Modular battery assembly

Abstract

A method of manufacturing a battery assembly is disclosed. The method includes sliding each of a plurality of cells into a certain cavity of a first plurality of cavities of a first cell stack panel. Each of the plurality of battery cells has a battery perimeter, and each cavity has a first end and a second end opposite the first end. The method further includes attaching a second cell stack panel to the first cell stack panel to form a cell stack. The second panel has a second plurality of cavities having a first end and a second end opposite the first end. A first end of each of the second plurality of cavities is aligned with a first end of a respective cavity of the first plurality of cavities.

Description

Technical Field

[0001] The present disclosure relates to batteries, and in particular to a modular battery assembly and system and a method of manufacturing such an assembly and system. Background Art

[0002] As battery technology advances, the demand for improved power sources, such as energy storage modules for vehicles, continues to grow. Existing battery systems typically require expensive epoxy resins and often also require complex and expensive processes to ensure that the subcomponents of the battery system fit together.

[0003] Therefore, existing systems lack configurations for supporting modular battery assemblies and methods for manufacturing modular battery assemblies. Summary of the invention

[0004] As battery technology advances, a need exists to provide improved power sources, as well as more efficient and cost-effective methods for manufacturing such power sources, as compared to conventional systems and methods.

[0005] Thus, the embodiments described herein provide a battery system and assembly that overcomes the shortcomings of conventional devices while being easy to manufacture, economical, and versatile compared to conventional devices. The embodiments described herein can be adapted and assembled while meeting the specific requirements imposed by modern battery chemistries, such as lithium-ion battery chemistries. The embodiments described herein provide a method for assembling such batteries in an efficient and cost-effective manner.

[0006] The present invention provides an apparatus, method, and system for a battery assembly. According to one aspect, the battery assembly includes a battery housing having a housing cavity. A battery cell stack is disposed in the housing cavity, wherein the battery cell stack includes a first battery cell stack panel and a second battery cell stack panel, the first battery cell stack panel including a first inner surface and a first outer surface, and the second battery cell stack panel including a second inner surface and a second outer surface. The first battery cell stack panel and the second battery cell stack panel are coupled together at the respective first inner surface and the second inner surface. The coupling of the second battery cell stack panel and the first battery cell stack panel forms a plurality of cavities, each of the plurality of cavities extending from the first outer surface to the second outer surface. A plurality of battery cells are each disposed in a corresponding cavity in the plurality of cavities. A plurality of bus bars are each electrically coupled to at least one of the positive terminal and the negative terminal of at least one battery cell.

[0007] In some embodiments, at least one of the plurality of cavities includes a vent area (also referred to as a vent cavity). In some embodiments, the inner bottom surface of the housing cavity includes a first plurality of interlocking features. The bottom surface of the battery cell stack includes a second plurality of interlocking features. The first plurality of interlocking features of the inner bottom surface of the housing cavity are coupled to the second plurality of interlocking features of the bottom surface of the battery cell stack. In some embodiments, the first plurality of interlocking features include at least one of guide ribs and interlocking circular features. In some embodiments, the second plurality of interlocking features include at least one of guide ribs and interlocking circular features. In some embodiments, the plurality of bus bars include at least one copper bus bar and at least one nickel-plated steel bus bar. In some embodiments, the first plurality of interlocking features are coupled to the second plurality of interlocking features by an adhesive, the adhesive being at least one of a gap-filling epoxy and a structural adhesive. In some embodiments, the battery cell stack includes a top surface, and the battery assembly further includes a battery management unit BMU attached to the top surface of the battery cell stack. In some embodiments, each of the plurality of battery cells is a cylindrical battery cell. In some embodiments, each of the plurality of cavities is a cylindrical cavity.

[0008] The present invention provides a method for manufacturing a battery system, the method comprising: sliding each of a plurality of battery cells into a corresponding cavity in a first plurality of cavities of a first battery cell stack panel, each of the plurality of battery cells having a battery circumference, each cavity in the first plurality of cavities having a first end and a second end opposite to the first end, the circumference of the first end being at least as large as the battery circumference, and the circumference of the second end being smaller than the battery circumference; attaching a second battery cell stack panel to the first battery cell stack panel to form a battery cell stack, the second panel having a second plurality of cavities, each of the second plurality of cavities having a first end and a second end opposite to the first end, the circumference of the first end being at least as large as the battery circumference, the circumference of the second end being smaller than the battery circumference, and the first end of each of the second plurality of cavities being aligned with the corresponding first end of the corresponding cavity in the first plurality of cavities; and attaching a battery management unit (BMU) to a first surface of the battery cell stack.

[0009] In some embodiments, the method further includes: applying an adhesive to a first plurality of interlocking features of an inner surface of the cavity of the battery case; and inserting the battery cell stack into the battery case. The second surface of the battery cell stack panel is aligned with the inner surface of the cavity of the battery case. The second surface of the battery cell stack panel includes a second plurality of interlocking features aligned with the first plurality of interlocking features using an adhesive. The adhesive is at least one of a gap filling epoxy and a structural adhesive.

[0010] In some embodiments, the first plurality of interlocking features include at least one of guide ribs and interlocking circular features. In some embodiments, the second plurality of interlocking features include at least one of guide ribs and interlocking circular features. In some embodiments, the method further includes attaching a first plurality of bus bars to a surface of a first battery cell stack panel. Each of the first plurality of bus bars includes a plurality of plates and pad connectors. The method further includes attaching a second plurality of bus bars to a surface of a second battery cell stack panel. Each of the second plurality of bus bars includes a plurality of plates and pad connectors. For each of the first plurality of bus bars, the method further includes welding each bus bar plate to at least one of a positive terminal and a negative terminal of at least one of the battery cells in the plurality of battery cells via a second end of a corresponding cavity in the first plurality of cavities. For each of the second plurality of bus bars, the method further includes welding the plate of each bus bar to at least one of a positive terminal and a negative terminal of at least one of the battery cells in the plurality of battery cells via a second end of a corresponding cavity in the second plurality of cavities. For each busbar in the first plurality of busbars, the method further comprises soldering a pad connector of the busbar to a corresponding pad of the BMU. For each busbar in the second plurality of busbars, the method further comprises soldering a pad connector of the busbar to a corresponding pad of the BMU.

[0011] In some embodiments, the method further includes attaching a cover to the first surface of the battery cell stack. The cover includes an inner surface, an outer surface, and a hole passing through the cover from the outer surface to the inner surface. The method further includes coupling the inner surface of the cover to a rubber gasket of a BMU connector port disposed on the BMU. The size of the rubber gasket is set to seal the hole. In some embodiments, each of the plurality of battery cells is a cylindrical battery cell. In some embodiments, each of the plurality of cavities is a cylindrical cavity.

[0012] According to a first embodiment of the present disclosure, a battery assembly is provided. The battery assembly includes a battery housing having a housing cavity and a battery cell stack disposed in the housing cavity. The battery cell stack includes a first battery cell stack panel, a second battery cell stack panel, and a plurality of battery cells, the first battery cell stack panel including a first inner surface and a first outer surface, the second battery cell stack panel including a second inner surface and a second outer surface, the first battery cell stack panel and the second battery cell stack panel are coupled together at the respective first inner surface and the second inner surface, the coupled first battery cell stack panel and the second battery cell stack panel form a plurality of cavities, each of the plurality of cavities extending from the first outer surface to the second outer surface, and each of the plurality of battery cells is disposed in a corresponding cavity among the plurality of cavities.

[0013] According to one or more embodiments of this aspect, the battery assembly further includes a plurality of bus bars, each of the plurality of bus bars being electrically coupled to at least one of a positive terminal and a negative terminal of at least one battery cell via at least one hole in at least one of the first outer surface and the second outer surface.

[0014] According to one or more embodiments of this aspect, each of the plurality of battery cells is disposed perpendicular to the first battery cell stack panel and the second battery cell stack panel.

[0015] According to one or more embodiments of this aspect, a first cavity of the plurality of cavities includes a vent area adjacent to the first outer surface, the vent area for venting the first battery cell of the plurality of battery cells.

[0016] According to one or more embodiments of this aspect, the inner bottom surface of the shell cavity includes a first plurality of interlocking features, and the bottom surface of the battery cell stack includes a second plurality of interlocking features, and the first plurality of interlocking features are connected to the second plurality of interlocking features to help secure the battery cell stack to the shell cavity.

[0017] According to one or more embodiments of this aspect, the first plurality of interlocking features are coupled to the second plurality of interlocking features by an adhesive that is at least one of a gap-filling epoxy and a structural adhesive.

[0018] According to one or more embodiments of this aspect, the battery assembly further includes a top cover and a battery management unit BMU, the top cover including a top hole and an inner surface, the BMU is attached to the top surface of the battery cell stack, the BMU includes a connector port and a gasket, the connector port is used to provide power to an external device, and when the connector port is set to pass through the top hole, the gasket is sealed to the inner surface of the top cover.

[0019] According to one or more embodiments of this aspect, the battery assembly further includes a temperature sensor including a first end and a second end, the first end being pressed against a first surface of a first battery cell among the plurality of battery cells, and the second end being attached to the BMU.

[0020] According to one or more embodiments of this aspect, a top cover is attached to the battery housing and the battery cell stack.

[0021] According to one or more embodiments of this aspect, each of the plurality of battery cells is a cylindrical battery cell, each of the plurality of battery cells has a battery circumference and a battery length, each of the plurality of cavities is a cylindrical cavity, each of the plurality of cavities has a first end at a first outer surface, a second end at a second outer surface, and a portion between the first outer surface and the second outer surface, the circumference of the first end is smaller than the battery circumference, the circumference of the second end is smaller than the battery circumference, the circumference of the portion between the first outer surface and the second outer surface is at least as large as the battery circumference and its length is approximately equal to the battery length.

[0022] According to another aspect of the present disclosure, a method for manufacturing a battery assembly is provided. The method includes placing each of a plurality of battery cells into a corresponding cavity in a first plurality of cavities of a first battery cell stack panel of a battery cell stack, the first battery cell stack panel having a first inner surface and a first outer surface, each of the plurality of battery cells having a battery perimeter, each of the first plurality of cavities having a first end at the first inner surface and a second end at the first outer surface, the perimeter of the first end being at least as large as the battery perimeter, and the perimeter of the second end being less than the battery perimeter. The method further includes attaching a second battery cell stack panel to the first battery cell stack panel to form a battery cell stack, the second battery cell stack panel having a second plurality of cavities, the second battery cell stack panel having a second inner surface and a second outer surface, each of the second plurality of cavities having a first end at the second inner surface and a second end at the second outer surface, the perimeter of the first end being at least as large as the battery perimeter, the perimeter of the second end being less than the battery perimeter, the first end of each of the second plurality of cavities being aligned with the corresponding first end of the corresponding cavity in the first plurality of cavities, and the first inner surface being aligned with the second inner surface. The method further includes: attaching a battery management unit (BMU) to the first surface of the battery cell stack; and inserting the battery cell stack into the battery housing.

[0023] According to one or more embodiments of this aspect, the method further includes: applying an adhesive to a first plurality of interlocking features on an inner surface of a cavity of a battery case; and inserting a battery cell stack into the battery case so that a second surface of the battery cell stack is aligned with the inner surface of the cavity of the battery case, the second surface of the battery cell stack including a second plurality of interlocking features aligned with the first plurality of interlocking features using an adhesive, the adhesive being at least one of a gap-filling epoxy resin and a structural adhesive.

[0024] According to one or more embodiments of this aspect, the first plurality of interlocking features includes at least one of guide ribs and interlocking circular features, and the second plurality of interlocking features includes at least one of guide ribs and interlocking circular features.

[0025] According to one or more embodiments of this aspect, the method further includes: attaching a first plurality of bus bars to the surface of a first battery cell stack panel, each of the first plurality of bus bars including a plurality of plates and pad connectors; attaching a second plurality of bus bars to the surface of a second battery cell stack panel, each of the second plurality of bus bars including a plurality of plates and pad connectors; for each of the first plurality of bus bars, welding the plates of each bus bar to at least one of the positive terminal and the negative terminal of at least one of the plurality of battery cells via the second end of the corresponding cavity in the first plurality of cavities; for each of the second plurality of bus bars, welding the plates of each bus bar to at least one of the positive terminal and the negative terminal of at least one of the plurality of battery cells via the second end of the corresponding cavity in the second plurality of cavities; for each of the first plurality of bus bars, welding the pad connector of the bus bar to the corresponding pad of the BMU; and for each of the second plurality of bus bars, welding the pad connector of the bus bar to the corresponding pad of the BMU.

[0026] According to one or more embodiments of this aspect, the method further includes: attaching a top cover to a first surface of the battery cell stack, the top cover comprising an inner surface, an outer surface, and a hole passing through the top cover from the outer surface to the inner surface; and connecting the inner surface of the top cover to a gasket of a connector port provided on the BMU, the gasket being sized to seal the hole when the connector port is provided to pass through the hole.

[0027] According to one or more embodiments of this aspect, the method further includes attaching a top cover to the battery housing and the battery cell stack.

[0028] According to one or more embodiments of this aspect, each of the plurality of battery cells is a cylindrical battery cell having a corresponding battery length, and each of the first plurality of cavities and the second plurality of cavities is a cylindrical cavity having approximately half the corresponding battery length.

[0029] According to one or more embodiments of this aspect, each of the plurality of battery cells is disposed perpendicular to the first battery cell stack panel and the second battery cell stack panel.

[0030] In accordance with one or more embodiments of this aspect, a first cavity in the first plurality of cavities includes a vent area adjacent to the first outer surface.

[0031] According to one or more embodiments of this aspect, the method further includes attaching a temperature sensor to the battery assembly, the temperature sensor comprising a first end and a second end, the first end being pressed against a first surface of a first battery cell among the plurality of battery cells, and the second end being attached to the BMU. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] A more complete understanding of the embodiments described herein and their attendant advantages and features will be more readily appreciated by reference to the following detailed description considered in conjunction with the accompanying drawings, in which:

[0033] Figure 1 is a perspective view of an exemplary battery assembly according to an aspect of the present disclosure;

[0034] Figure 2 According to one aspect of the present disclosure Figure 1 An exploded view of a battery assembly;

[0035] Figure 3 is an exploded view of a battery cell stack according to one aspect of the present disclosure;

[0036] Figure 4 According to one aspect of the present disclosure Figure 3 A perspective view of a battery cell stack;

[0037] Figure 5 According to one aspect of the present disclosure Figure 3 A perspective view of a portion of a battery cell stack;

[0038] Figure 6 According to one aspect of the present disclosure Figure 3 a cutaway perspective view of a portion of a battery cell stack;

[0039] Figure 7 According to one aspect of the present disclosure Figure 6 A close-up of a portion of a cutaway perspective view;

[0040] Figure 8 According to one aspect of the present disclosure Figure 3 A perspective view of a bottom surface of a battery cell stack;

[0041] Fig. 9 is a perspective view of a battery housing according to one aspect of the present disclosure;

[0042] Fig.10 According to one aspect of the present disclosure Figure 1 A cutaway perspective view of a battery assembly;

[0043] Fig.11 is a flow chart of an exemplary method of assembling a battery assembly according to one or more embodiments of the present invention; and

[0044] Fig.12 is a flow chart of another exemplary method of assembling a battery assembly according to one or more embodiments of the present invention. DETAILED DESCRIPTION

[0045] Before describing the exemplary embodiments in detail, it should be noted that the embodiments reside primarily in a combination of device components and manufacturing steps associated with battery assemblies. Accordingly, device and method components are represented by conventional symbols in the drawings where appropriate, and only those specific details that may be relevant to understanding the embodiments of the present disclosure are shown, so as not to obscure the present disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0046] As used herein, relational terms such as "first" and "second", "top" and "bottom", etc. may be used only to distinguish one entity or element from another entity or element, and do not necessarily require or imply any physical or logical relationship or order between these entities or elements. The terms used herein are for the purpose of describing specific embodiments only and are not intended to limit the concepts described herein. As used herein, the singular forms "a / an" and "the" may also be intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that when the term "comprises / comprising / includes / including" is used herein, it specifies the presence of stated features, wholes, steps, operations, elements and / or parts, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or groups thereof.

[0047] Unless otherwise defined, all terms (including technical terms and scientific terms) used herein have the same meaning as those commonly understood by those of ordinary skill in the art to which the present disclosure belongs. It should be further understood that, unless explicitly defined herein, the terms used herein should be interpreted as having a meaning consistent with the context of this specification and the meaning in the relevant field, and will not be interpreted in an idealized or overly formal sense.

[0048] In the embodiments described herein, connection terms such as "in communication with..." may be used to indicate electrical communication or data communication, which may be achieved, for example, by physical contact, induction, electromagnetic radiation, radio signaling, infrared signaling, or optical signaling. Those skilled in the art will appreciate that multiple components may interoperate and that various modifications and variations may be made to achieve electrical communication and data communication.

[0049] In some embodiments described herein, the terms "coupled," "connected," and the like may be used herein to indicate connections, but not necessarily directly, and may include wired and / or wireless connections.

[0050] The terms used herein are for the purpose of describing specific embodiments only and are not intended to limit the concepts described herein. As used herein, the singular forms "a / an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that when the term "comprises / comprising / includes / including" is used herein, it specifies the presence of stated features, wholes, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or groups thereof.

[0051] Generally speaking, the disclosed embodiments may relate to battery assemblies and / or systems, and methods of manufacturing battery assemblies and / or systems that reduce or eliminate the need for expensive epoxy resins, are easily upgradeable, and allow for proper ventilation of battery cells within the assembly. Such battery assemblies may be used, for example, as auxiliary batteries for vehicles, but they are not limited thereto and may be suitable for any application requiring a battery assembly.

[0052] Referring to the drawings, wherein like elements may be indicated by like reference numerals, Figure 1 , a simplified diagram of a battery assembly 10 according to an embodiment is shown, which includes a battery housing 12 and a (battery cell stack) cover 14 that can be attached to the battery housing 12. The connector port 16 is configured to communicate power and / or data with an external device (which is in electronic communication with the battery assembly 10 in the vehicle).

[0053] Now will be Figure 2 An exemplary embodiment of the battery assembly 10 discussed in the above paragraphs is described in Figure 1 1 is an exploded view of a battery assembly 10. As depicted, the battery assembly 10 may include a battery cell stack cover 14, a battery management unit (BMU) 18 configured to perform one or more battery management functions, a connector port 16 of the BMU 18, a battery cell stack 20, nickel-plated steel bus bars 22a-c and copper bus bars 24a-b coupled to the battery cell stack 20, a temperature sensor 26 coupled to the battery cell stack 20, and a battery housing 12. Each of the bus bars 22a-c may have a plurality of battery connector members 23. Each of the bus bars 24a-b may have a plurality of battery connector members 25. The temperature sensor 26 may be attached to the battery cell stack 20. The battery housing 12 may include a plurality of (e.g., four) walls defining a housing cavity for receiving the battery cell stack 20, the battery cell stack cover 14, the BMU 18, the temperature sensor 26, and the bus bars 22a-c and 24a-b.

[0054] Figure 3. The battery cell stack 20 may include an upper battery cell stack panel 28, a bottom battery cell stack panel 30, and sixteen battery cells 32a-p (collectively, battery cells 32), although any number of battery cells may be used in a number and configuration to provide sufficient energy density, voltage, current, capacity, etc. for a particular application. Moreover, although the battery cells 32 are shown as cylinders, it should be understood that the battery cells 32 may have other geometric configurations, such as rectangular prisms, etc. The upper battery cell stack panel 28 may include sixteen cavities 34a-p (collectively, cavities 34), i.e., at least one cavity is allocated to each battery cell 32. The bottom battery cell stack panel 30 may include sixteen cavities 36a-p (collectively, cavities 36), i.e., one cavity is allocated to each battery cell 32. In some embodiments, each of the battery cells 32 may have a cylindrical shape having a circumference configured to be equal to or slightly smaller than the circumference of each of the cylindrical cavities 34 and 36 so that the cylindrical battery cells 32 fit securely into the cylindrical cavities 34 and 36 with sufficient space to accommodate changes caused by temperature variations, manufacturing conditions, etc. Figure 3 In the example shown in , the battery cells 32 and the cavities 34 and 36 are cylindrical in shape, but any shape of battery cells and cavities may be used without departing from the scope of the present invention. In some embodiments, for example, the shape of each battery cell is similar to the shape of each corresponding cavity, wherein the size of the cavity is set to be equal to or slightly larger than the shape of the battery cell so that the battery cell is securely assembled in the cavity. The upper battery cell stack panel 28 may have an inner surface 40 and an outer surface 38 opposite thereto, wherein the cavity 34 is arranged perpendicular to the plane of the outer surface 38 and the plane of the inner surface 40. Similarly, the bottom battery cell stack panel 30 may have an inner surface 44 and an outer surface 42 opposite thereto, wherein the cavity 36 is arranged perpendicular to the plane of the outer surface 42 and the plane of the inner surface 44. The inner surface 40 of the upper battery cell stack panel 28 may be configured to couple with the inner surface 44 of the bottom battery cell stack panel 30.

[0055] Still reference Figure 3 , cavities 34 and 36 may be distributed in a similar pattern on the upper battery cell stack panel 28 and the bottom battery cell stack panel 30, respectively, so that when the upper battery cell stack panel 28 and the bottom battery cell stack panel 30 are coupled together at their inner surfaces 40 and 44, the cavities 34 align with the cavities 36 to form cavities 46a-p ( Figure 4The length of the battery cells 32 may be configured to be substantially equal to or slightly less than the length of the cavities 46, such that when the upper battery cell stack panel 28 and the bottom battery cell stack panel 30 are coupled together at their inner surfaces 40 and 44 to form the cavities 46, the length of each cavity 46 is substantially equal to or slightly greater than the length of the battery cells 32, such that each battery cell 32 is securely received in the corresponding cavity 46.

[0056] Still reference Figure 3 , the outer surface 38 of the upper battery cell stack panel 28 may include sixteen holes 48a-p (collectively referred to as holes 48) defined by circular segments of the outer surface 38 corresponding to the outer ends of the cavities 34. The circumference of each (circular) hole 48 may be at most slightly less than the circumference of each battery cell 32, so that when the battery cell 32 can be placed in the cavity 34 via the inner surface 40 of the upper battery cell stack panel 28, the battery cell 32 is retained within the corresponding cavity 34. Similarly, the outer surface 42 of the bottom battery cell stack panel 30 may include sixteen circular holes 50a-p (collectively referred to as circular holes 50), which are defined by circular segments of the outer surface 42 corresponding to the outer ends of the cavities 36. The circumference of each circular hole 50 is at most slightly less than the circumference of each battery cell 32, so that when the battery cell 32 can be placed in the cavity 36 via the inner surface 44 of the bottom battery cell stack panel 30, the battery cell 32 is retained within the corresponding cavity 36. Although in the above examples, the circular apertures 48a-p are described as being circular, the apertures 48a-p may be any shape without departing from the scope of the present disclosure.

[0057] Still reference Figure 3 , the upper battery cell stack panel 28 may include a surface 52, and the bottom battery cell stack panel 30 may include a surface 54. The upper battery cell stack panel 28 and the bottom battery cell stack panel 30 may have similar shapes and sizes. The upper battery cell stack panel 28 and the bottom battery cell stack panel 30 may be coupled together at the inner surface 40 and the inner surface 44, and the surface 52 of the upper battery cell stack panel 28 may be coupled to the surface 54 of the bottom battery cell stack panel 30 to form a top surface 55. The coupling may be achieved using screws, adhesives, and / or other suitable attachment techniques known in the art. The top surface 55 may include threaded holes and / or other elements for assembling the (top) surface 55 to the battery cell stack cover 14 ( Figure 2 The top surface 55 of the bottom battery cell stack panel 30 may include a receptacle 56 configured to hold the temperature sensor 26 in place.

[0058] Still reference Figure 3, each of the battery cells 32a-p may include a positive terminal end 58a-p (collectively referred to as the positive terminal end 58) and a negative terminal end 60a-p (collectively referred to as the negative terminal end 60). The battery cells 32 may be arranged in a grid arrangement, wherein the orientation of the terminals of the battery cells varies row by row or column by column. For example, the battery cells 32a-d in row 1 may be arranged so that the positive terminal ends 58a-d are oriented facing the circular holes 48a-d of the upper battery cell stack panel 28, while the battery cells 32e-h in row 2 may be arranged so that the negative terminal ends 60e-h are oriented facing the circular holes 48e-h of the upper battery cell stack panel 28. Other patterns and / or orientations may be used without departing from the scope of the present disclosure. In addition, in the above example, sixteen battery cells 32 are stored in sixteen cavities 46, but various numbers of battery cells 32 and / or cavities 46 may be used without departing from the scope of the present disclosure. Further, the number of battery cells 32 may be equal to or less than the number of cavities 46.

[0059] Figure 4 is a perspective view of the assembled battery cell stack 20. The upper battery cell stack panel 28 and the bottom battery cell stack panel 30 can have similar shapes and sizes, or can have different shapes and sizes, as long as the cavity 34 is aligned with the cavity 36 when the upper battery cell stack panel 28 and the bottom battery cell stack panel 30 are attached together. The upper battery cell stack panel 28 and the bottom battery cell stack panel 30 can be attached together at the inner surface 40 and the inner surface 44, and the surface 52 of the upper battery cell stack panel 28 can be attached to the surface 54 of the bottom battery cell stack panel 30 to form a top surface 55. The attachment can be achieved using adhesives, screws, and / or any other suitable assembly techniques known in the art. The connection can be reversible, for example to allow the battery cells 32 to be repaired, replaced, and / or recycled.

[0060] Still reference Figure 4, the BMU 18 (which includes a circuit board 62 and a connector port 16) can be coupled to the top surface 55. The connector port 16 can include a gasket 61 disposed around the periphery of the connector port 16. The gasket 61 can be formed of rubber and / or some other suitable sealing material. The circuit board 62 can include pads 64a-e (collectively referred to as pads 64) (e.g., at least one pad for each of the bus bars 22a-c and at least one pad for each of the bus bars 24a-b) and a temperature sensor port 66. In some embodiments, the circuit board 62 can be a printed circuit board. In some embodiments, the BMU 18 can include one or more controllers, one or more processors, a processing circuit system, one or more memory devices, and / or one or more internal / external signal connectors disposed on the circuit board 62. In some embodiments, the BMU can include multiple circuit boards 62.

[0061] Still reference Figure 4 , bus bars 22a-b and 22c ( Figure 2 Each of the bus bars 24a-b (shown in FIG. 1 ) may have a top end 68a-c formed perpendicular to the body of the bus bars 22a-c. Similarly, the bus bars 24a-b ( Figure 2 Each of the top ends 68a-b and 68c and the top ends 70a-b can be connected to the corresponding pads 64a-e of the circuit board 62.

[0062] Still reference Figure 4 , busbars 24a-b( Figure 2 Each of the Figure 2 . The battery connector members 25 can be coupled to the positive terminal 58 and / or the negative terminal 60 of each of the battery cells 32 via the (circular) hole 48 or the (circular) hole 50. Similarly, each of the bus bars 22a-c can have a plurality of battery connector members 23. The battery connector members 23 can be coupled to the positive terminal 58 and / or the negative terminal 60 of each of the battery cells 32 via the (circular) hole 48 or the (circular) hole 50. Figure 3 A plurality of positive terminals 58 and a plurality of negative terminals 60 are also referred to herein as positive terminals 58 and negative terminals 60 for simplicity.

[0063] Still reference Figure 4, the bottom battery cell stack panel 30 may include bus bar receptacles 76a-b into which the bottom ends 78a-b of the bus bars 22a-b may be inserted to securely hold the bus bars 22a-b in place on the outer surface 42 of the bottom battery cell stack panel 30. The outer surface 42 of the bottom battery cell stack panel 30 may include hooks 80a-b that may be coupled to the bus bars via holes 82a-b in the bus bars 22a-b to securely hold the bus bars 22a-b in place on the outer surface 42 of the bottom battery cell stack panel 30. Similarly, the upper battery cell stack panel 28 may include bus bar receptacles 84a-c ( Figure 3 ), bus bars 24a-b ( Figure 2 The bottom end 86a-b (shown in Figure 2 ) and bus bar 22c ( Figure 2 The bottom end 78c (shown in Figure 2 ) can be inserted into these bus bar receptacles to securely hold the bus bars 24a-b and the bus bar 22c to the outer surface 38 (shown in FIG. 28 ) of the upper battery cell stack panel 28. Figure 3 The outer surface 38 of the upper battery cell stack panel 28 may include hooks 88a-c ( Figure 3 ), these hooks can be connected via holes 90a-b in bus bars 24a-b ( Figure 2 ) and the hole 82c (shown in FIG. Figure 2 ) are coupled to the bus bars to securely hold the bus bars 24a-b and the bus bar 22c in place on the outer surface 38 of the upper battery cell stack panel 28.

[0064] In some embodiments, busbars 22a-c may be nickel-plated steel, however busbars 22a-c may be constructed of any suitable conductive material known in the art. In some embodiments, busbars 24a-b may be copper and / or copper-plated, however busbars 24a-b may be constructed of any suitable conductive material known in the art.

[0065] Figure 5 2 is a cutaway perspective view of a portion of a battery cell stack 20 including a battery cell 32a inserted into a bottom battery cell stack cavity 36a of a bottom battery cell stack panel 30. The temperature sensor 26 is shown inserted into a receptacle 56, which may be, for example, designated temperature sensor receptacle 56. The temperature sensor 26 may include a temperature sensor connector 92 for interfacing with a circuit board 62 ( Figure 4 The temperature sensor port 66 (shown in FIG. Figure 41 and 12) for transmitting data and / or control signals and / or power between the temperature sensor 26 and the circuit board 62 and / or the connector port 16 and / or the BMU 18. The temperature sensor 26 may include a body 93 shaped to fit into the temperature sensor receptacle 56. The temperature sensor may include a foam pad 94 for providing close contact with the battery cell 32a, and / or for ensuring that the sensor circuit system 96 accurately reads the temperature of the battery cell 32a, and / or for insulating the sensor circuit system 96 from the temperature sensor receptacle 56. The foam pad 94, the sensor circuit system 96, and / or the temperature sensor connector 92 may be disposed on the body 93.

[0066] Figure 6 50a. The diagram of the embodiment of the present invention is a perspective cutaway view of a battery cell 32a inserted into a combined cavity 46a formed by coupling the cavity 34a of the upper battery cell stack panel 28 with the cavity 36a of the bottom battery cell stack 30. A circuit board 62 is mounted on the (top) surface 55. The temperature sensor 26 is inserted into the receptacle 56 and attached to the circuit board 62. The connector port 16 is coupled to the circuit board 62. The connector port 16 may include a gasket 61. The positive terminal 58a of the battery cell 32a is disposed adjacent to the outer surface 42 and the hole 50a. Figure 7 The Figure 6 The region 100 in FIG. 4 is a subsection of the interface between the battery cell 32 a and the hole 50 a of the outer surface 42 .

[0067] Figure 7 yes Figure 6 100. The wall of the structural element 102 in the cavity 36a and the positive terminal 58a of the battery cell 32a form a vent cavity 104. By introducing the vent cavity 104 in the cavity 36a, rather than making the battery cell 32a flush with the structural element 102, the battery cell 32a is able to vent and / or expand, thereby preventing undesirable heat and / or pressure accumulation. Similar structural elements 102 and vent cavities 104 can be included in some or all of the cavities 34, cavities 36, and / or cavities 46.

[0068] Figure 8 1 is a perspective view of an assembled battery cell stack 20 coupled to the cover 14. The bottom surface 106 of the battery cell stack 20 is formed by coupling the upper battery cell stack panel 28 with the bottom battery cell stack panel 30. The bottom surface 106 may include rib features 108 and interlocking circular features 110 to help secure the battery cell stack 20 to the inner cavity 112 ( Fig. 9 ). Although the interlocking circular features 110 are described as being circular, any shape may be used without departing from the scope of the present disclosure.

[0069] Fig. 9 1 is a perspective view of a battery housing 12. The battery housing 12 may include an inner cavity 112 formed by the walls of the housing 12, and further include a rim 114 around the perimeter of the inner cavity 112 at a vertical interface of the walls forming the inner cavity 112 and an upper surface 115. The bottom surface 116 of the cavity 112 may include guide and retention ribs 118 and interlocking circular features 120 for coupling with the rib features 108 and / or interlocking circular features 110 of the bottom surface 106 of the battery cell stack 20. The upper surface 115 may include slits 122 to help secure the cover 14 to the battery housing 12, such as via tabs on the cover 14. Although the interlocking circular features 120 are described as being circular, any shape may be used without departing from the scope of the present disclosure.

[0070] Fig.10 1 is a cross-sectional view of an assembled battery assembly 10, wherein the assembled battery cell stack 20 is coupled to the cover 14 and inserted into the cavity 112 of the battery housing 12. The tabs 124 of the cover 14 can be inserted into the slits 122 to help secure the cover 14 to the battery housing 12. The cover 14 is coupled to the battery cell stack 20 so that the gasket 61 of the BMU connector port 16 forms a seal with the inner surface 126 of the top cover (i.e., the cover) 14.

[0071] Still reference Fig.10 , the rib features 108 of the battery cell stack 20 can be secured to the guide and retention ribs 118 of the battery case 12 using a caulking epoxy 128 (although any suitable epoxy / adhesive can be used), and the interlocking circular features 110 of the battery cell stack 20 can be coupled to the interlocking circular features 120 of the battery case 12 using a caulking epoxy 128 (although any suitable epoxy / adhesive can be used). The rim 114 of the battery case 12 is coupled to the inner surface 126 of the cover 14 using a structural adhesive 130 (although any suitable epoxy / adhesive can be used).

[0072] Fig.111 is a flow chart of an exemplary method of assembling a battery assembly 10 according to one or more embodiments of the present invention. One or more of the blocks described herein may be performed during manufacture of the battery assembly 10. The manufacturing method includes sliding (block S100) each of a plurality of battery cells 32 into a corresponding cavity 36a-p in a first plurality of cavities 36 of a first panel 30 (e.g., a bottom panel) of a battery cell stack 20, each of the plurality of battery cells 32a-p having a battery perimeter, each cavity 36a-p in the first plurality of cavities 36 having a first end and a second end opposite the first end, the first end having a perimeter at least as large as the battery perimeter, and the second end having a perimeter less than the battery perimeter. The method further includes attaching (block S102) a second (e.g., upper) battery cell stack panel 28 to the first battery cell stack panel 30 to form the battery cell stack 20, the second battery cell stack panel 28 having a second plurality of cavities 34, each of the second plurality of cavities 34 having a first end and a second end opposite the first end, the first end having a perimeter at least as large as the perimeter of the battery, the second end having a perimeter less than the perimeter of the battery, and the first end of each of the second plurality of cavities 34 being aligned with a corresponding first end of the first plurality of cavities 36. The method further includes attaching (block S104) a battery management unit BMU 18 to the first surface of the battery cell stack 20.

[0073] Fig.121 is a flow chart of another exemplary method of assembling a battery assembly 10 according to one or more embodiments of the present invention. One or more of the blocks described herein may be performed during manufacture of the battery assembly 10. The method includes placing (block S106) each of a plurality of battery cells 32 into a corresponding cavity 36 of a first plurality of cavities 36 of a first battery cell stack panel 30 of a battery cell stack 20, the first battery cell stack panel 30 having a first inner surface 44 and a first outer surface 42, each of the plurality of battery cells 32 having a battery perimeter, each of the first plurality of cavities 36 having a first end at the first inner surface and a second end at the first outer surface 42, the first end having a perimeter at least as large as the battery perimeter, and the second end having a perimeter less than the battery perimeter. The method further includes attaching (block S108) a second battery cell stack panel 28 to the first battery cell stack panel 30 to form the battery cell stack 20, the second battery cell stack panel 28 having a second plurality of cavities 34, the second battery cell stack panel 28 having a second inner surface 40 and a second outer surface 38, each of the second plurality of cavities 34 having a first end at the second inner surface 40 and a second end at the second outer surface 38, the first end having a perimeter at least as large as the perimeter of the battery, the second end having a perimeter less than the perimeter of the battery, the first end of each of the second plurality of cavities 34 being aligned with a corresponding first end of a corresponding cavity 36 in the first plurality of cavities 36, and the first inner surface being aligned with the second inner surface. The method further includes: attaching (block S110) a battery management unit BMU 18 to the first surface of the battery cell stack 20; and inserting (block S112) the battery cell stack 20 into the battery housing 12.

[0074] According to one or more embodiments of this aspect, the method further includes: applying an adhesive to a first plurality of interlocking features 120 of an inner surface 126 of a cavity of a battery housing 12; and inserting a battery cell stack 20 into the battery housing 12 so that a second surface of the battery cell stack 20 is aligned with the inner surface 126 of the cavity of the battery housing 12, the second surface of the battery cell stack 20 including a second plurality of interlocking features 110 aligned with the first plurality of interlocking features 120 using an adhesive, the adhesive being at least one of a gap-filling epoxy resin and a structural adhesive.

[0075] According to one or more embodiments of this aspect, the first plurality of interlocking features 120 includes at least one of guide ribs and interlocking circular features, and the second plurality of interlocking features 110 includes at least one of guide ribs and interlocking circular features.

[0076] According to one or more embodiments of this aspect, the method further includes: attaching a first plurality of bus bars 22 to a surface of a first battery cell stack panel 30, each of the first plurality of bus bars 22 including a plurality of plates and pad connectors; attaching a second plurality of bus bars to a surface of a second battery cell stack panel 28, each of the second plurality of bus bars including a plurality of plates and pad connectors; for each bus bar in the first plurality of bus bars, welding each of the plates of the bus bars to at least one of the battery cells in the plurality of battery cells 32 via a second end of a corresponding cavity 36 in the first plurality of cavities 36; at least one of the positive terminal 58 and the negative terminal 60; for each bus bar 22 in the second plurality of bus bars 22, welding each of the plates of the bus bar 22 to at least one of the positive terminal 58 and the negative terminal 60 of at least one battery cell in the plurality of battery cells 32 via the second end of the corresponding cavity in the second plurality of cavities 34; for each bus bar 22 in the first plurality of bus bars 22, welding the pad connector of the bus bar to the corresponding pad of the BMU 18; and for each bus bar 22 in the second plurality of bus bars 22, welding the pad connector of the bus bar to the corresponding pad of the BMU 18.

[0077] According to one or more embodiments of this aspect, the method further includes: attaching a cover 14 to a first surface of the battery cell stack 20, the cover 14 including an inner surface, an outer surface, and a hole passing through the cover 14 from the outer surface to the inner surface; and connecting the inner surface of the cover 14 to a gasket 61 of a connector port provided on the BMU 18, the size of the gasket 61 being set to seal the hole when the connector port 16 is set to pass through the hole.

[0078] According to one or more embodiments of this aspect, the method further includes attaching the cover 14 to the battery housing 12 and the battery cell stack 20 .

[0079] According to one or more embodiments of this aspect, each of the plurality of battery cells 32 is a cylindrical battery cell 32 having a corresponding battery length, and each of the first plurality of cavities and the second plurality of cavities 34, 36 is a cylindrical cavity having approximately half the corresponding battery length.

[0080] According to one or more embodiments of this aspect, each of the plurality of battery cells 32 is disposed perpendicularly to the first battery cell stack panel 30 and the second battery cell stack panel 28. Here, "vertically" may be relative to an axis extending from the bottom surface 116 of the battery housing 12 to the cover / lid 14, on which the BMU 18 may be mounted.

[0081] According to one or more embodiments of this aspect, a first cavity 36a of the first plurality of cavities 36 includes a vent cavity / vent area 104 adjacent to the first exterior surface.

[0082] According to one or more embodiments of this aspect, the method further includes attaching a temperature sensor 26 to the battery assembly 10 , the temperature sensor 26 including a first end and a second end, the first end being pressed against a first surface of a first battery cell 32 among the plurality of battery cells 32 , and the second end being attached to the BMU 18 .

[0083] Some embodiments are described herein with reference to flowchart illustrations and / or block diagrams of methods and devices. It should be understood that the functions / actions indicated in the blocks may not occur in the order indicated in the operation diagram. For example, depending on the functions / actions involved, two blocks shown in succession may actually be performed substantially simultaneously, or the blocks may sometimes be performed in the opposite order. Although some figures include arrows on communication paths to illustrate the primary direction of communication, it should be understood that communication may occur in the direction opposite to the arrows depicted.

[0084] Many different embodiments have been disclosed herein in conjunction with the above description and accompanying drawings. It should be understood that literally describing and illustrating every combination and subcombination of these embodiments would be overly repetitive and obscure. Accordingly, all embodiments may be combined in any manner and / or combination, and this specification, including the accompanying drawings, should be interpreted as constituting a complete written description of all combinations and subcombinations of the embodiments described herein and the manner and process of making and using them, and should support the claim for protection of any such combination or subcombination.

[0085] Those skilled in the art will appreciate that the present embodiments may not be limited to what may have been specifically shown and described above. In addition, unless otherwise noted above, it should be noted that all drawings may not be drawn to scale. In view of the above teachings, various modifications and changes are possible without departing from the scope of the appended claims.

Claims

1. A battery assembly (10), comprising: A battery housing (12), the battery housing comprising a housing cavity (112); A battery cell stack (20), the battery cell stack being arranged in the housing cavity (112), the battery cell stack (20) comprising: a first battery cell stack panel (30), the first battery cell stack panel comprising a first inner surface and a first outer surface; a second battery cell stack panel (28), the second battery cell stack panel comprising a second inner surface and a second outer surface, the first battery cell stack panel (30) and the second battery cell stack panel (28) being coupled together at respective first and second inner surfaces (40), (44); The coupled first battery cell stack panel (30) and the second battery cell stack panel (28) form a plurality of cavities (46), each of the plurality of cavities (46) extending from the first exterior surface (42) to the second exterior surface (38); and A plurality of battery cells (32), each of the plurality of battery cells (32) being disposed within a corresponding cavity (46) of the plurality of cavities (46).

2. The battery assembly (10) according to claim 1, wherein: The battery assembly (10) further comprises: A plurality of bus bars (22), each of the plurality of bus bars (22) being electrically coupled to at least one of a positive terminal (58) and a negative terminal (60) of at least one battery cell (32) via at least one hole (48) in at least one of the first outer surface (42) and the second outer surface (38).

3. The battery assembly (10) according to any one of claims 1 and 2, wherein: Each of the plurality of battery cells (32) is arranged perpendicular to the first battery cell stack panel (30) and the second battery cell stack panel (28).

4. The battery assembly (10) according to any one of claims 1 to 3, wherein: A first cavity (46) of the plurality of cavities (46) includes a vent region (104) adjacent the first exterior surface (42), the vent region being configured to ventilate a first battery cell of the plurality of battery cells (32).

5. The battery assembly (10) according to any one of claims 1 to 4, wherein: An inner bottom surface (116) of the housing cavity (112) includes a first plurality of interlocking features (120); and The bottom surface (106) of the battery cell stack (20) includes a second plurality of interlocking features (110), the first plurality of interlocking features (120) coupled to the second plurality of interlocking features (110) to help secure the battery cell stack (20) to the housing cavity (112).

6. The battery assembly (10) according to claim 5, wherein: The first plurality of interlocking features (120) is coupled to the second plurality of interlocking features (110) by an adhesive, the adhesive being at least one of: a gap filling epoxy and a structural adhesive.

7. The battery assembly (10) according to any one of claims 1 to 6, wherein: The battery assembly (10) further comprises: a top cover (14), the top cover comprising a top hole and an inner surface; and A battery management unit (BMU) (18) is attached to a top surface (55) of the battery cell stack (20), the BMU comprising: a connector port (16) for providing power to an external device; and A gasket (61) seals to the inner surface of the top cover (14) when the connector port (16) is disposed through the top hole.

8. The battery assembly (10) according to claim 7, wherein: The battery assembly (10) further includes a temperature sensor (26), the temperature sensor (26) including a first end and a second end, the first end being pressed against a first surface of a first battery cell (32) among the plurality of battery cells (32), and the second end being attached to the BMU (18).

9. The battery assembly (10) according to any one of claims 7 and 8, wherein: The top cover (14) is attached to the battery housing (12) and the battery cell stack (20).

10. The battery assembly (10) according to any one of claims 1 to 9, wherein: Each of the plurality of battery cells (32) is a cylindrical battery cell (32), each of the plurality of battery cells (32) has a battery circumference and a battery length, each of the plurality of cavities (46) is a cylindrical cavity, each of the plurality of cavities has: a first end at the first outer surface (42), the first end having a circumference less than the battery circumference; a second end at the second outer surface (38), the second end having a circumference less than the battery circumference; as well as The portion between the first outer surface (42) and the second outer surface (38) has a circumference at least as large as the circumference of the battery and a length approximately equal to the length of the battery.

11. A method for manufacturing a battery assembly (10), the method comprising: Placing (block S106) each of a plurality of battery cells (32) into a corresponding cavity (36) of a first plurality of cavities (36) of a first battery cell stack panel (30) of a battery cell stack (20), the first battery cell stack panel (30) having a first inner surface (44) and a first outer surface (42), each of the plurality of battery cells (32) having a battery perimeter, each of the first plurality of cavities (36) having a first end at the first inner surface (44) and a second end at the first outer surface (42), the first end having a perimeter at least as large as the battery perimeter and the second end having a perimeter less than the battery perimeter; Attaching (block S108) a second battery cell stack panel (28) to the first battery cell stack panel (30) to form a battery cell stack (20), the second battery cell stack panel (28) having a second plurality of cavities (34), the second battery cell stack panel (28) having a second inner surface (40) and a second outer surface (38), each of the second plurality of cavities (34) having a first end at the second inner surface (40) and a second end at the second outer surface (38), the first end having a perimeter at least as large as the battery perimeter and the second end having a perimeter less than the battery perimeter, the first end of each of the second plurality of cavities (34) being aligned with a corresponding first end of a corresponding cavity in the first plurality of cavities (36), and the first inner surface (44) being aligned with the second inner surface (40); attaching (block S110) a battery management unit (BMU) (18) to a first surface (55) of the battery cell stack (20); and The battery cell stack (20) is inserted (block S112) into the battery housing (12).

12. The method of claim 11, wherein: The method further comprises: applying adhesive to a first plurality of interlocking features (120) of an inner surface (116) of a cavity (112) of the battery housing (12); and The battery cell stack (20) is inserted into the cavity (112) of the battery housing (12) so that the second surface (106) of the battery cell stack (20) is aligned with the inner surface (116) of the cavity (112) of the battery housing (12), and the second surface (106) of the battery cell stack (20) includes a second plurality of interlocking features (110), and the second plurality of interlocking features are aligned with the first plurality of interlocking features (120) using the adhesive, and the adhesive is at least one of a gap-filling epoxy resin and a structural adhesive.

13. The method of claim 12, wherein: The first plurality of interlocking features (120) includes at least one of guide ribs and interlocking circular features; and The second plurality of interlocking features (110) includes at least one of guide ribs and interlocking circular features.

14. The method according to any one of claims 11 to 13, wherein: The method further comprises: attaching a first plurality of bus bars (22) to a surface of the first battery cell stack panel (30), each of the first plurality of bus bars (22) comprising a plurality of plate and pad connectors; attaching a second plurality of bus bars (22) to a surface of the second battery cell stack panel (28), each of the second plurality of bus bars (22) comprising a plurality of plate and pad connectors; for each bus bar (22) of the first plurality of bus bars (22), welding each of the plurality of plates of the bus bar to at least one of a positive terminal (58) and a negative terminal (60) of at least one battery cell (32) of the plurality of battery cells (32) via a second end of a corresponding cavity (36) of the first plurality of cavities (36); for each bus bar (22) of the second plurality of bus bars (22), welding each of the plurality of plates of the bus bar (22) to at least one of the positive terminal (58) and the negative terminal (60) of at least one battery cell of the plurality of battery cells (32) via a second end of a corresponding cavity (34) of the second plurality of cavities (34); For each bus bar (22) of the first plurality of bus bars (22), soldering a pad connector of the bus bar (22) to a corresponding pad of the BMU (18); and For each bus bar (22) of the second plurality of bus bars (22), a pad connector of the bus bar (22) is soldered to a corresponding pad of the BMU (18).

15. The method according to any one of claims 11 to 14, wherein: The method further comprises: attaching a top cover (14) to a first surface of the battery cell stack (20), the top cover (14) comprising an inner surface, an outer surface, and a hole through the top cover (12) from the outer surface to the inner surface; and The inner surface of the top cover is coupled to a gasket (61) of a connector port (16) disposed on the BMU (18), the gasket (61) being sized to seal the hole when the connector port (16) is disposed through the hole.

16. The method of claim 15, wherein: The method further includes attaching the top cover (14) to the battery housing (12) and the battery cell stack (20).

17. The method according to any one of claims 11 to 16, wherein: Each of the plurality of battery cells (32) is a cylindrical battery cell (32) having a corresponding battery length, and each of the first plurality of cavities and the second plurality of cavities (34), (36) is a cylindrical cavity having approximately half of the corresponding battery length.

18. The method according to any one of claims 11 to 17, wherein: Each of the plurality of battery cells (32) is disposed perpendicular to the first battery cell stack panel (30) and the second battery cell stack panel (28).

19. The method according to any one of claims 11 to 18, wherein: A first cavity (36) of the first plurality of cavities (36) includes a vent area (104) adjacent the first exterior surface (42).

20. The method according to any one of claims 11 to 19, wherein: The method further includes attaching a temperature sensor (26) to the battery assembly (10), the temperature sensor (26) including a first end and a second end, the first end being pressed against a first surface of a first battery cell (32) among the plurality of battery cells (32), and the second end being attached to the BMU (18).

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