of battery cells in the two groups of battery cells 120 from the second group of battery cells in the two groups of battery cells 120 by removing the jumper connector 318 from the jumper 314 of the body 312 of the bus bar 310.

[0066] The battery system 300 may include a second bus bar 310 to electrically couple the battery pack 110 with the second battery pack 110. The battery system 300 may include a second jumper connector 318 that electrically couples a first jumper 314 of a first body 312 of the second bus bar 310 coupled to the battery pack 110 and a second jumper 314 of a second body 312 of the second bus bar 310 coupled to the second battery pack 110. For example, the jumper connector 318 may electrically couple any number of bodies 312 that are coupled to their respective groups of battery cells 120 via their respective jumpers 314. The battery system 300 may include a second jumper connector 318 that is configured to electrically disconnect the battery pack 110 from the second battery pack 110 by removing the second jumper connector 318 from the jumpers 314 of the body 312 of the second bus bar 310 through the access opening 350.

[0067] In some aspects, the present solution relates to a battery system 300 for an electric vehicle 105. The battery system 300 may include a bus bar 310 to electrically connect the battery pack 110 between two groups of battery cells of the battery pack 110. The bus bar 310 may be disposed at an opening of a housing 344 of the battery pack 110. The bus bar 310 may be exposed through an access cover 340. The battery system may include a jumper connector 318 to electrically connect a first body 312 of the bus bar 310 to a second body 312 of the bus bar 310. The jumper connector 318 may be removed via the access cover 340 on the end plate of the housing 344 to electrically disconnect a first group of battery cells electrically connected to the first body of the two groups of battery cells 120 and a second group of battery cells electrically connected to the second body of the two groups of battery cells 120.

[0068] Figure 8 A method 800 is depicted for providing access to a busbar of a battery pack to electrically disconnect at least a portion of the battery pack via the busbar. The method 800 may also involve using the busbar of the battery pack or electrically disconnecting at least a portion of the battery pack to reduce the voltage of the battery pack. The method 800 may be used, for example, in Figures 3 to 7At act 805, the method may include electrically coupling the busbar. At act 810, the method may include positioning the busbar at the opening. At act 815, the method may include exposing the busbar for access through an access cover.

[0069] At action 805, the method may include electrically connecting a busbar. The method may include electrically connecting the busbar to two groups of battery cells of the battery pack. For example, the busbar may be formed to include a body of the busbar and a jumper of the busbar. The jumper of the busbar may be formed, shaped or configured to be bent relative to the body of the busbar. The jumper and the body may be located within the housing of the battery pack. The jumper and the body may be formed to include a conductive material (e.g., a metal) and may include a single structure or component or a plurality of structures or components. The jumper may be formed, configured or shaped to provide physical and electrical contact with a flush surface of the jumper connector.

[0070] The method may include providing a first body of a busbar electrically connected to a first group of battery cells in two groups of battery cells. The first body may include a conductive rod, a wire or a bar, and one or more components that can maintain electrical continuity with a group of battery cells. The group of battery cells may include battery cells of one or more battery subassemblies. The group of battery cells may include battery cells within a single battery subassembly. The group of battery cells may include, for example, half of the battery cells of a battery pack, one-third of the battery cells of a battery pack, one-quarter of the battery cells of a battery pack, or any other fraction of the battery cells, such as 1 / 5, 1 / 6, 1 / 7, 1 / 8, 1 / 9, 1 / 10, 1 / 16 or less than 1 / 16 of the battery cells. Each group of battery cells in the group of battery cells can be connected to its own body in the busbar.

[0071] The method may include providing a second body of the busbar that is electrically connected to a second group of battery cells in the two groups of battery cells. The second body of the busbar may be electrically insulated from the first body of the busbar, except for electrical contact via a jumper connector. The second body of the busbar may be spaced apart from the first body of the busbar. For example, in a configuration including more than two bodies, all bodies of the busbar may be spaced apart from each other. The second body of the busbar may be electrically connected to a second group of battery cells, which may include any amount or fraction of battery cells in the battery pack, such as half, one-third, one-quarter, 1 / 5, 1 / 6, 1 / 7, 1 / 8, 1 / 9, 1 / 10, 1 / 16, or less than 1 / 16 of the battery cells.

[0072] The method may include providing a first body of a busbar, the first body having a first jumper, the first jumper exposed for access via an access cover. The method may include providing a second body of the busbar, the second body having a second jumper, the second jumper exposed for access via an access cover. A jumper connector of the busbar may electrically connect the first body to the second body via the first jumper and via the second jumper. The coupling of the first body and the second body via the jumper connector may electrically couple a first group of battery cells in two groups of battery cells that are electrically coupled to the first body and a second group of battery cells in two groups of battery cells that are electrically coupled to the second body. The jumper connector may be removed via an access cover on an end plate of the housing. The jumper connector may be removed by removing a fastener or screw coupling the jumper connector to the jumper or body of the busbar.

[0073] At action 810, the method may include disposing a busbar at an opening. The method may include disposing a busbar at an opening of a housing of a battery pack. The busbar may be disposed at an opening in an end plate, front plate, side plate, top plate, or bottom plate or surface of the housing. The busbar may be disposed so that its end (e.g., the jumper connector side of the busbar) is accessible to a user (e.g., a mechanic or technician) via an opening. The method may include providing a busbar having a body electrically coupled to a jumper. For example, the jumper and the busbar may be integrated or formed as a single structure or component, or they may include multiple structures electrically coupled to each other.

[0074] The method may include providing a cover configured to cover a portion of the body. The cover may be formed using an electrically insulating material, such as plastic. The cover may be removable so as to provide access to a portion of the body of the busbar. The cover may be integrated or coupled to a housing or plate (e.g., an end plate or a top plate) of the battery pack. The method may include electrically coupling the busbar to the battery pack at an intermediate position between two groups of battery cells. For example, the busbar may be disposed along a middle portion of the battery pack such that a first body of the busbar located on the left side of the battery pack may be coupled to a battery cell on the left side of the battery pack, and a second body of the busbar located on the right side of the battery pack may be coupled to a battery cell on the right side of the battery pack. The method may include arranging the busbar to be accessible via an access opening of an access cover at an end plate of the housing.

[0075] At action 815, the method may include exposing the busbar for access through or via an access cover. The method may include exposing the busbar for access through an opening through an access cover. For example, the busbar may be exposed for access by a user (e.g., a technician or mechanic) via an opening, and the cover may be removed from the opening. The method may include exposing the jumpers of the busbar by removing the access cover. For example, the cover may be removed to expose the jumper side of the body of the busbar. The access cover may cover the access opening and may be movable, slidable, or removable from the access opening to expose the jumper connector at the end of the busbar.

[0076] The method may include providing a jumper connector that electrically connects a first jumper of a first body of a busbar that is coupled to a first group of battery cells in the two groups of battery cells and a second jumper of a second body of the busbar that is coupled to a second group of battery cells in the two groups of battery cells. For example, the jumper connector may be provided or exposed for user access via an access opening to allow the user to electrically disconnect the bodies of the busbar from each other by removing the jumper connector. The jumper connector may be configured to electrically disconnect the first group of battery cells in the two groups of battery cells from the second group of battery cells in the two groups of battery cells by removing the jumper connector through the access opening of the access cover.

[0077] The method may include electrically coupling the battery pack to the second battery pack via a second busbar. For example, the second busbar may be configured to couple a battery pack having a plurality of battery subassemblies and / or battery cells to another battery pack having a plurality of battery subassemblies and / or battery cells. The second busbar may include structural features and functional features that are the same or similar to those of the busbar. The second busbar may include a second jumper connector that electrically couples a first jumper of a first body of the second busbar coupled to the battery pack and a second jumper of a second body of the second busbar coupled to the second battery pack. The second jumper connector may be configured to electrically disconnect the battery pack from the second battery pack by removing the second jumper connector from the jumper of the body of the second busbar.

[0078] The systems described above may provide multiple components of any one or each of these components, and these components may be provided on a standalone system, or on multiple instances in a distributed system.

[0079] Example and non-limiting module implementation elements include sensors that provide any value identified herein, sensors that provide any value that is a predecessor of a value identified herein, data link or network hardware including communication chips, oscillator crystals, communication links, cables, twisted pairs, coaxial lines, shielded lines, transmitters, receivers or transceivers, logic circuits, hard-wired logic circuits, reconfigurable logic circuits in a specific non-transient state configured according to module specifications, any actuator including at least an electric actuator, a hydraulic actuator or a pneumatic actuator, a solenoid, an operational amplifier, an analog control element (spring, filter, integrator, adder, divider, gain element) or a digital control element.

[0080] 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.

[0081] Now that some exemplary implementations have been described, it is apparent that the foregoing is illustrative rather than restrictive and has been presented by way of example. Specifically, although many of the examples presented herein relate to specific combinations of method actions or system elements, these actions and these elements may be combined in other ways to achieve the same purpose. The actions, elements, and features discussed in conjunction with one implementation are not intended to be excluded from similar roles in other implementations.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] For example, the description of positive and negative electrical characteristics may be reversed. For example, the positive or negative polarity of the battery cell 120, the battery subassembly 115, or the battery pack 110 may be reversed. An element described as a negative element may be configured as a positive element, while an element described as a positive element may be configured as a negative element. For example, an element described as having a first polarity may have a second polarity, while an element described as having a second polarity may have a first polarity. Further relative parallel, vertical, vertical or other positioning or orientation descriptions include changes within + / -10% or + / -10 degrees of pure vertical, parallel or vertical positioning. Unless otherwise expressly stated, references to "approximately", "substantially" or other degree terms include changes of + / -10% with a given measurement, unit or range. The connected elements may be electrically connected, mechanically connected or physically connected to each other directly or through an intermediate element. Therefore, the scope of the systems and methods described herein is indicated by the appended claims rather than the foregoing description, and changes falling within the meaning and scope of the equivalents of the claims are included therein.

Claims

1. A system, comprising: A bus bar is electrically connected to the battery pack between two groups of battery cells of the battery pack, and the bus bar is arranged at an opening of a shell of the battery pack, wherein the bus bar is exposed through an inspection cover.

2. The system of claim 1, wherein the system comprises the bus bar, the bus bar comprising a body and a jumper, the jumper being bent relative to the body, the jumper being located within the housing and exposed by removing the access cover.

3. The system according to claim 1, wherein the system comprises: The busbar comprises a main body and a jumper; A cover is provided to cover a portion of the body.

4. The system of claim 1, wherein the system comprises the bus bar coupled to the battery pack at a midpoint between the two groups of battery cells.

5. The system of claim 1, wherein the system comprises a first body of the bus bar electrically coupled to a first group of battery cells of the two groups of battery cells and a second body of the bus bar electrically coupled to a second group of battery cells of the two groups of battery cells.

6. The system of claim 1, wherein the system comprises the bus bar, the bus bar being disposed at an end plate of the housing.

7. A system according to claim 1, wherein the system includes a jumper connector, which electrically connects the first body of the busbar with the second body of the busbar, and the jumper connector can be removed through the inspection opening of the inspection cover on the end plate of the shell to electrically disconnect the first group of battery cells in the two groups of battery cells from the second group of battery cells in the two groups of battery cells.

8. The system of claim 1, wherein the system comprises a jumper connector electrically connecting a first jumper of a first body of the bus bar connected to a first group of battery cells in the two groups of battery cells and a second jumper of a second body of the bus bar connected to a second group of battery cells in the two groups of battery cells.

9. The system of claim 1 , wherein the system includes a jumper connector configured to electrically disconnect a first group of battery cells in the two groups of battery cells from a second group of battery cells in the two groups of battery cells by removing the jumper connector from a jumper of a body of the busbar.

10. The system of claim 1, wherein the system comprises a second bus bar electrically coupling the battery pack with a second battery pack.

11. The system of claim 10, wherein the system comprises a second jumper connector electrically connecting a first jumper of a first body of the second busbar coupled to the battery pack and a second jumper of a second body of the second busbar coupled to the second battery pack.

12. The system of claim 10, wherein the system includes a second jumper connector configured to electrically disconnect the battery pack from the second battery pack by removing the second jumper connector from a jumper of the body of the second busbar through an access opening.

13. A method for electrically disconnecting at least a portion of a battery pack, the method comprising: electrically connecting the busbar to two groups of battery cells of the battery pack; Disposing the busbar at an opening of the housing of the battery pack; as well as The busbars are exposed for access through the opening via an access cover.

14. The method according to claim 13, comprising: The busbar is formed into a body of the busbar and a jumper of the busbar bent relative to the body, wherein the jumper is located in the housing; as well as The jumper wires of the busbar are exposed by removing the access cover.

15. The method according to claim 13, comprising: providing the busbar having a body electrically coupled to a jumper wire; providing a cover configured to cover a portion of the body; as well as The bus bar is electrically coupled to the battery pack at a midpoint between the two groups of battery cells.

16. The method according to claim 13, comprising: Providing a first body of the busbar electrically connected to a first group of battery cells in the two groups of battery cells; Providing a second body of the busbar electrically connected to a second group of battery cells in the two groups of battery cells; and The busbars are provided to be accessible via an access opening of the access cover at an end plate of the housing.

17. The method according to claim 13, comprising: providing a first body of the busbar, the first body having a first jumper, the first jumper being exposed for access through the access cover; providing a second body of the busbar, the second body having a second jumper, the second jumper being exposed for access through the access cover; The first body is electrically connected to the second body via the first jumper and via the second jumper through a jumper connector so that a first group of battery cells in the two groups of battery cells that is electrically connected to the first body and a second group of battery cells in the two groups of battery cells that is electrically connected to the second body are electrically connected, and the jumper connector can be removed through the inspection cover on the end plate of the shell.

18. The method according to claim 13, comprising: A jumper connector is provided, which electrically connects a first jumper of a first body of the busbar connected to a first group of battery cells among the two groups of battery cells and a second jumper of a second body of the busbar connected to a second group of battery cells among the two groups of battery cells, wherein the jumper connector is configured to electrically disconnect the first group of battery cells among the two groups of battery cells from the second group of battery cells among the two groups of battery cells by removing the jumper connector through an inspection opening of the inspection cover.

19. The method according to claim 13, comprising: electrically connecting the battery pack to a second battery pack via a second bus bar; A first jumper of a first body of the second busbar connected to the battery pack and a second jumper of a second body of the second busbar connected to the second battery pack are electrically connected via a second jumper connector, wherein the second jumper connector is configured to electrically disconnect the battery pack from the second battery pack by removing the second jumper connector from the jumper of the body of the second busbar.

20. A battery system for an electric vehicle, the battery system comprising: A bus bar, the bus bar being electrically connected to the battery pack between two groups of battery cells of the battery pack, the bus bar being disposed at an opening of a housing of the battery pack, wherein the bus bar is exposed through an access cover; and A jumper connector electrically connects the first body of the busbar with the second body of the busbar, and the jumper connector can be removed through the inspection cover on the end plate of the shell to disconnect the first group of battery cells in the two groups of battery cells that are electrically connected to the first body and the second group of battery cells in the two groups of battery cells that are electrically connected to the second body.

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