Battery subassembly

Abstract

Aspects of the present disclosure relate to various features of a battery subassembly, such as a battery module. The battery subassembly may be implemented in an electric vehicle or building.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 511,609, filed on June 30, 2023, entitled “Battery Subassembly,” the disclosure of which is hereby incorporated herein in its entirety. Background Art

[0003] Batteries are commonly used as a source of electrical power, including as a source of electrical power for electric vehicles that include wheels driven by electric motors that receive power from the batteries.

[0004] Aspects of the subject technology may help improve the efficiency and / or range of electric vehicles, which may help mitigate climate change by reducing greenhouse gas emissions. Summary of the invention

[0005] The present disclosure generally relates to various aspects of battery modules. As examples, aspects of the present disclosure include the following features: (i) masks for battery cells, (ii) sustainable covers with potting dam features, (iii) cell carrier impact absorption features, (iv) cold plate thermal, alignment and / or structural features, (v) current collector assembly (CCA) notch features, (vi) CCA weld and / or tab features, and (vii) cell to cold plate and cell to cell carrier features.

[0006] According to aspects of the present disclosure, a device is provided that includes a unit carrier for a plurality of battery cells. The unit carrier may include a portion defining an arrangement of a plurality of openings, each opening being configured to receive a battery cell. The unit carrier portion may be configured to secure a lower portion of each battery cell within a corresponding opening in the opening to allow an upper portion of each battery cell to be contacted by a potting material extending between adjacent battery cells and from a top height of the battery cell to the portion of the unit carrier. The device may also include a first adhesive that attaches the portion of the unit carrier to the battery cell. The first adhesive may include a polyurethane. The potting material may include the polyurethane and a plurality of microspheres.

[0007] The device may also include a cold plate and a second adhesive different from the first adhesive, the second adhesive attaching the bottom surface of each of the battery cells to the cold plate. The second adhesive may include a thermally conductive adhesive. The second adhesive may include a double-sided adhesive tape that substantially covers the surface of the cold plate. The lower portion of each battery cell may include a portion of the battery cell extending from the bottom of the battery cell to a position less than halfway from the top of the battery cell. The lower portion of each battery cell may include a portion of the battery cell extending from the bottom of the battery cell to a position less than one-quarter of the distance from the top of the battery cell. The portion of the cell carrier may include a crate-type structure of the cell carrier.

[0008] According to other aspects of the present disclosure, a device may be provided, the device including a battery subassembly, the battery subassembly including: a unit carrier for a plurality of battery cells. The unit carrier may include a crate structure having a plurality of openings, each opening being configured to receive a battery cell. The crate structure may be configured to stabilize a lower portion of each battery cell to allow an upper portion of each battery cell to be contacted by a potting material extending between adjacent battery cells and from a top height of the battery cell to the crate structure. The battery subassembly may also include the plurality of battery cells, each battery cell having its lower portion stabilized to the crate structure by a first adhesive. The battery subassembly may also include the potting material extending between adjacent battery cells and from a top height of the battery cell to the crate structure. The first adhesive may include polyurethane, and the potting material may include the polyurethane and a plurality of microspheres. The first adhesive and the crate structure may prevent the potting material from flowing into contact with the lower portion of each of the battery cells. The device may include a vehicle, the vehicle including the battery subassembly. The vehicle may include a battery pack including a battery subassembly and a plurality of additional battery subassemblies.

[0009] According to other aspects of the present disclosure, an electric vehicle may be provided, the electric vehicle including a battery pack including one or more battery subassemblies, each of the one or more battery subassemblies including a cell carrier for a plurality of battery cells. The cell carrier may include a crate structure having a plurality of openings, each opening configured to receive a battery cell. The crate structure may be configured to stabilize a lower portion of each battery cell to allow an upper portion of each battery cell to be contacted by a potting material extending between adjacent battery cells and from a top level of the battery cell to the crate structure.

[0010] According to other aspects of the present disclosure, a method may be provided, the method comprising: inserting a plurality of battery cells into a cell carrier; attaching a lower end of each of the plurality of battery cells to a crate structure of the cell carrier using a first adhesive; and providing a potting material to a plurality of spaces between the battery cells in the plurality of battery cells such that the potting material contacts the battery cells and the crate structure. The method may also include attaching a cold plate to a bottom of each of the plurality of battery cells using a second adhesive different from the first adhesive. The second adhesive may include a thermally conductive adhesive that conducts heat between the battery cell and the cold plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Certain features of the subject technology are set forth in the appended claims. However, for purposes of explanation, several embodiments of the subject technology are set forth in the following figures.

[0012] Figure 1A and Figure 1B A schematic perspective side view of an exemplary implementation of a vehicle having a battery pack according to one or more implementations is shown.

[0013] Figure 1C A schematic perspective view of a building with a battery pack is shown according to one or more implementations.

[0014] Figure 2A A schematic perspective view of a battery pack is shown according to one or more implementations.

[0015] Figure 2B Schematic perspective views of various battery modules that may be included in a battery pack according to one or more implementations are shown.

[0016] Figure 2C A cross-sectional end view of a battery cell is shown according to one or more implementations.

[0017] Figure 2D A cutaway perspective view of a cylindrical battery cell is shown according to one or more implementations.

[0018] Figure 2E A cut-away perspective view of a prismatic battery cell is shown according to one or more implementations.

[0019] Figure 2F A cut-away perspective view of a pouch-shaped battery cell is shown according to one or more implementations.

[0020] Figure 3 A perspective view of a battery module according to one or more implementations is illustrated.

[0021] Figure 4The invention illustrates a method according to one or more specific implementations. Figure 3 An exploded perspective view of a battery module.

[0022] Figure 5 A portion of an example battery cell is illustrated according to one or more implementations.

[0023] Figure 6 A top view of an example battery cell is illustrated according to one or more implementations.

[0024] Figure 7 An example mask mounted to a battery cell according to one or more implementations is illustrated.

[0025] Figure 8 A rear perspective view of a balanced voltage and temperature (BVT) module of a battery module is illustrated according to one or more implementations.

[0026] Fig. 9A A perspective view of a cover of a battery module according to one or more implementations is illustrated.

[0027] Fig. 9B A cross-sectional view of a portion of a battery module including a cover according to one or more implementations is illustrated.

[0028] Fig.10 A perspective view of a battery module showing features of a cell carrier of the battery module is illustrated according to one or more implementations.

[0029] Fig.11 A top view of a portion of a battery pack including a battery module is illustrated according to one or more implementations.

[0030] Fig.12 A top perspective view of a cold plate of a battery module is illustrated according to one or more implementations.

[0031] Fig.13 A top view of a portion of a cold plate of a battery module is illustrated according to one or more implementations.

[0032] Fig.14 A side view of a portion of a cold plate attached to a battery cell is illustrated according to one or more implementations.

[0033] Fig.15 A perspective bottom view of a partially assembled battery module having a cold plate with locating features is illustrated according to one or more implementations.

[0034] Fig.16 A top view of a cold plate with locating features is illustrated according to one or more implementations.

[0035] Fig.17A top view of a portion of a cold plate having a support structure is illustrated according to one or more implementations.

[0036] Fig.18 A perspective view of a current collector assembly (CCA) of a battery module is illustrated according to one or more implementations.

[0037] Fig.19A A perspective view of a portion of a current collector assembly (CCA) of a battery module is illustrated according to one or more implementations.

[0038] Fig.19B An edge portion of a conductive layer of a current collector assembly of a battery module according to one or more implementations is illustrated, the edge portion being bent over a portion of a bus bar of the battery module.

[0039] Fig. 20 A cross-sectional side view of a portion of a battery module including a cell carrier and a cold plate is illustrated according to one or more implementations.

[0040] Fig.21 A perspective view of a portion of a unit carrier is illustrated according to one or more implementations.

[0041] Fig. 22 A bottom perspective view of a portion of a flange of a unit carrier is illustrated according to one or more implementations.

[0042] Fig.23 A cross-sectional side view of a portion of a battery module is illustrated according to one or more implementations.

[0043] Fig.24 A side view of a bus bar according to one or more implementations is illustrated.

[0044] Fig.25 A perspective view of a housing of a balanced voltage and temperature (BVT) module of a battery module is illustrated according to one or more implementations. DETAILED DESCRIPTION

[0045] The specific embodiments set forth below are intended to be described as various configurations of the subject technology, and are not intended to represent the only configurations that can practice the subject technology. The accompanying drawings are incorporated herein and constitute a part of the specific embodiments. The specific embodiments include specific details in order to provide a thorough understanding of the subject technology. However, the subject technology is not limited to the specific details set forth herein, and one or more other specific implementations can be used to practice. In one or more specific implementations, well-known structures and components are shown in block diagram form to avoid confusion to the concepts of the subject technology.

[0046] Various aspects of the subject technology described herein relate to battery modules. A battery module may include a battery cell. A battery module may be implemented in a battery pack including a plurality of battery modules. A battery module may be implemented in an electric vehicle or other movable device and / or implemented as a power source for a building or other fixed device. Further details of various aspects of the battery module are described below.

[0047] Figure 1A is a diagram showing an exemplary implementation of a mobile device as described herein. Figure 1A In the example of FIG. 1 , the mobile device is implemented as a vehicle 100. As shown, the vehicle 100 may include one or more battery packs, such as a battery pack 110. The battery pack 110 may be coupled to one or more power systems of the vehicle 100 to provide power to the power systems.

[0048] In one or more specific implementations, the vehicle 100 can be an electric vehicle having one or more electric motors that use electricity from the battery pack 110 to drive the wheels 102 of the vehicle. In one or more specific implementations, the vehicle 100 may also or alternatively include one or more chemical power engines, such as a gasoline-powered engine or a fuel cell-powered motor. For example, the electric vehicle can be fully electric or partially electric (e.g., a hybrid or plug-in hybrid). In various specific implementations, the vehicle 100 can be a fully autonomous vehicle capable of traveling on roads without a human operator or driver, a partially autonomous vehicle capable of traveling on some roads without a human operator or driver or capable of traveling on roads under the supervision of a human operator, an unmanned vehicle capable of traveling on roads or other paths without any human occupants, or a human-operated (non-autonomous) vehicle configured for a human operator.

[0049] exist Figure 1A In the example of FIG. 1 , the vehicle 100 is implemented as a truck (e.g., a pickup truck) having a battery pack 110. As shown, the battery pack 110 may include one or more battery subassemblies, such as a battery module 115, which may include one or more battery cells 120. Figure 1AAs shown, the battery pack 110 may also or alternatively include one or more battery cells 120 directly mounted in the battery pack 110 (e.g., in a battery cell-battery pack configuration). In one or more specific implementations, the provided battery pack 110 may not have any battery modules 115, but instead have battery cells 120 directly mounted in the battery pack 110 (e.g., in a battery cell-battery pack configuration) and / or in other battery devices disposed in the battery pack 110. A vehicle battery pack may include a plurality of energy storage devices that may be arranged as battery modules or battery devices. A battery subassembly, device, or module may include a cell assembly that may be combined with other elements (e.g., a structural frame, a thermal management device) that can protect the cell assembly from heat, shock, and / or vibration.

[0050] For example, the battery cell 120 may include a battery, a battery device, a battery module, and / or a battery pack to power components of the vehicle 100. For example, a battery cell housing of the battery cell 120 may be disposed in a battery module 115, a battery pack 110, a battery array, or other battery devices disposed in the vehicle 100.

[0051] As discussed in further detail below, the battery cell 120 may have a battery cell housing that may have any of a variety of external shapes. In some embodiments (e.g., for cylindrical or prismatic battery cells), the battery cell housing may be a rigid housing. In some embodiments, the battery cell housing may also or alternatively be formed as a bag or other flexible or extensible housing for the battery cell. In various other embodiments, the battery cell housing may have any other suitable external shape, such as a triangular external shape, a square external shape, a rectangular external shape, a pentagonal external shape, a hexagonal external shape, or any other suitable external shape. In some embodiments, the battery pack 110 may not include a module (e.g., the battery pack may be module-free). For example, the battery pack 110 may have a module-free or battery cell-battery pack configuration, in which the battery cells 120 are directly arranged into the battery pack 110 without being assembled into a battery module 115. In one or more implementations, the vehicle 100 may include one or more busbars, electrical connectors, or other charge collection, current collection, and / or coupling components to provide power from the battery pack 110 to various systems or components of the vehicle 100. In one or more implementations, the vehicle 100 may include control circuitry such as a power stage circuit that may be used to convert DC power from the battery pack 110 to AC power for one or more components and / or systems of the vehicle (e.g., including one or more power outlets of the vehicle and / or motors driving the vehicle wheels 102). The power stage circuitry may be provided as part of the battery pack 110 or may be disposed within the vehicle 100 separately from the battery pack 110.

[0052] Figure 1A The example of is merely illustrative, in which the vehicle 100 is implemented as a pickup truck having a cabin at the rear thereof. Figure 1B Another implementation is shown in which the vehicle 100 including the battery pack 110 is implemented as a sport utility vehicle (SUV), such as an electric sport utility vehicle. Figure 1B In the example of FIG. 1 , the vehicle 100 including the battery pack 110 may include a cargo storage area enclosed within the vehicle 100 (e.g., behind a row of seats within the vehicle cabin). In other specific implementations, the vehicle 100 may be implemented as another type of electric truck, electric van, electric car, electric car, electric motorcycle, electric scooter, electric bicycle, electric passenger vehicle, electric passenger or commercial truck, hybrid vehicle, aircraft, watercraft, and / or any other mobile device having a battery pack 110 (e.g., a battery pack or other battery device that powers a propulsion or drive component of the mobile device).

[0053] In one or more specific implementations, a battery pack such as battery pack 110, battery module 115, battery cell 120, and / or any other battery device as described herein may also or alternatively be implemented as a power supply and / or energy storage system in a building such as a residential or commercial building. For example, Figure 1C An example of a battery pack 110 implemented in a building 180 is shown. For example, the building 180 can be a residential building, a commercial building, or any other building. As shown, in one or more specific implementations, the battery pack 110 can be mounted to the wall of the building 180.

[0054] As shown, the battery 110A installed in the building 180 may be coupled to the battery pack 110 in the vehicle 100, such as via a cable / connector 106, an electric vehicle supply equipment 170 (EVSE), a power stage circuit 172, and / or a cable / connector 174 that may be connected to the charging port 130 of the vehicle 100. For example, the cable / connector 106 may be coupled to the EVSE 170, which may be coupled to the battery 110A via the power stage circuit 172, and / or may be coupled to an external power source 190. In this way, in some use cases, the external power source 190 or the battery 110A installed in the building 180 may be used as an external power source to charge the battery pack 110 in the vehicle 100. In some examples, the battery 110A installed in the building 180 may also or alternatively be coupled (e.g., via the cable / connector 174, the power stage circuit 172, and the EVSE 170) to the external power source 190. For example, the external power source 190 may be a solar power source, a wind power source, and / or an electrical grid in a city, town, or other geographic area (e.g., an electrical grid powered by a remote power plant). During a time when, for example, the battery pack 110 in the vehicle 100 is not coupled to the battery 110A installed in the building 180, the battery 110A installed in the building 180 may be coupled (e.g., using the power stage circuit 172 of the building 180) to the external power source 190 to charge and store electrical energy. In some use cases, this stored electrical energy in the battery 110A installed in the building 180 may be used later to charge the battery pack 110 in the vehicle 100 (e.g., during times when solar or wind power is unavailable, in the event of a regional or local power outage in the building 180, and / or during high-rate time periods for accessing the grid).

[0055] In one or more implementations, the power stage circuit 172 may electrically couple the battery 110A installed in the building 180 to the power system of the building 180. For example, the power stage circuit 172 may convert DC power from the battery 110A into AC power for one or more loads in the building 180. For example, the battery 110A installed in the building 180 may be used to power one or more lighting, lights, appliances, fans, heaters, air conditioners, and / or any other electrical components or loads in the building 180 (e.g., via one or more electrical outlets coupled to the battery 110A installed in the building 180). For example, the power stage circuit 172 may include a control circuit that is operable to switchably couple the battery 110A between the external power source 190 and one or more electrical outlets and / or other electrical loads in the power system of the building 180. In one or more implementations, the vehicle 100 may include the power stage circuit ( Figure 1C), the power stage circuit may be used to convert power received from the electric vehicle power supply device 170 into DC power for powering / charging the battery pack 110 of the vehicle 100, and / or to convert DC power from the battery pack 110 into AC power for one or more power systems, components and / or loads of the vehicle 100.

[0056] In one or more use cases, the battery 110A installed in the building 180 can be used as a source of power for the building 180, such as during times when solar or wind power is unavailable, in the event of a regional or local power outage to the building 180, and / or during a high-rate time period for accessing the grid (as an example). In one or more other use cases, the battery pack 110 installed in the vehicle can be used to charge the battery 110A installed in the building 180 and / or to power the power system of the building 180 (e.g., in use cases where the stored energy of the battery 110A installed in the building 180 is insufficient or depleted and solar or wind power is unavailable, a regional or local power outage occurs to the building 180, and / or a high-rate time period for accessing the grid occurs (as an example)).

[0057] Figure 2A An example battery pack 110 is depicted. The battery pack 110 may include a plurality of battery cells 120 (e.g., mounted directly within the battery pack 110, or mounted within a battery, battery device, and / or battery module 115, as described herein) and / or battery modules 115, and one or more conductive coupling elements for coupling the voltage generated by the battery cells 120 to power consuming components of the power system of the vehicle 100 and / or building 180, such as one or more conductive coupling elements. For example, the conductive coupling elements may include internal connectors and / or contactors that couple together the plurality of battery cells 120, battery devices, batteries, and / or plurality of battery modules 115 within the battery pack frame 205 to generate a desired output voltage for the battery pack 110. The battery pack 110 may also include one or more external connection ports, such as electrical contacts 203 (e.g., high voltage terminals). For example, a power cable (e.g., cable / connector 106) may be connected between the electrical contacts 203 and the power system of the vehicle 100 or building 180 to provide power to the vehicle 100 or building 180.

[0058] As shown, the battery pack 110 may include a battery pack frame 205 (e.g., a battery pack housing or pack frame). For example, the battery pack frame 205 may house or enclose one or more battery modules 115 and / or one or more battery cells 120 and / or other battery pack components. In one or more specific implementations, the battery pack frame 205 may include or form a shielding structure on its outer surface (e.g., its bottom and / or under one or more battery modules 115, battery devices, batteries, and / or battery cells 120) to protect the battery modules 115, battery devices, batteries, and / or battery cells 120 from external conditions (e.g., if the battery pack 110 is installed in a vehicle 100 and the vehicle 100 is driven on rough terrain such as off-road terrain, ditches, rocks, rivers, streams, etc.).

[0059] In one or more implementations, the battery pack 110 may include one or more thermal control structures 207 (e.g., cooling lines and / or plates and / or heating lines and / or plates). For example, the thermal control structures 207 may couple thermal control structures and / or fluids to the battery modules 115, battery devices, batteries, and / or battery cells 120 within the battery pack frame 205, such as by distributing the fluid through the battery pack 110.

[0060] For example, the thermal control structure 207 may form part of a thermal / temperature control or heat exchange system that includes one or more thermal components 281, such as a plate or bladder, disposed in thermal contact with one or more battery modules 115 and / or battery cells 120 disposed within the battery pack frame 205. For example, the thermal component 281 may be positioned in contact with one or more battery modules 115, battery devices, batteries, and / or battery cells 120 within the battery pack frame 205. In one or more specific implementations, the battery pack 110 may include one or more thermal control structures 207 and / or other thermal components for each of a number of top and bottom battery module pairs. As shown, the battery pack 110 may include electrical contacts 203 (e.g., high voltage connectors) through which an external load (e.g., the electrical system of the vehicle 100 or the building 180) may be electrically coupled to the battery modules and / or battery cells in the battery pack 110.

[0061] Figure 2B The battery pack 110 (e.g., Figure 2A Various examples of battery modules 115 within a battery pack frame 205. Figure 2BIn the example of , a battery module 115A is shown, which includes a battery module housing 223 having a rectangular cube shape with a length approximately similar to the width. In this example, the battery module 115A includes a plurality of battery cells 120 implemented as cylindrical battery cells. In this example, the battery module 115A includes rows and columns of cylindrical battery cells coupled together by an interconnect structure 200 (e.g., a current connector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together, and / or couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115A may include a charge collector or busbar 202. For example, the busbar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115A.

[0062] Figure 2B Also shown are battery modules 115B having an elongated shape, wherein the length of the battery module housing 223 (e.g., extending in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., a lateral direction in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110). For example, one or more battery modules 115B may span the entire front-to-back length of the battery pack within the battery pack frame 205. As shown, the battery module 115B may also include a bus bar 202 electrically coupled to the interconnect structure 200. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115B.

[0063] In the implementation of battery module 115A and battery module 115B, battery cell 120 is implemented as a cylindrical battery cell. However, in other implementations, the battery module may include battery cells having other form factors, such as battery cells having a right prism outer shape (e.g., prismatic cells), or pouch cell implementations of battery cells. For example, Figure 2BAlso shown is a battery module 115C having a battery module housing 223 having a rectangular cube shape having a length that is approximately similar to the width and including a plurality of battery cells 120 implemented as prismatic battery cells. In this example, the battery module 115C includes rows and columns of prismatic battery cells coupled together by an interconnect structure 200 (e.g., a collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together, and / or couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115C may include a charge collector or bus bar 202. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115C.

[0064] Figure 2B Also shown is a battery module 115D including prismatic battery cells and having an elongated shape, wherein the length of the battery module housing 223 (e.g., extending in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., a lateral direction along a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110). For example, one or more battery modules 115D having prismatic battery cells may span the entire front-to-back length of the battery pack within the battery pack frame 205. As shown, the battery module 115D may also include a bus bar 202 electrically coupled to the interconnect structure 200. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115D.

[0065] Another example: Figure 2B Also shown is a battery module 115E having a battery module housing 223 having a rectangular cube shape with a length approximately similar to the width and including a plurality of battery cells 120 implemented as pouch-shaped battery cells. In this example, the battery module 115C includes rows and columns of pouch-shaped battery cells coupled together by an interconnect structure 200 (e.g., a collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together and couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115E may include a charge collector or busbar 202. For example, the busbar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115E.

[0066] Figure 2BAlso shown is a battery module 115F including pouch-shaped battery cells and having an elongated shape, wherein the length of the battery module housing 223 (e.g., extending in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., a lateral direction in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110). For example, one or more battery modules 115E having pouch-shaped battery cells may span the entire front-to-back length of the battery pack within the battery pack frame 205. As shown, the battery module 115E may also include a bus bar 202 electrically coupled to the interconnect structure 200. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115E.

[0067] In various implementations, the battery pack 110 may have any one or more of the battery modules 115A, 115B, 115C, 115D, 115E, and 115F. In one or more other implementations, the battery pack 110 may be provided without the battery modules 115 (eg, in a battery cell-pack implementation).

[0068] In one or more specific implementations, Figure 2B A plurality of battery modules 115 of any of the embodiments may be coupled (e.g., in series) to a current collector of the battery pack 110. In one or more embodiments, the current collector may be coupled to one or more external connectors (e.g., electrical contacts 203) on the battery pack 110 via a high voltage wiring harness. In one or more embodiments, a battery pack 110 may be provided without any battery modules 115. For example, the battery pack 110 may have a cell-pack configuration in which the battery cells 120 are arranged directly into the battery pack 110 without being assembled into modules 115 (e.g., without including a separate battery module housing 223). For example, the battery pack 110 (e.g., the battery pack frame 205) may include or define a plurality of structures for positioning the battery cells 120 directly within the battery pack frame 205.

[0069] Figure 2C A cross-sectional end view of a portion of a battery cell 120 is shown. Figure 2CAs shown, the battery cell 120 may include an anode 208, an electrolyte 210, and a cathode 212. As shown, the anode 208 may include or be electrically coupled to a first current collector 206 (e.g., a metal layer, such as a layer of copper foil or other metal foil). As shown, the cathode 212 may include or be electrically coupled to a second current collector 214 (e.g., a metal layer, such as a layer of aluminum foil or other metal foil). As shown, the battery cell 120 may include a first terminal 216 (e.g., a negative terminal) coupled to the anode 208 (e.g., via the first current collector 206) and a second terminal 218 (e.g., a positive terminal) coupled to the cathode (e.g., via the second current collector 214). In various specific implementations, the electrolyte 210 may be a liquid electrolyte layer or a solid electrolyte layer. In one or more specific implementations (e.g., an implementation in which the electrolyte 210 is a liquid electrolyte layer), the battery cell 120 may include a separator 220 that separates the anode 208 from the cathode 212. In one or more specific implementations in which the electrolyte 210 is a solid electrolyte layer, the solid electrolyte layer may serve as both a separator and an electrolyte layer.

[0070] In one or more specific implementations, the battery cell 120 may be implemented as a lithium-ion battery cell, wherein the anode 208 is formed of a carbonaceous material (e.g., graphite or silicon carbon). In these specific implementations, lithium ions may move from the anode 208 to the cathode 212 through the electrolyte 210 during the discharge of the battery cell 120 (e.g., and move from the cathode 212 to the anode 208 through the electrolyte 210 during the charging of the battery cell 120). For example, the anode 208 may be formed of a graphite material coated on a copper foil corresponding to the first current collector 206. In these lithium-ion specific implementations, the cathode 212 may be formed of one or more metal oxides (e.g., lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese cobalt oxide (NMC), etc.) and / or lithium iron phosphate. As shown, the battery cell 120 may include a separator 220 that separates the anode 208 from the cathode 212. In the specific implementation in which the battery cell 120 is implemented as a lithium-ion battery cell, the electrolyte 210 may include a lithium salt in an organic solvent. The separator 220 may be formed of one or more insulating materials (e.g., polymers such as polyethylene, polypropylene, polyolefins, and / or polyamides, or other insulating materials such as rubber, glass, cellulose, etc.). The separator 220 may prevent contact between the anode 208 and the cathode 212, and may be permeable to the electrolyte 210 and / or ions within the electrolyte 210. In one or more specific implementations, the battery cell 120 may be implemented as a lithium polymer battery cell having a dry solid polymer electrolyte and / or a gel polymer electrolyte.

[0071] Although some examples are described herein in which the battery cells 120 are implemented as lithium-ion battery cells, some or all of the battery cells 120 in the battery module 115, battery pack 110, or other battery or battery device may be implemented using other battery cell technologies such as nickel metal hydride battery cells, lead acid battery cells, and / or supercapacitor cells. For example, in a nickel-metal hydride battery cell, the anode 208 may be formed of a hydrogen storage alloy, and the cathode 212 may be formed of nickel oxide-hydride. In the example of a nickel-metal hydride battery cell, in one or more examples, the electrolyte 210 may be formed of an aqueous potassium hydroxide solution.

[0072] In one or more other specific implementations, the battery cell 120 may be implemented as a lithium-sulfur battery cell. For example, in a lithium-sulfur battery cell, the anode 208 may be at least partially formed of lithium, the cathode 212 may be at least partially formed of sulfur, and the electrolyte 210 may be formed of a cyclic ether, a short-chain ether, a glycol ether, an ionic liquid, a supersaturated salt-solvent mixture, a polymer gel organic medium, a solid polymer, a solid inorganic glass, and / or other suitable electrolyte materials.

[0073] In various specific implementations, Figure 2C The anode 208, electrolyte 210, and cathode 212 are packaged into a battery cell housing having any of a variety of shapes and / or sizes and / or formed from any of a variety of suitable materials. For example, the battery cell 120 may have an outer shape that is cylindrical, rectangular, square, cubic, flat, pouch-shaped, elongated, or prismatic. Figure 2D As depicted, for example, a battery cell such as battery cell 120 may be implemented as a cylindrical core. Figure 2D In the example of , the battery cell 120 includes a cell housing 215 having a cylindrical outer shape. For example, the anode 208, the electrolyte 210, and the cathode 212 can be wound into one or more substantially cylindrical windings 221. As shown, one or more windings 221 of the anode 208, the electrolyte 210, and the cathode 212 (e.g., and / or one or more separator layers, such as separator layer 220) can be disposed within the cell housing 215. For example, a separator layer can be disposed between adjacent windings 221. However, Figure 2D The cylindrical cell implementation of is merely exemplary, and other implementations of the battery cell 120 are contemplated.

[0074] For example, Figure 2E 2 shows an example in which the battery cell 120 is implemented as a prismatic cell. Figure 2EAs shown, the battery cell 120 may include a cell housing 215 having a right prism-like outer shape. As shown, one or more layers of an anode 208, a cathode 212, and an electrolyte 210 disposed therebetween may be disposed (e.g., with a separator material between each layer) within a cell housing 215 having a right prism-like shape. For example, multiple layers of an anode 208, an electrolyte 210, and a cathode 212 may be stacked (e.g., with a separator material between each layer), or a single layer of an anode 208, an electrolyte 210, and a cathode 212 may be formed into a flat spiral shape and provided in a cell housing 215 having a right prism-like shape. Figure 2E In a specific implementation, the unit housing 215 has a relatively thick cross-sectional width 217 and is formed of a rigid material. For example, Figure 2E The unit housing 215 in a specific implementation may be formed from a welded, stamped, deep drawn and / or impact extruded metal sheet such as a welded, stamped, deep drawn and / or impact extruded aluminum sheet. For example, Figure 2E The cross-sectional width 217 of the cell housing 215 may be up to or greater than 1 millimeter (mm) to provide a rigid housing for the prismatic battery cell. In one or more specific implementations, Figure 2E The first terminal 216 and the second terminal 218 in the prismatic unit embodiment may be formed by a feed-through conductor, which is formed by the conductor passing through the unit housing 215 to expose the first terminal 216 and the second terminal 218 to the outside of the unit housing 215 (for example, for use with Figure 2B However, Figure 2E This implementation of is also exemplary, and yet other implementations of the battery cell 120 are contemplated.

[0075] For example, Figure 2F 2 shows an example in which the battery cell 120 is implemented as a pouch-shaped cell. Figure 2F As shown, one or more layers of anode 208, cathode 212, and electrolyte 210 disposed therebetween may be disposed (e.g., with separator material between the layers) within a cell housing 215 that forms a flexible or stretchable pouch-like housing. Figure 2F In a specific implementation, the unit housing 215 has a relatively thin cross-sectional width 219. For example, Figure 2F The unit housing 215 in a specific implementation may be formed of a flexible or ductile material (e.g., a foil, such as a metal foil, or a film, such as an aluminum-coated plastic film). Figure 2F The cross-sectional width 219 of the cell housing 215 can be as low as or less than 0.1 mm, 0.05 mm, 0.02 mm, or 0.01 mm to provide a flexible or stretchable housing for the pouch-shaped battery cell. In one or more specific implementations, Figure 2FThe first terminal 216 and the second terminal 218 in the pouch cell embodiments of the present invention may be formed by conductive tabs (e.g., foil tabs) that are coupled (e.g., welded) to the anode 208 and cathode 212, respectively, and sealed to the pouch that forms the cell housing 215 in these embodiments. Figure 2C , Figure 2E and Figure 2F In the example of FIG. 1 , the first terminal 216 and the second terminal 218 are formed on the same side (e.g., the top side) of the battery cell 120. However, this is merely illustrative, and in other specific implementations, the first terminal 216 and the second terminal 218 may be formed on two different sides (e.g., opposite sides, such as the top side and the bottom side) of the battery cell 120. In various specific implementations, the first terminal 216 and the second terminal 218 may be formed on Figure 2D on the same side or different sides of the cylindrical unit.

[0076] In one or more specific implementations, the battery module 115, the battery pack 110, the battery device, or any other battery may include some battery cells 120 implemented as solid-state battery cells and other battery cells 120 implemented with liquid electrolytes for lithium ions or other battery cells with liquid electrolytes. One or more of the battery cells 120 may be included in the battery module 115 or the battery pack 110 to provide a power supply for a component of the vehicle 100, a building 180, or any other electric component or device. The cell housing 215 of the battery cell 120 may be disposed in the battery module 115, disposed in the battery pack 110, or installed in any of the vehicle 100, the building 180, or any other electric component or device.

[0077] Figure 3 A perspective view of a battery module according to one or more implementations is illustrated. Figure 3 In the example of , the battery module 115 includes a top submodule 304 and a bottom submodule 306. As shown, each of the top submodule 304 and the bottom submodule 306 may include a cell carrier 310. In one or more specific implementations, each cell carrier 310 may be a single-piece, unitary body (e.g., a molded body formed of plastic and / or other materials) and may include structural features 311 along its sidewalls. These structural features 311 may enhance the strength of the sidewalls of the carrier and thereby reduce or eliminate the need for additional structural reinforcement components of the battery module 115, such as shear walls attached to the cell carrier 310. Figure 3 Also visible in FIG. 3 is a cold plate 308 disposed between the top submodule 304 and the bottom submodule 306. The cold plate 308 may be connected to the battery cells in the top submodule 304 (in Figure 3 ) and the battery cells in the bottom submodule 306 (not visible in Figure 3) to provide thermal control for both the top submodule 304 and the bottom submodule 306.

[0078] Figure 3 Also illustrated is a cover 314 that may be disposed on the top and / or bottom of the battery module 115 . Figure 3 Also illustrated is a balanced voltage and temperature (BVT) module 316 to which a plurality of thermistor assemblies 318 are communicatively coupled. The BVT may be a modular assembly of various electrical components to monitor or control components of a battery subassembly. For example, the BVT may include a circuit board attached to a housing of the BVT. The BVT may have various connectors to couple with, for example, a thermistor that can measure the temperature of a battery subassembly, a battery module, and / or its battery cells, a voltage sensor or balancer that can sense or control the voltage flowing through a battery subassembly, a battery module, and / or its battery cells, or a communication device that can receive, transmit, or analyze data associated with a battery subassembly, a battery module, and / or its battery cells. Figure 3 Also illustrated are a bus bar 320 (e.g., a positive bus bar) electrically coupled to a first terminal (e.g., a positive terminal) of the battery cells of the top submodule 304 and the bottom submodule 306 and a bus bar 322 (e.g., a negative bus bar) electrically coupled to a second terminal (e.g., a negative terminal) of the battery cells of the top submodule 304 and the bottom submodule 306.

[0079] Figure 4 Illustrated Figure 3 1, wherein the battery cells 120 of the top submodule 304 and the battery cells 120 of the bottom submodule 306 can be seen. In one or more examples described herein, the battery modules 115, Figure 3 and / or Figure 4 A subset of the components of the battery module 115 shown (e.g., the top submodule 304, the bottom submodule 306, and / or another subset of the components of the battery module) or any other grouping of battery cells (e.g., including a battery pack having multiple battery modules and / or other battery subassemblies) may be referred to as a battery subassembly.

[0080] exist Figure 4 In the example of FIG. 1 , two current collector assemblies (CCAs) 400 can also be seen, which connect the terminals of the battery cells 120 of the top submodule 304 and the bottom submodule 306 to the busbars 320 and 322 when the battery module 115 is assembled. Figure 4As shown, a series bus bar 406 may also be provided (e.g., on an end of the unit carrier 310 opposite the end of the unit carrier where the bus bars 320 and the bus bars 322 are mounted). For example, the series bus bar 406 may electrically couple the battery cells 120 of the top submodule 304 to the battery cells 120 of the bottom submodule 306. As shown, a cover 314 may be provided for the top submodule 304, and a cover 314 may be provided for the bottom submodule 306.

[0081] As discussed in further detail below, the battery cells 120 of the top submodule 304 may be inserted into a crate structure formed by the cell carrier 310 of the top submodule 304, and the battery cells 120 of the bottom submodule 306 may be inserted into a crate structure formed by the cell carrier 310 of the bottom submodule 306. Figure 3 and Figure 4 As shown, the orientation of the cell carrier 310 and battery cells 120 of the top submodule 304 can be substantially opposite (e.g., upside down relative to the orientation of the cell carrier 310 and battery cells 120 of the bottom submodule 306). In this way, the single cold plate 308 can be in thermal contact with the same end (e.g., the bottom end) of the battery cells 120 of both the top submodule and the bottom submodule and provide substantially symmetrical thermal contact with the top submodule and the bottom submodule.

[0082] Figure 5 A cross-sectional view of a portion of an example battery cell is illustrated according to one or more specific implementations. Figure 5 In the example of FIG. 1 , the battery cell 120 includes a terminal structure 500. For example, the terminal structure 500 may include a terminal contact 505 that is electrically coupled to one or more electrodes (e.g., a positive electrode, such as a positive electrode) within the cell housing 215. Figure 2C212 of the cathode). As shown, the terminal structure 500 may be formed above the corresponding current interrupt device (CID) 508 of the battery cell 120. For example, the terminal contact 505 may be coupled to the electrode within the cell housing 215 via the CID 508. The CID 508 may be formed as part of the terminal structure 500 or may be a component separated from the terminal structure 500. In one or more specific implementations, the terminal structure 500 may form a closure member or cover of the battery cell, which together with the cell housing 215 (e.g., a can) seals the electrode and electrolyte of the battery cell. In one or more specific implementations, the peripheral edge 507 of the battery cell 120 may form another terminal contact (e.g., a negative terminal), which may be electrically coupled to one or more other electrodes (e.g., a negative electrode, such as an anode 208) within the cell housing 215. The peripheral edge 507 may be electrically insulated from the terminal contact 505 and may be formed as part of the terminal structure 500 or may be a separate structure attached to the cell housing 215.

[0083] As shown, the terminal structure 500 may include one or more openings 504. For example, the openings 504 may be cutouts in the terminal structure 500 (e.g., cutouts in the cover of the battery cell 120). For example, the openings 504 may be arranged to allow gas to flow out of the battery cell through the CID 508 when the CID 508 is triggered. For example, in response to pressure from within the battery cell, the CID 508 may be moved upward (e.g., in the Figure 5 The CID 508 is pressed upwardly (in the "y" direction) into the cavity 510 between the CID 508 and the terminal structure 500 to disengage the terminal structure 500 from the electrode, thereby disconnecting the circuit of the battery cell 120. In one or more specific implementations, in some cases (e.g., when there is increased pressure in the battery cell housing), the CID 508 can also mechanically break or otherwise open a vent path when pressed upwardly into the cavity 510, which allows gas from within the battery cell 120 to be discharged to and through the opening 504.

[0084] Figure 6 Illustrated Figure 5 FIG. 5 is a top view of the battery cell 120 showing a view of the opening 504 . Figure 5 and Figure 6 In the example of , a gasket 506 is also shown. In one or more specific implementations, the gasket can be provided with a color (e.g., black, yellow, or orange) that is configured to be recognized by the positioning equipment of the assembly equipment of the battery module 115. In this way, the gasket 506 can perform a gasket function and a reference index function for the battery cell.

[0085] exist Figure 6In the example of , it can be seen that the opening 504 opens from the top of the battery cell 120. The battery module 115 or another battery subassembly in which the battery cell 120 is disposed may be provided with a potting material that substantially fills the space between the battery cells 120 (e.g., to provide structural support and / or thermal coupling to the battery cell). During the assembly process of the battery module 115, the potting material may be disposed or poured onto the battery module in liquid form. Some of the potting material may inadvertently flow into the cavity 510 via the opening 504. The potting material in the cavity 510 may prevent the CID 508 from moving upward into the cavity 510, which may affect the ability of the CID to function to disconnect the battery circuit within the battery cell and exhaust gas from the battery cell.

[0086] Figure 7 1. The mask 700 is illustrated as to how a battery cell 120 may be provided in one or more specific implementations. For example, the mask 700 may be configured to be mounted to the terminal structure 500 of the battery cell 120. As shown, the mask 700 may include at least one barrier structure 701. The barrier structure 701 may be configured to be mounted above the opening 504 in the terminal structure 500 of the battery cell 120. For example, the mask may prevent liquid (e.g., potting material) from flowing into the opening 504 and allow gas to flow between the opening 504 in the terminal structure 500 of the battery cell 120 and the environment outside the mask 700.

[0087] For example, Figure 7 As shown, the mask 700 may include a plurality of blocking structures 701, which are configured to be mounted above a plurality of corresponding openings 504 in the terminal structure 500 of the battery cell 120. As shown, the mask 700 may also include a bridge structure 703. As shown, the blocking structure 701 may extend radially outward from the bridge structure 703. The bridge structure 703 may define a central opening 705, which is configured to be mounted above the terminal structure 500 of the battery cell 120 (e.g., mounted above the central portion of the terminal structure 500 forming the positive terminal of the battery cell). For example, the bridge structure 703 may extend around the periphery of the central opening 705 and interconnect with the blocking structure 701. In one or more specific implementations, the bridge structure 703 may be adhesively attached to the terminal structure 500 to keep the mask in place on the cover of the battery cell 120. In one or more specific implementations, the bridge structure 703 may be attached to the terminal structure 500 via snap fit or press fit to keep the mask in place on the cover of the battery cell 120.

[0088] like Figure 7As shown, the mask 700 may also include one or more peripheral openings 702. For example, each of the peripheral openings 702 may be disposed between a pair of blocking structures 701. In one or more implementations, each of the peripheral openings 702 may be configured (e.g., sized, shaped, and / or positioned) to allow gas to flow therethrough (e.g., to allow air to flow into the opening 504 and / or gas from the battery cell to flow out through the opening 504 and the peripheral openings 702) and to prevent liquid (e.g., potting material) from flowing therethrough (e.g., into the opening 504). For example, each of the peripheral openings may extend above a portion of the opening 504 in the cover of the battery cell. For example, one or more openings 504 and / or one or more peripheral openings 702 may form a vent for a current interrupt device (CID) (508) of the battery cell 120.

[0089] In one or more implementations, the mask 700 may be formed of a flexible material. As an example, the flexible material may include a polymer (e.g., polyethylene terephthalate (PET)) or a rubber. As discussed herein, in one or more implementations, the mask 700 and the battery cell 120 (e.g., the battery cell to which the mask 700 is mounted) may be implemented in a vehicle (e.g., the vehicle 100, such as in a battery module 115 of a battery pack 110 within an electric vehicle). As discussed herein, in one or more implementations, the mask 700 and the battery cell 120 (e.g., the battery cell to which the mask 700 is mounted) may be implemented in a building (e.g., the building 180, such as in a battery module 115 of a battery pack 110 within a building).

[0090] In one or more other implementations, the mask of the battery cell may include a bridge structure at the outer periphery of the mask and a blocking structure extending radially inward from the bridge structure. In this example, the blocking structures may each be configured to be hidden in a corresponding opening in the opening 504 in the terminal structure 500 of the battery cell 120. In this way, the mask can be mechanically attached to the terminal structure 500 of the battery cell 120 via hiding the blocking structure in the opening. Once hidden in the opening 504, the blocking structure can block liquids such as potting materials from flowing through the opening 504 into the cavity 510.

[0091] Figure 8 A rear perspective view of a balanced voltage and temperature (BVT) module of a battery module according to one or more specific implementations is illustrated. Figure 8As shown, the BVT module 316 may be provided with a housing 800, and a printed circuit board 802 is disposed within the housing. For example, the printed circuit board may be a double-sided printed circuit board (e.g., having circuits mounted to both sides of the printed circuit board, such as integrated circuits, transistors, capacitors, inductors, etc.). The circuit board 802 may be disposed in a cavity of the housing 800. The circuit board 802 may be coupled to the housing 800 via heat staking. Figure 8 Also shown is how the housing 800 of the BVT module 316 may include mounting features 804 for mounting the BVT module 316 to the battery module 115. For example, the mounting features 804 may be implemented as snap-fit ​​features, such as Figure 8 In one or more specific implementations, the mounting feature 804 can be received on the unit carrier 310 and / or the busbar (such as Figure 3 and Figure 4 One or more openings in busbar 322 or busbar 320).

[0092] Fig. 9A A perspective view of a cover 314 of a battery module is illustrated according to one or more implementations. Fig. 9A As shown, the cover 314 may include a substantially planar main structure 905 configured to cover the electrical components of the battery module 115. As shown, the cover 314 may include one or more attachment features 900 configured to allow an edge portion 910 of the cover 314 to be secured to another structure of the battery module 115 (e.g., to the cell carrier 310). Fig. 9A As shown, the edge portion 910 of the cover 314 can include an overhang 904. For example, in one or more implementations, the overhang 904 can be configured to bend over the outer edge of the unit carrier 310.

[0093] In one or more specific implementations, the attachment feature 900 can include an opening. For example, Fig. 9B A cross-sectional view of a portion of a battery module including a cover 314 is illustrated according to one or more implementations. Fig. 9B As shown in the cross-sectional side view of , the opening can be configured to receive a fastener 908 therethrough. As an example, the fastener 908 can be a pin, a screw, or other fastening member. Fig. 9B As shown, the fastener 908 may pass through the opening and into a portion of the unit carrier 310 .

[0094] As shown, a cover 314 (e.g., for a battery module 115) may include a substantially planar main structure 905 configured to cover an electrical structure of the battery module (e.g., CCA 400). The substantially planar main structure 905 may include an outer surface 907 and an opposite inner surface 909 that is configured to face the electrical structure of the battery module. The cover 314 may also include a sealing feature 906 that protrudes from the inner surface 909 of the substantially planar main structure 905. For example, the sealing feature 906 may extend around at least a portion of the perimeter of the substantially planar main structure 905 (e.g., around the entire perimeter of the substantially planar main structure, along one, two, three, or four edges of the substantially planar main structure, or around another portion of the substantially planar main structure).

[0095] As shown, the sealing feature 906 can be configured to sealingly interface with a peripheral surface 915 of the battery subassembly (e.g., a peripheral surface of the cell carrier 310) to prevent or inhibit the passage of liquids, such as potting material, between the cell carrier 310 and the cover 314. For example, the cover 314 can be placed over the CCA 400 and attached to the cell carrier 310, after which the potting material is injected into the spaces between the battery cells 120 in the cell carrier 310. Fig. 9B In the arrangement of the cover 314 (eg, including the sealing feature 906 ) can act as a potting dam to prevent the potting material from leaking during injection. Thus, in some implementations, the battery module 115 can include potting material in contact with the sealing feature 906 of the cover 314 .

[0096] In one or more specific implementations, the edge portion 910 of the substantially planar primary structure 905 extends beyond the sealing feature 906 and includes an attachment feature 900 (configured to allow the edge portion 910 to be secured to the unit carrier 310). As discussed herein, the attachment feature 900 may include an opening configured to receive a fastener 908 therethrough. As discussed herein, the edge portion 910 of the cover 314 may also include an overhang 904 configured to bend over an outer edge 917 of the unit carrier 310. In various specific implementations, the sealing feature 906 may be attached to the inner surface 909 of the cover 314 or may be an integral feature of the cover 314 (e.g., a protruding portion forming a unitary structure of the cover). In one or more specific implementations, the cover 314 may be a sustainable cover and may be formed of a material of which at least twenty-five percent, fifty percent, seventy percent, or seventy-five percent is a recycled polymer material. For example, the cover 314 may be formed from a thermoplastic material (eg, polyethylene terephthalate (PET)) and / or a recycled thermoplastic material (eg, rPET).

[0097] Fig.10A perspective view of a battery module 115 is illustrated, wherein various features of a cell carrier 310 can be seen, according to one or more implementations. Fig.10 In an example of the present invention, each unit carrier 310 (e.g., configured to receive and carry battery cells 120) may include sidewalls 1001. As shown, each of the sidewalls 1001 may include a structural feature 311. For example, the structural feature 311 may include a rib 1002 extending outwardly from an exterior of the sidewall 1001. For example, the rib 1002 may be configured to distribute at least a portion of an impact force to the unit carrier 310 (e.g., due to an impact to the battery pack 110, such as an impact caused by a vehicle collision) away from the battery cells carried by the unit carrier 310.

[0098] In one or more implementations, the sidewalls 1001 and ribs 1002 of each unit carrier 310 may be integrally formed parts of a common unitary structure (eg, unit carrier 310). Fig.10 As shown in the example of , one or more of the ribs 1002 can be implemented as a gusset extending perpendicularly from the sidewall 1001 to the flange 1000, which extends outwardly from the base of the sidewall 1001 perpendicular to the sidewall 1001 and perpendicular to each of the ribs 1002. In one or more specific implementations, the flange 1000 can be another integrally formed part of the common unitary structure (e.g., the unit carrier 310).

[0099] exist Fig.10 In the example of FIG. 1 , each of the ribs 1002 extends from the corresponding sidewall 1001 to a first distance at the corresponding flange 1000 and tapers toward the corresponding sidewall 1001 , ie, moves vertically away from the corresponding flange 1000 .

[0100] Fig.11 1 illustrates a top view of a portion of a battery pack having two battery modules 115 that are laterally (eg, horizontally) separated from each other. Fig.11 Can be expressed Fig.10 A top-down view of the portion of the battery module 115 in the dashed box 1004 and a similar portion of another battery module 115.

[0101] like Fig.11 As shown, the ribs 1002 on the sidewalls 1001 of the unit carrier 310 can be configured to be received by corresponding recesses 1102 in the cross member 1100 disposed between the unit carrier 310 and another unit carrier 310. In this arrangement, the ribs 1002 can be configured to distribute at least some of the portion of the impact force to the cross member 1100. In this way, the impact force of the impact on the battery pack and / or battery module can be redirected away from the battery cells 120 stored in the unit carrier 310 and absorbed by the cross member 1100.

[0102] exist Fig.10 and Fig.11 In the example shown, only one side of each unit carrier is visible. However, it should be understood that Fig.10 The side walls 1001 shown may each be a first side wall 1001 on a first side of a corresponding unit carrier 310, each unit carrier 310 may include a second side wall 1001 on an opposite second side of the unit carrier 310, and the second side wall 1001 may include an additional rib 1002 extending outwardly from the exterior of the second side wall 1001. Fig.11 In the example of FIG. 1 , the ribs 1002 of the first side wall of one unit carrier 310 may be opposite to the ribs 1002 of the second side wall of another unit carrier 310 (eg, with the cross member 1100 interposed therebetween).

[0103] like Fig.11 As shown, the cross member 1100 of the battery pack 110 can be an elongated main body 1101 and one or more notches 1102 configured to receive one or more corresponding gussets (e.g., ribs 1002) extending from the sidewall 1001 of the cell carrier 310 for the battery cell 120. For example, the cross member 1100 can be configured to absorb impact forces distributed from the corresponding gussets. For example, the notches 1102 of the cross member 1100 can include a first set of notches 1102 spaced apart along a first elongated edge 1103 of the elongated main body 1101. The notches 1102 of the cross member 1100 can also include a second set of notches 1102 spaced apart along a second elongated edge 1105 of the elongated main body 1101.

[0104] like Figure 3 As shown, the second set of notches 1102 can be configured to receive a second set of corresponding gussets (e.g., ribs 1002) extending from the sidewall 1001 of the second unit carrier 310 of the battery cell. The cross member can be formed of a material including a metal (e.g., aluminum or an aluminum alloy, such as aluminum a380). As shown, the cross member 1100 can also include one or more attachment features 1107, which are configured to secure the cross member 1100 in place relative to one or more unit carriers 310.

[0105] like Figure 1A , Figure 1B , Figure 3 , Figure 4 and Fig.10As shown, in one or more specific implementations, the battery pack 110 may include a battery module 115, which may include: a first unit carrier 310, the first unit carrier configured to receive a first group of battery cells 120, wherein the first unit carrier 310 includes a first side wall 1001, the first side wall having a first set of ribs 1002 extending outwardly from an exterior of the first side wall 1001; and a second unit carrier 310, the second unit carrier stacked with the first unit carrier 310 and configured to receive a second group of battery cells 120, wherein the second unit carrier includes a second side wall 1001, the second side wall is substantially coplanar with the first side wall 1001 of the first unit carrier 310, and has a second set of ribs 1002 extending outwardly from an exterior of the second side wall 1001. In this configuration, the first set of ribs 1002 and the second set of ribs 1002 can be configured to distribute at least a portion of an impact force on the battery module 115 away from the first plurality of battery cells or the second plurality of battery cells.

[0106] In one or more specific implementations, the battery pack 110 may also include a cross member 1100 including an elongated main body 1101 and a first set of recesses 1102 configured to receive a first set of ribs 1002 extending from a first side wall 1001 of a first unit carrier 310. The first set of recesses 1102 may also be configured to receive a second set of ribs 1002 extending from a second side wall 1001 of a second unit carrier 310 stacked with the first unit carrier 310 in the battery module. In one or more specific implementations, the cross member 1100 may also include a second set of recesses 1102 configured to receive a third set of ribs 1002 extending from a third side wall of a third unit carrier 310 (e.g., as in Fig.11 For example, the third unit carrier 310 may be a unit carrier of another battery module that is laterally offset relative to the battery module including the first unit carrier and the second unit carrier. The cross member 1100 may be configured to absorb a first portion of the impact force distributed from the first plurality of ribs and a second portion of the impact force distributed from the second plurality of ribs.

[0107] In one or more specific implementations, the battery pack 110 may include: a first unit carrier 310 of the battery cells 120 and a second unit carrier 310 of the battery cells 120, wherein the first unit carrier 310 includes a first set of ribs 1002 extending from a first side wall 1001 of the first unit carrier 310, and wherein the second unit carrier 310 includes a second set of ribs 1002 extending from a second side wall 1001 of the second unit carrier 310; and a cross member 1100, which is disposed between the first unit carrier 310 and the second unit carrier 310, and the cross member 1100 has a first set of notches 1102 on a first edge 1103 of the cross member to receive the first set of ribs 1002 and a second set of notches 1102 on a second edge 1105 of the cross member to receive the second set of ribs 1002.

[0108] In one or more specific implementations, a method is provided that includes obtaining a first unit carrier 310 of a battery cell 120 and a second unit carrier 310 of the battery cell 120. The first unit carrier may include a first set of ribs 1002 extending from a first side wall 1001 of the first unit carrier 310, and the second unit carrier 310 may include a second set of ribs 1002 extending from a second side wall 1001 of the second unit carrier 310. The method may also include arranging the first unit carrier 310 and the second unit carrier 310 such that the first set of ribs 1002 extend toward the second set of ribs 1002 (e.g., as in Fig.11 The method may also include providing a cross member 1100 between the first unit carrier 310 and the second unit carrier 310 such that a first set of notches 1102 on a first edge 1103 of the cross member receive the first set of ribs 1002 and a second set of notches 1102 on a second edge 1105 of the cross member 1100 receive the second set of ribs 1002. One or more battery cells 120 may be disposed within the first unit carrier 310 and / or the second unit carrier 310.

[0109] In one or more specific embodiments, a method is provided, the method comprising: receiving an impact on a body of a vehicle 100 including a battery pack 110, the battery pack including a unit carrier 310 having a set of gussets (e.g., ribs 1002) extending from a side wall 1001 thereof; and distributing at least a portion of the force of the impact through the set of gussets away from a set of battery cells 120 in the unit carrier 310 and to a cross member 1100 having a set of recesses 1102 in which the set of gussets are disposed.

[0110] Fig.12 A top perspective view of a thermal component (eg, a cold plate) of a battery module according to one or more implementations is illustrated. Fig.12As shown, the cold plate 308 may include a plate assembly 1200. The plate assembly 1200 may include a flange 1204 along one or more edges thereof. In one or more specific implementations, one or more positioning features 1206 (e.g., for the unit carrier 310) and / or one or more positioning (e.g., datuming) features 1208 may be formed along the flange 1204. In one or more specific implementations, a thermally conductive material 1202 (e.g., a thermally conductive adhesive) may be formed on a substantially planar outer surface of the plate assembly 1200. In one or more other specific implementations, the thermally conductive adhesive may be a multi-component acrylic paste. Fig.12 In the example of FIG. 3 , it can be seen that the thermally conductive material 1202 is on one side of the cold plate 308 for thermally coupling to the battery cells 120 of the first submodule (the bottom submodule 306). In one or more specific implementations, the thermally conductive material 1202 can also be disposed on the cold plate 308. Fig.12 On the other side, which is not visible in FIG. 1 , for thermal coupling to the battery cells 120 of the second submodule (top submodule 304 ).

[0111] Fig.13 A top view of a portion of a thermal component (eg, a cold plate) of a battery module according to one or more implementations is illustrated. For example, Fig.13 An example is shown with a top plate (in Fig.13 Not visible in the Fig.13 1350 of the plate assembly 1200 (not visible in the figure) and an intermediate plate disposed between the top plate and the bottom plate. Fig.13 As shown, in one or more specific implementations, the intermediate plate 1350 may define a serpentine flow path 1300 for a fluid (e.g., a thermal fluid, such as a coolant fluid or a warming fluid) from an inlet port 1302 to an outlet port 1304. For example, the serpentine flow path 1300 may define a plane and / or be defined within a plane. For example, the cold plate 308 may include one or more structural features 1307 that extend across (e.g., through) the serpentine flow path (e.g., across or through the plane). For example, the structural features 1307 may increase the burst pressure threshold of the cold plate. The structural features 1307 may prevent the cold plate from being compressed by an external force and / or may prevent the cold plate from expanding due to fluid pressure within the cold plate.

[0112] The structural features 1307 can separate some portions of the serpentine flow path 1300 from some other portions of the serpentine flow path 1300. For example, a plurality of structural features 1307 can separate a plurality of sub-channels 1306 that are partially defined by the structural features 1307. As shown, the sub-channels 1306 can be formed on the first side 1303 of the intermediate plate 1350 (e.g., at the bottom of the intermediate plate 1350). Fig.131300). As shown, multiple sub-channels 1306 can be combined to form each of several segments of the serpentine flow path 1300. For example, these segments may include linear segments extending between turns or corners of the serpentine flow path 1300.

[0113] In one or more specific implementations, the subchannels 1306 within each segment of the serpentine flow path 1300 can be separated from each other by structural features 1307 along the length of the segment, and can be fluidically coupled together at or near the end of each segment. As shown, each segment of the serpentine flow path 1300 (e.g., each segment includes multiple subchannels 1306) can be fluidly separated from adjacent parallel segments of the serpentine flow path 1300 by a fluid barrier 1330 that at least partially defines the serpentine flow path 1300.

[0114] In one or more specific implementations, the structural features 1307 can each extend from the floor of the corresponding subchannel 1306 to a corresponding ridge 1309. As discussed in further detail below, each ridge 1309 can be on an opposite second side of the plate (at Fig.13 As shown, the structural feature 1307 may include a structural feature formed into segments, the segments including a first segment extending from the inlet port 1302 to a first center portion of the intermediate plate 1350, a segment extending perpendicularly to the first segment from the first center portion to a second center portion of the intermediate plate 1350, a third segment extending perpendicularly to the first segment and parallel to the first segment from the second center portion to a first edge portion of the intermediate plate 1350, a fourth segment extending perpendicularly to the third segment from the first edge portion to a first corner of the intermediate plate 1350, a fifth segment extending perpendicularly to the fourth segment and parallel to the third segment from the first corner of the intermediate plate 1350 to the second corner of the intermediate plate 1350, a sixth segment extending perpendicularly to the fifth segment from the second corner to the third corner of the intermediate plate 1350, and a seventh segment extending perpendicularly to the sixth segment from the third corner of the intermediate plate 1350 to the outlet port 1304. Fig.13As shown, the middle plate 1350 may include one or more openings 1308. As shown, the first, second, third, fourth, fifth, sixth, and seventh segments of the structural feature 1307 may be separated from each other by gaps, and one or more of the openings 1308 are formed at the gaps. The openings 1308 may be configured to allow cooling fluid to flow through the middle plate 1350 (e.g., between the serpentine flow path 1300 on a first side of the plate and an additional serpentine flow path on an opposite second side of the middle plate 1350). In this way, the cooling fluid flowing through the serpentine flow path 1300 may traverse the opposite side of the middle plate 1350, and vice versa. In one or more specific implementations, the openings 1308 may be configured (e.g., sized, shaped, and / or positioned) to generate turbulence in the flow of fluid through the serpentine flow path 1300. For example, turbulence may increase the efficiency of heat transfer of the fluid (e.g., to the top plate and the bottom plate).

[0115] like Fig.13 As shown, a first group 1311 of openings 1308 may be arranged in a first row that extends diagonally from a first corner of the cold plate away from a first edge and a second edge of the cold plate that defines the first corner. For example, the first group 1311 of openings 1308 may be located at a turn (e.g., a corner) in the serpentine flow path 1300 (e.g., to increase the amount of mixing across the middle plate 1350 and / or to increase the amount of turbulence in the cooling fluid flowing through the serpentine flow path 1300). As shown, a second group 1313 of openings 1308 may be arranged in a second row that extends diagonally from a second corner of the cold plate toward an inner end of the first row and away from a second edge and a third edge of the cold plate that defines the second corner (e.g., at another turn or corner in the serpentine flow path 1300).

[0116] As shown, a third group 1315 of openings 1308 can be arranged in a third row that extends diagonally from a third corner of the cold plate away from a third edge and a fourth edge of the cold plate that define the third corner (e.g., at another turn or corner in the serpentine flow path 1300). As shown, a fourth group 1317 of openings 1308 can be arranged in a fourth row that extends from a location along the fourth edge of the cold plate toward an inner end of the third row (e.g., at another turn or corner in the serpentine flow path 1300). In one or more specific implementations, the middle plate 1350 can include one or more openings 1308 (e.g., one or more rows of openings 1308) at each corner or turn of the serpentine flow path 1300. In one or more specific implementations, the middle plate 1350 can include a row of openings 1308 at the beginning of each linear segment of the serpentine flow path 1300 and a row of openings 1308 at the end of each linear segment of the serpentine flow path 1300. In one or more implementations, a row of openings 1308 at the beginning of each linear segment of the serpentine flow path 1300 may be parallel to a row of openings 1308 at the end of the next linear segment of the serpentine flow path 1300 (e.g., such that each row of openings 1308 forms a row of parallel opening pairs). Fig.13 In the example of FIG. 1 , each of the openings 1308 forms a slot (eg, an elongated narrow opening) in the middle plate 1350. In one or more other implementations, one or more of the openings 1308 may have a Fig.13 The slot shape shown is different from one or more other shapes.

[0117] exist Fig.13 In the example of , the serpentine flow path 1300 includes four sub-channels 1306 (e.g., separated by three ridges 1309), each of which traverses the entire serpentine flow path 1300 and is fluidically coupled together at each turn or corner of the serpentine flow path 1300 (e.g., at the end of each linear segment). However, this is merely exemplary, and in other specific implementations, the serpentine flow path 1300 may include fewer than or more than four sub-channels 1306 (e.g., separated by fewer than or more than three ridges 1309), each of which traverses some or all of the entire serpentine flow path 1300 and may be fluidically separated or fluidically coupled together at one or more turns or corners or other locations along the serpentine flow path 1300.

[0118] As shown, the openings 1308 may include openings 1308 located away from the inlet port 1302 and the outlet port 1304, and may include a fifth group 1351 of openings 1308 at or near the inlet port 1302. For example, by providing the openings 1308 at or near the inlet port 1302, a portion of the cooling fluid introduced into the cold plate 308 via the inlet port 1302 on a first side of the intermediate plate 1350 may immediately traverse (e.g., through the openings 1308 at or near the inlet port 1302) to the other side of the intermediate plate 1350. In this way, the opening 1308 at or near the inlet port 1302 can facilitate the simultaneous initiation of the flow of the cooling fluid (e.g., upon introduction into the cold plate 308 via the inlet port 1302 and before the cooling fluid travels to the end of the serpentine flow path 1300 on the first side of the plate) through a first serpentine flow path (e.g., serpentine flow path 1300) on the first side 1303 of the middle plate 1350 and a second serpentine flow path (e.g., a second serpentine flow path that is a mirror image of the serpentine flow path 1300) on the opposite second side of the middle plate 1350. In this way, the thermal control provided by the cold plate 308 can be provided to the battery cells 120 on both sides of the cold plate 308 (e.g., in the top submodule 304 and the bottom submodule 306) more quickly and therefore more efficiently, which can facilitate more efficient and / or more reliable power delivery from the battery cells 120. As shown, intermediate plate 1350 may also include a sixth set 1353 of openings 1308 at or near outlet port 1304 .

[0119] Fig.14 A side view of a portion of a cold plate 308 attached to a battery cell 120 is illustrated according to one or more implementations. For example, the thermally conductive material 1202 may include an adhesive that attaches the bottom end of the battery cell 120 to the cold plate 308. Fig.14 In an example of , the battery cell 120 can be the outermost battery cell of a group of battery cells (e.g., in a battery subassembly, such as the top submodule 304 or the bottom submodule 306 described herein). As shown, the battery cells 120 (e.g., the bottom surfaces of the battery cells 120) can each be disposed within the outer boundary 1400 of the thermal contact surface 1402 of the cold plate 308 (e.g., the outer edge of the outermost battery cell 120 can be substantially aligned with the outer boundary 1400 of the thermal contact surface 1402). For example, the thermal contact surface 1402 can be the outer surface of the thermally conductive material 1202 (e.g., a thermally conductive adhesive). In this way, the entire bottom surface of each battery cell 120 can be in thermal contact with the cold plate 308 (e.g., with the thermally conductive material 1202), which can prevent or avoid reduced thermal control of the outer rows / columns of battery cells 120 in the battery subassembly.

[0120] Fig.15A perspective bottom view of a partially assembled battery module 115 having a cold plate 308 with a locating feature 1206 is illustrated according to one or more implementations. As shown, the locating feature 1206 may include an opening that receives a pin 1501 or other protrusion on a cell carrier 310 (e.g., a cell carrier 310 of a top submodule 304 or a bottom submodule 306 as described herein). Fig.15 In the example of FIG. 3 , the pin 1501 of the unit carrier 310 is received in the inner locating feature 1206 of the two locating features 1206 . Fig.15 Not shown, but related to Fig.15 Another unit carrier 310 (e.g., a unit carrier 310 of the other of the top submodule 304 or the bottom submodule 306 described herein) that is oriented opposite to the orientation of the unit carrier 310 shown in FIG. 1 may have locating pins that are received in the outer locating features 1206. In this way, the locating features 1206 of the cold plate 308 may be used to locate the top submodule 304 and the bottom submodule 306 of the battery module 115 to the cold plate 308.

[0121] Fig.16 A top view of a cold plate 308 is illustrated showing how positioning features 1208 (e.g., datuming features) may be used to position the cold plate 308 (and / or the battery modules 115 or other battery subassemblies within which the cold plate 308 is disposed) relative to one or more battery pack structures. For example, positioning features 1208 (e.g., datuming features) may be used to position the cold plate 308 (and / or the battery modules 115 or other battery subassemblies within which the cold plate 308 is disposed) relative to a cross member 1251 extending between battery modules 115 within a battery pack 110. As shown, the positioning features 1208 may include openings or recesses that allow positioning equipment (e.g., a camera or other sensor of positioning equipment that may lift and / or move the cold plate 308 and / or the battery modules 115 within which the cold plate 308 is disposed) to view one or more positioning features 1250 on the cross member 1100 or another battery pack structure. For example, positioning equipment including a camera or other sensor can lift and lower a battery module 115 including a cold plate 308 and can track the position of the positioning feature 1250 relative to the positioning feature 1208 while placing the battery module including the cold plate 308 in an appropriate position relative to the cross member 1251 (e.g., for attachment to the cross member 1251 and / or other battery pack structures).

[0122] For example Fig.12 , Fig.15 and Fig.16As shown, in one or more specific implementations, the cold plate 308 includes a flange 1204 extending along the edge of the cold plate 308 outside the serpentine flow path 1300. The flange may include one or more positioning features 1206, which are used to attach the cold plate to one or more cell carriers 310 of the battery module 115. In one or more specific implementations (e.g., as Figure 3 and Figure 4 ), the cold plate 308 may be disposed between two groups of battery cells, such as between a pair of battery modules (eg, the top submodule 304 and the bottom submodule 306 of the battery module 115) in an electric vehicle (eg, the vehicle 100). Fig.17 A top view of a portion of the cold plate 308 is illustrated, showing how the openings 1308 may be separated by gaps 1310 and gaps 1380 in one or more implementations.

[0123] Fig.18 A perspective view of a current collector assembly of a battery module according to one or more specific implementations is illustrated. Fig.18 As shown, CCA 400 may include one or more tabs 1800, one or more interconnect structures 1802, a connector 1804, a connector 1806, one or more edge portions 1808, and one or more notches 1810 (e.g., strain relief notches) in each of the edge portions.

[0124] Fig.19A Illustrated Fig.18 A perspective view of a portion of a current collector assembly (CCA) 400. Fig.19A As shown, the collector assembly 400 of the battery module 115 may include a conductive layer 1905, a first tab 1800A extending from the conductive layer 1905, and a second tab 1800B extending from the conductive layer 1905. For example, the conductive layer 1905 may be electrically interconnected with the tab 1800A (e.g., to be electrically interconnected with the positive terminal of the battery cell), and may be electrically interconnected with the tab 1800B (e.g., to be electrically interconnected with the negative terminal of the battery cell). As shown, the first tab 1800A may be configured to be welded to the positive terminal of the first battery cell 120 through a first plurality of (e.g., parallel) welding points 1900. The second tab 1800B may be configured to be welded to the negative terminal of the first battery cell 120 through a second plurality of (e.g., parallel) welding points 1902 and to the negative terminal of the second battery cell 120 through a third plurality of (e.g., parallel) welding points 1904. As shown Fig.19A As shown, the first insert 1800A may have a substantially straight shape. Fig.19AAs shown, the second insert sheet 1800B may have a substantially rectilinear shape. Thus, in addition to the first plurality of (e.g., parallel) welds, the first insert sheet 1800A may be provided with sufficient surface area for at least one additional plurality of (e.g., parallel) welds, and / or in addition to the second plurality of (e.g., parallel) welds and the third plurality of (e.g., parallel) welds, the second insert sheet 1800B may be provided with sufficient surface area for at least one additional plurality of (e.g., parallel) welds.

[0125] like Fig.19A As shown, the collector assembly 400 may include a plurality of first plug tabs 1800A having a first plug tab 1800A and a plurality of second plug tabs 1800B having a second plug tab 1800B. As shown, each of the plurality of first plug tabs 1800A may be electrically coupled and mechanically coupled to the conductive layer 1905 via a corresponding first flexible conductive connector 1909, and each of the plurality of second plug tabs 1800B may be electrically coupled and mechanically coupled to the conductive layer 1905 via a corresponding second flexible conductive connector 1911. As shown, the first plug tab 1800A and the second plug tab 1800B may each be disposed in a cutout in the conductive layer 1905.

[0126] In one or more specific implementations, the battery module 115 may include: a first battery cell 120 and a second battery cell 120; and a collector assembly 400. The collector assembly 400 may include a conductive layer 1905, a first tab 1800A extending from the conductive layer 1905, and a second tab 1800B extending from the conductive layer 1905. The first tab may be welded to the positive terminal of the first battery cell 120 through a first plurality of (e.g., parallel) welding points 1900, and the second tab may be welded to the negative terminal of the first battery cell 120 through a second plurality of (e.g., parallel) welding points 1902 and welded to the negative terminal of the second battery cell through a third plurality of (e.g., parallel) welding points 1904. In one or more specific implementations, the battery module 115 may also include: a third battery cell 120 and a fourth battery cell 120, which are mounted in an orientation substantially opposite to that of the first battery cell 120 and the second battery cell 120; and an additional collector assembly 400. The additional current collector assembly 400 may include an additional conductive layer 1905, a third tab 1800A extending from the additional conductive layer 1905, and a fourth tab 1800B extending from the additional conductive layer 1905. The third tab 1800A may be welded to the positive terminal of the third battery cell 120 via a fourth plurality of (e.g., parallel) welding points 1900, and the fourth tab 1800B may be welded to the negative terminal of the fourth battery cell 120 via a fifth plurality of (e.g., parallel) welding points 1902 and welded to the negative terminal of the third battery cell 120 via a sixth plurality of (e.g., parallel) welding points 1904.

[0127] In one or more specific implementations, an electric vehicle (e.g., vehicle 100) may include a collector assembly 400, wherein the collector assembly 400 includes a conductive layer 1905, a plurality of first tabs 1800A extending from the conductive layer 1905, and a plurality of second tabs 1800B extending from the conductive layer 1905. Each first tab may be welded to the positive terminal of a first battery cell 120 in a corresponding pair of battery cells 120 via a first plurality of (e.g., parallel) welding points 1900, and each second tab may be welded to the negative terminal of the first battery cell 120 via a second plurality of (e.g., parallel) welding points 1902 and welded to the negative terminal of a second battery cell 120 in a corresponding pair of battery cells 120 via a third plurality of (e.g., parallel) welding points 1904.

[0128] In one or more specific implementations, a method may be provided, the method comprising: providing a plurality of battery cells 120, each battery cell having a positive terminal and a negative terminal at a first end thereof; aligning a first plurality of tabs 400 of a collector assembly 1800A with the positive terminals of the plurality of battery cells 120 and aligning a second plurality of tabs 400 of a collector assembly 1800B with the negative terminals of the plurality of battery cells 120; forming a first plurality of (e.g., parallel) welding points 1900 on each of the first plurality of tabs 1800A to align the positive terminals of the plurality of battery cells 120; A first plurality of plug-ins 1800A are respectively connected to the positive terminals of the plurality of battery cells 120; and a second plurality of (e.g., parallel) welding points 1902 are formed on each of the second plurality of plug-ins 1800B to connect the negative terminal of one of the plurality of battery cells 120 to the second plug-in 1800B and a third plurality of (e.g., parallel) welding points 1904 are formed on each of the second plurality of plug-ins 1800B to connect the negative terminal of another battery cell in the plurality of battery cells 120 to the second plug-in.

[0129] As discussed herein, edge portion 1808 of conductive layer 1905 of CCA 400 may be provided with one or more notches 1810. Fig.19A As shown, in one or more specific implementations, at least one notch 1810 may include a first extension 1907 in a first corner of the notch 1810 and a second extension 1907 in a second corner of the notch 1810. Fig.19A As shown, notch 1810 can be configured to extend from outer edge 1921 of conductive layer to a position beyond inner edge 1923 of electrical structure 1906 when edge portion 1808 is bent and welded to electrical structure 1906 .

[0130] like Fig.19A As shown, the notch 1810 can facilitate bending of the edge portion 1808. For example, the collector assembly 400 of the battery module 115 may include a conductive layer 1905 having an edge portion 1808 that is configured to be bent and welded to an electrical structure 1906. For example, the electrical structure 1906 can be a busbar, such as the busbar 320, busbar 322, or series busbar 406 described herein. In one or more specific implementations, at least one notch 1810 in the edge portion 1808 facilitates bending of the edge portion 1808 to the electrical structure 1906. For example, Fig.19B An edge portion 1808 of the conductive layer 1905 of the current collector assembly 400 is illustrated, which is bent over a portion of the electrical structure 1906. For example, Fig.19BAs shown, the conductive layer 1905 can be provided in a substantially planar configuration, and then, the edge portion 1808 (e.g., on either side of the notch) can be bent into contact and / or over the edge of the electrical structure 1906 (e.g., during a clamping process), and attached to the electrical structure 1906 using a weld 1910 (e.g., an edge weld, such as using a laser weld). Providing a strain relief notch (e.g., notch 1810) that allows the edge portion 1808 to be bent toward the electrical structure 1906 for forming the weld 1910 can improve the weld 1910, which can improve the structural reliability of the battery module 115, and can improve the current carrying performance of the CCA 400, which can enhance the charging performance of the battery subassembly, the battery module 115, and / or the battery module 110. For example, improving the weld 1910 as described can increase the rate at which the battery cells 120 can be charged (e.g., up to or more than several minutes).

[0131] Fig. 20 A cross-sectional side view of a portion of a battery module including a cell carrier and a cold plate according to one or more implementations is illustrated. Fig. 20 In an example of , a cell carrier 310 for a plurality of battery cells 120 includes a portion (e.g., a crate-like structure 2000) defining an arrangement (e.g., an array) of a plurality of openings, each of which is configured to receive a battery cell 120. As shown, the portion of the cell carrier 310 can be configured to secure a lower portion of each battery cell 120 within a corresponding one of the openings to allow an upper portion of each battery cell 120 to be contacted by a potting material 2004 (e.g., a foamed or synthetic potting material) between adjacent battery cells 120 (e.g., and substantially filling the space between adjacent battery cells) and extending from a top level of the battery cells 120 (e.g., at tops 2022) to the portion of the cell carrier (e.g., to the crate-like structure 2000). In one or more specific implementations, the crate-like structure 2000 can be a structure that includes the components described herein (e.g., in combination with the components described herein). Fig.10 )'s side wall 1001, flange 1000 and rib 1002 are an integral part of the one-piece structure.

[0132] like Fig. 20 As shown, the first adhesive 2002 can attach the crate structure 2000 to the battery cell 120. For example, the first adhesive can be partially formed of a polyurethane, such as a two-part polyurethane system. In one or more specific implementations, the potting material 2004 can also be formed of the same polyurethane or a similar polyurethane (e.g., and a plurality of microspheres). In this way, the first adhesive 2002 can provide a low viscosity adhesive to bond the battery cell 120 to the cell carrier 310 and can be compatible with the polyurethane potting system of the potting material 2004.

[0133] like Fig. 20As shown, the cold plate 308 may be provided with a second adhesive (e.g., thermally conductive material 1202) different from the first adhesive 2002, which attaches the bottom surface (e.g., bottom 2003) of each of the battery cells 120 to the cold plate 308. For example, the second adhesive may be a thermally conductive adhesive corresponding to the thermally conductive material 1202. For example, the second adhesive may be implemented as a conductive adhesive transfer tape or a double-sided adhesive tape that substantially covers the surface of the cold plate. For example, the double-sided conductive adhesive tape may be sized and cut to the size of the cold plate below the cell, and then adhered to the cold plate 308 with a release liner. As shown in FIG. Fig. 20 As shown, the cold plate 308 may be provided with a layer of thermally conductive adhesive tape on each side thereof (e.g., for attaching oppositely oriented battery cells 120 of the top submodule 304 and the bottom submodule 306 of the battery module 115). Providing a double-sided conductive adhesive tape may reduce or eliminate powder coating that may otherwise be provided on the aluminum cold plate. For example, powder coating is sometimes used as an isolation barrier, and reducing or eliminating the need for powder coating may save costs, reduce complexity, reduce manufacturing cycle time, and / or reduce health and safety risks in manufacturing.

[0134] In one or more implementations, the lower portion 2016 of each battery cell 120 may include a portion of the battery cell that extends from the bottom 2003 of the battery cell 120 to a position that is less than halfway 2020 from the top 2022 of the battery cell 120. For example, the lower portion 2016 of each battery cell may include a portion of the battery cell 120 that extends from the bottom of the battery cell to a position that is less than one-quarter of the distance from the top 2022 of the battery cell 120. For example, in one or more implementations, the battery cell 120 may have a height of, for example, between 25 and 200 millimeters (mm), and the crate structure 2000 may be located at a height D (e.g., from the bottom of the battery cell 120 or from the bottom of the cell carrier 310) that is less than 20 mm, less than 10 mm, or less than 5 mm.

[0135] In one or more specific implementations, a battery subassembly such as a battery module 115 may include a cell carrier 310 of a plurality of battery cells 120, wherein the cell carrier 310 includes a crate structure 2000 having a plurality of openings, each of which is configured to receive a battery cell 120. The crate structure 2000 may be configured to secure a lower portion 2016 of each battery cell 120 to allow an upper portion 2018 of each battery cell 120 to be contacted by a potting material contact 2004 between adjacent battery cells and extending from a top level of the battery cell to the crate structure 2000. The battery module 115 may also include a plurality of battery cells 120, each having its lower portion 2016 secured to the crate structure 2000 by a first adhesive 2002. The potting material 2004 may extend between adjacent battery cells 120 and from a top level of the battery cells 120 (e.g., at a top 2022) to the crate structure 2000.

[0136] In one or more specific implementations, an electric vehicle (e.g., vehicle 100) is provided with a battery pack 110 including one or more battery subassemblies (e.g., battery modules 115), each of the one or more battery subassemblies including a unit carrier 310 of a plurality of battery cells 120, wherein the unit carrier 310 includes a crate structure 2000 having a plurality of openings, each opening being configured to receive a battery cell 120. The crate structure 2000 can be configured to secure a lower portion 2016 of each battery cell 120 to allow an upper portion 2018 of each battery cell 120 to be contacted by a potting material contact 2004 between adjacent battery cells and extending from a top level of the battery cell to the crate structure 2000.

[0137] In one or more specific implementations, a method may be provided, the method comprising inserting a plurality of battery cells 120 into a cell carrier 310; attaching a lower end (e.g., a lower portion 2016) of each of the plurality of battery cells 120 to a portion of the cell carrier 310 (e.g., a crate structure 2000 of the cell carrier 310) using a first adhesive 2002; and providing a potting material 2004 to a plurality of spaces between the battery cells 120 in the plurality of battery cells 120 such that the potting material contacts the battery cells 120 and the portion of the cell carrier (e.g., a crate structure 2000 of the cell carrier 310). Fig. 20 The method may also include attaching the cold plate 308 to the bottom 2003 of each battery cell in the plurality of battery cells 120 using a second adhesive (eg, thermally conductive material 1202 ) different from the first adhesive 2002 .

[0138] Various examples are described herein in which the cell carrier 310 is provided with sidewall structures, such as ribs 1002, which can be configured to distribute at least a portion of an impact force on the cell carrier 310 (e.g., due to an impact to the battery pack 110, such as caused by a vehicle collision) away from the battery cells carried by the cell carrier 310. For example, in Figure 3 and Fig.10 In the example of , the ribs 1002 of the unit carrier 310 are implemented as gussets extending perpendicularly from the side wall 1001 to a flange 1000 extending outwardly from the base of the side wall 1001 perpendicularly to the side wall 1001 and perpendicularly to each of the ribs 1002 .

[0139] For example, in Figure 3 and Fig.10 In the example of FIG. 1 , each of the ribs 1002 extends from the corresponding sidewall 1001 to a first distance at the corresponding flange 1000 and tapers linearly toward the corresponding sidewall 1001, i.e., vertically moves away from the corresponding flange 1000. However, in one or more other implementations, the ribs 1002 may have the same Figure 3 and Fig.10 The linear tapers shown have different outer contours. For example, Fig.21 A specific implementation of a unit carrier 310 is illustrated in which at least some of the ribs 1002 have a curved outer profile. In this example, the curved outer profile may include a portion that tapers (e.g., non-linearly) away from the sidewall 1001, and a recessed portion 2100 having a first section that tapers (e.g., non-linearly) back toward the sidewall 1001 and a second section that tapers (e.g., non-linearly) away from the sidewall 1001 toward the flange 1000. Providing the recessed portion 2100 on the rib 1002 may help reduce stress experienced by the rib 1002 and / or the flange 1000 during assembly of the battery module 115 into the battery pack 110 (e.g., including inserting the rib 1002 into the recess 1102 in the cross member 1100). For example, the recessed portion 2100 may allow the rib to flex during assembly, which may help prevent cracking or breaking of the rib and / or other portions of the unit carrier.

[0140] Fig. 22 A portion of a unit carrier having a flange 1000 is illustrated. Figure 3 In the example of the present invention, a portion of the crate structure 2000 (eg, Fig. 20 120) is also visible, which has an opening 2202 for receiving the battery cell 120. For example, the opening 2202 may be provided with an adhesive 2002, as described above in conjunction with Fig. 20 As discussed. Fig. 22As shown, in one or more implementations, the flange 1000 may also have ribs 2200 (eg, on a bottom surface thereof, such as a bottom surface configured to interface with the cold plate 308). Fig.23 A cross-sectional side view of a portion of a battery module 115 is illustrated, wherein a flange 1000 of a cell carrier of a top submodule 304 and a flange 1000 of a cell carrier of a bottom submodule 306 are mounted to contact a cold plate 308 (e.g., in one or more implementations, contact is made on opposite top and bottom sides of the flange 1204 of the cold plate 308). The ribs 2200 on the bottom surface of the flange 1000 can reduce stress experienced by the flange 1000 and / or the ribs 1002 during assembly of the battery module 115 into the battery pack 110. For example, the ribs 2200 can allow the flange 1000 to flex during assembly, which can help prevent cracking or breaking of the flange, ribs, and / or other portions of the cell carrier. Fig.23 Also shown is how the cold plate 308 may be provided with a compression limiter 2300. The compression limiter 2300 may have a height that extends (e.g., completely) from the top of the opening in the flange 1000 of the top submodule 304 to the bottom of the opening in the flange 1000 in the bottom submodule 306. In this way, the compression limiter 2300 may act as a gap filler to help provide an even distribution of loads on the module flange 1000.

[0141] During operation of the vehicle, shock and / or vibration loads may affect the installation of certain vehicle components (e.g., particularly in use cases where the vehicle is used for off-road travel). For example, in some use cases, BVT rattling and / or BVT interface wear may be caused by movement of the vehicle relative to other module components. If the BVT is not adequately retained in place, this may impose stress and / or strain on the flexible wiring harness, such as connector 1804 of connector 1806 for CCA 400. The stress and / or strain on the flexible wiring harness may result in damage to the weld traces therein and / or loss of p-string voltage. In some use cases, the loss of p-string voltage during vehicle operation may cause the vehicle to be placed in a safe state or otherwise become (e.g., temporarily) unusable. In one or more specific implementations, the battery module or other battery subassembly may be provided with additional mounting and / or retention features for the BVT. For example, Fig.24 An example of a bus bar 322 is illustrated that may be provided with mounting features for a BVT module 316. As shown, the bus bar 322 may be provided with a notch 2400 and / or one or more holes 2402. Fig.25 1 illustrates a specific implementation of a housing 800 of a BVT module 316 that can be at least partially mounted to a Fig.24 The busbar 322. Fig.25As shown, in addition to the mounting feature 804 (eg, which may snap into a corresponding feature in the unit carrier 310), the housing 800 may be provided with a snap feature 2500 configured to be provided by Fig.24 The housing 800 of the BVT module 316 may also include one or more extensions 2502 as shown. As shown, the extensions 2502 may have holes that are configured to align with the holes 2402 on the busbar 322 to allow fasteners (e.g., push pins) to pass through the extensions 2502 and the holes 2402 to further secure the BVT module 316 to the unit carrier. Fig.25 In the example of FIG. 8 , the housing 800 includes snap features at two outer edges thereof, snap features at the top thereof, and extensions at the top of the outer edges thereof for receiving push pins. In various other implementations, vertical ribs on the busbar overmold may be provided, one or more additional pin features may be provided (e.g., along the top or bottom of the housing 800), and / or one or more additional snap features may be provided (e.g., along the bottom of the housing 800). Additional mounting and / or retention features may be provided for the BVT module 316 (e.g., as in FIG. 8 ). Fig.24 and Fig.25 ) can help prevent movement of the BVT module 316 relative to other portions of the battery module 115 during operation of the vehicle, which can also help reduce vibration and flexing of the voltage sensing harness (VSH) that may include connectors 1804 and / or 1806. Reducing VSH flexing can reduce strain and / or stress on the traces therein and thereby reduce the risk of p-string voltage loss. As in Fig.24 and Fig.25 As in the example of FIG. 1 , a robust retention mechanism can reduce and / or eliminate maintenance instances of the BVT and / or VSH, thereby reducing field repair costs and resources and / or improving the reliability of the electric vehicle. Fig.24 and Fig.25 The installation / retention features of the device can provide a common strategy for different transportation projects. Fig.24 and Fig.25 In the example of , busbar 322 is provided with additional retention features (e.g., push pin holes) that can serve as backup retention features (e.g., in the event that the BVT clip breaks during handling / installation), thereby reducing scrap and / or improving production yields to enable high volume production.

[0142] Aspects of the subject technology can help improve the efficiency and / or range of electric vehicles. This can help promote the operation and / or popularity of electric vehicles, which can have a positive impact on the climate by reducing greenhouse gas emissions.

[0143] Unless otherwise specified, an element mentioned in the singular is not intended to represent one and only one, but one or more. For example, "a" module may refer to one or more modules. In the absence of further constraints, an element beginning with "a", "an", "the" or "said" does not exclude the presence of other identical elements.

[0144] Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the terms "including" or "having" and the like are used, such terms are intended to be inclusive in a manner similar to the term "comprising" as understood when "including" is used as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0145] Phrases such as an aspect, this aspect, another aspect, some aspects, one or more aspects, a specific implementation, this specific implementation, another specific implementation, some specific implementations, one or more specific implementations, an embodiment, this embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, this configuration, another configuration, some configurations, one or more configurations, subject technology, this disclosure, the present disclosure, other variations thereof, etc. are for convenience and do not imply that the disclosures associated with such phrases are necessary for the subject technology, or that such disclosures are applicable to all configurations of the subject technology. The disclosures associated with such phrases may be applicable to all configurations or one or more configurations. The disclosures associated with such phrases may provide one or more examples. Phrases such as an aspect or some aspects may refer to one or more aspects, and vice versa, and this is similarly applicable to other aforementioned phrases.

[0146] The phrase "at least one" preceding a list of items, with the terms "and" or "or" used to separate any of those items, modifies the list as a whole, rather than as each constituent item of the list. The phrase "at least one" does not require selection of at least one item; rather, the phrase allows for a meaning that includes at least one of any of those items, and / or at least one of any combination of those items, and / or at least one of each of those items. As an example, each of the phrases "at least one of A, B, and C" or "at least one of A, B, or C" means only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0147] It should be understood that the specific order or level of the disclosed steps, operations or processes is an illustration of an exemplary method. Unless otherwise clearly stated, it should be understood that the specific order or level of steps, operations or processes can be performed in different orders. Some of the steps, operations or processes can be performed simultaneously. The attached method claims (if any) present the elements of various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or level presented. These can be performed continuously, linearly, in parallel or in different orders. It should be understood that the instructions, operations and systems described can usually be integrated together in a single software / hardware product or packaged into multiple software / hardware products.

[0148] In one aspect, the term "coupled" or the like may refer to a direct coupling. In another aspect, the term "coupled" or the like may refer to an indirect coupling.

[0149] Terms such as top, bottom, front, back, side, horizontal, vertical, etc. refer to an arbitrary reference frame, not the ordinary gravitational reference frame. Thus, such terms may extend upward, downward, diagonally, or horizontally in a gravitational reference frame.

[0150] The present disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are shown in block diagram form to avoid confusion with the various concepts of the subject technology. The present disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Those skilled in the art will readily appreciate various modifications to these aspects, and the principles described herein may be applied to other aspects.

[0151] All structural and functional equivalents of the various elements of the various aspects described throughout this disclosure are known or will later become known to those of ordinary skill in the art, and these equivalents are expressly incorporated herein by reference and are intended to be included in the claims. In addition, nothing disclosed herein is intended to serve the public, regardless of whether such disclosure is explicitly stated in the claims. No claim element should be interpreted under the provisions of 35 U.S.C. §112(f) unless the element is explicitly stated using the phrase "means for..." or, in the case of a method claim, the element is stated using the phrase "step for..."

[0152] Those skilled in the art will appreciate that the various illustrative frames, modules, elements, parts, methods and algorithms described herein can be implemented as hardware, electronic hardware, computer software or a combination thereof. In order to illustrate this interchangeability of hardware and software, various illustrative frames, modules, elements, parts, methods and algorithms have been generally described above in terms of their functionality. Whether this functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the entire system. Those skilled in the art can implement the described functionality in different ways for each specific application. Various parts and frames can be arranged differently (e.g., arranged in different orders or divided in different ways), all of which do not depart from the scope of this subject technology.

[0153] The invention title, background technology, figure description, abstract of the specification, and drawings are hereby incorporated into the present disclosure and are provided as illustrative examples of the present disclosure rather than as limiting descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that for the purpose of simplifying the present disclosure, the description provides illustrative examples and various features are grouped together in various specific implementations. The method of the present disclosure should not be interpreted as reflecting the intention that the claimed subject matter requires more features than those explicitly stated in each claim. On the contrary, as reflected in the claims, the inventive subject matter lies in less than all the features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim independently serving as a separately claimed subject matter.

[0154] The claims are not intended to be limited to the aspects described herein, but should be given the full scope consistent with the language of the claims and encompassing all legal equivalents. Nevertheless, none of the claims is intended to encompass subject matter that fails to satisfy the requirements of applicable patent law, nor should it be interpreted in such a manner.

Claims

1. A device, comprising: a cell carrier for a plurality of battery cells, wherein the cell carrier includes a portion defining an arrangement of a plurality of openings, each opening being configured to receive a battery cell, Wherein the unit carrier portion is configured to secure a lower portion of each battery cell within a corresponding one of the openings to allow an upper portion of each battery cell to be contacted by potting material between adjacent battery cells and extending from a top level of the battery cells to the portion of the unit carrier. 2 . The device of claim 1 , further comprising a first adhesive attaching the portion of the cell carrier to the battery cell.

3. The device of claim 2, wherein the first adhesive comprises polyurethane.

4. The device of claim 3, wherein the potting material comprises the polyurethane and a plurality of microspheres. 5 . The apparatus of claim 2 , further comprising a cold plate and a second adhesive different from the first adhesive, the second adhesive attaching a bottom surface of each of the battery cells to the cold plate. The device of claim 5 , wherein the second adhesive comprises a thermally conductive adhesive.

7. The apparatus of claim 5, wherein the second adhesive comprises a double-sided adhesive tape that substantially covers a surface of the cold plate. 8 . The apparatus of claim 7 , wherein the lower portion of each battery cell comprises a portion of the battery cell extending from a bottom of the battery cell to a position less than halfway from a top of the battery cell. 9 . The device of claim 1 , wherein the lower portion of each battery cell comprises a portion of the battery cell extending from a bottom of the battery cell to a position less than one-quarter of the distance from a top of the battery cell.

10. The apparatus of claim 1, wherein the portion of the unit carrier comprises a crate structure of the unit carrier.

11. A device, comprising: A battery subassembly, the battery subassembly comprising: A cell carrier for a plurality of battery cells, wherein the cell carrier comprises a crate-like structure having a plurality of openings, each opening being configured to receive a battery cell, wherein the crate-like structure is configured to secure a lower portion of each battery cell to allow an upper portion of each battery cell to be contacted by potting material between adjacent battery cells and extending from a top level of the battery cells to the crate-like structure.

12. The apparatus of claim 11, the battery subassembly further comprising the plurality of battery cells, each battery cell having the lower portion of the battery cell secured to the crate structure by a first adhesive.

13. The apparatus of claim 12, the battery subassembly further comprising the potting material between adjacent battery cells and extending from a top level of the battery cells to the crate structure.

14. The device of claim 12, wherein the first adhesive comprises polyurethane, and wherein the potting material comprises the polyurethane and a plurality of microspheres. 15 . The apparatus of claim 14 , wherein the first adhesive and the crate structure prevent the potting material from flowing into contact with the lower portion of each of the battery cells.

16. The device of claim 11, wherein the device comprises a vehicle, the vehicle comprising the battery subassembly.

17. The apparatus of claim 16, wherein the vehicle includes a battery pack, the battery pack including the battery subassembly and a plurality of additional battery subassemblies.

18. A method comprising: inserting a plurality of battery cells into a cell carrier; attaching a lower end of each of the plurality of battery cells to the crate structure of the cell carrier using a first adhesive; as well as A potting material is provided into a plurality of spaces between the battery cells of the plurality of battery cells such that the potting material contacts the battery cells and the crate structure. 19 . The method of claim 18 , further comprising attaching a cold plate to a bottom of each battery cell in the plurality of battery cells using a second adhesive different from the first adhesive.

20. The method of claim 19, wherein the second adhesive comprises a thermally conductive adhesive that conducts heat between the battery cells and the cold plate.

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