Battery can with substantially zero radius internal corner

Abstract

A battery, the battery comprising: a cap comprising a cap main wall and a first cap side wall extending from the cap main wall at a first substantially vertical angle; a base including a base main wall and a first base sidewall extending from the base main wall at a second substantially perpendicular angle; and a sidewall structure. A first end of the sidewall structure is coupled against the cap main wall and the first cap sidewall to define a first interior corner between the sidewall structure and the cap main wall. A second end of the sidewall structure is coupled against the base main wall and the first base sidewall to define a second interior corner between the sidewall structure and the base main wall. The first inner corner and the second inner corner include a radius that is substantially zero. The cover, the base, the sidewall structure, the first interior corner, and the second interior corner define an interior volume. The battery also includes a cell stack positioned in the interior volume.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 604,795, filed on November 30, 2023, entitled "BATTERY CAN HAVING SUBSTANTIALLY ZERO-RADIUS INTERIOR CORNERS", which is hereby incorporated by reference in its entirety. BACKGROUND OF THE INVENTION

[0003] As electronic devices evolve in functionality, there is a corresponding need to reduce the size of the electronic devices. At the same time, the electronic devices are required to maintain a certain level of battery performance. However, the electronic devices may be limited by the shape and size of the battery. SUMMARY OF THE INVENTION

[0004] One aspect of the present disclosure provides a battery, the battery comprising: a cover including a cover main wall and a first cover side wall extending from the cover main wall at a first substantially vertical angle; a base including a base main wall and a first base side wall extending from the base main wall at a second substantially vertical angle; a side wall structure. A first end portion of the side wall structure is coupled against the cover main wall and the first cover side wall to define a first internal corner between the side wall structure and the cover main wall. A second end portion of the side wall structure is coupled against the base main wall and the first base side wall to define a second internal corner between the side wall structure and the base main wall. The first internal corner and the second internal corner include a substantially zero radius. The cover, the base, the side wall structure, the first internal corner and the second internal corner define an internal volume. The battery further includes a battery cell stack positioned within the internal volume. The substantially zero radius may include a radius less than 1 mm. All internal corners defined between the cover and the side wall structure, and between the base and the side wall structure include a substantially zero radius. The internal volume may be further defined by all internal corners. The first cover side wall and the first base side wall may extend from an edge of the cover main wall and an edge of the base main wall respectively. The cover main wall may include a second cover side wall extending transversely to the first cover side wall from the cover main wall, and the base main wall may include a second base side wall extending transversely to the first base side wall from the base main wall. The first cover side wall and the second cover side wall may be substantially perpendicular to each other, and the first base side wall and the second base side wall may be substantially perpendicular to each other. The cover main wall may include a cover extension portion extending outside the side wall structure, and the base main wall may include a base extension portion extending outside the side wall structure. The cover extension portion may be disposed substantially in the same plane as the cover main wall, and the base extension portion may be disposed substantially in the same plane as the base main wall. The side wall structure may include a plurality of side wall members, each of the side wall members including a first end portion and a second end portion. The first end portions of the side wall members may be coupled to each other and the second end portions of the side wall members may be coupled to each other to define the side wall structure. The first end portion may define a first slot and may include a first flange, and the second end portion defines a second slot and may include a second flange. The first flange may be received in the second slot, and the second flange may be received in the first slot. The battery may further include: an electrical contact extending from the internal volume of the side wall structure to the outside of the side wall structure; and a conductive member electrically coupling the battery cell stack to the electrical contact. The battery cell stack may be electrically coupled to the conductive member, and the conductive member may include less than two bends along the length of the conductive member.

[0005] Another aspect of the present disclosure provides a battery, the battery comprising: a cover including a cover main wall and a first cover sidewall extending laterally from the cover main wall; a base including a base main wall and a first base sidewall extending laterally from the base main wall; and a sidewall structure. A first end of the sidewall structure abuts and is coupled to the cover main wall and the first cover sidewall to define a first internal corner between the sidewall structure and the cover main wall. A second end of the sidewall structure abuts and is coupled to the base main wall and the first base sidewall to define a second internal corner between the sidewall structure and the base main wall. The first internal corner and the second internal corner include a substantially zero radius. The cover, the base, the sidewall structure, the first internal corner, and the second internal corner define an internal volume. The battery further includes a battery cell stack positioned within the internal volume. The substantially zero radius may include a radius less than 1 mm. The first cover sidewall may extend substantially perpendicularly from the cover main wall, and the first base sidewall may extend substantially perpendicularly from the base main wall. The cover main wall may include a second cover sidewall extending laterally from the cover main wall and transverse to the first cover sidewall, and the base main wall may include a second base sidewall extending laterally from the base main wall and transverse to the first base sidewall. The sidewall structure may include a plurality of sidewall members, each of the sidewall members including a first end and a second end. The first ends of the sidewall members may be coupled to each other, and the second ends of the sidewall members are coupled to each other to define the sidewall structure.

[0006] Another aspect of the present disclosure provides a battery, the battery comprising a rigid metal housing characterized by an internal volume, wherein the housing includes: a cover including a cover main wall and a first cover sidewall extending from the cover main wall; a base including a base main wall and a first base sidewall extending from the base main wall; and a structural sidewall extending between the cover and the base to define a plurality of internal corners having a substantially zero radius. The cover is coupled to the structural sidewall at the first cover sidewall, and the base is coupled to the structural sidewall at the first base sidewall. The battery further includes a battery cell stack positioned within the internal volume. The first cover sidewall may extend from the cover main wall at a first substantially perpendicular angle, and the first base sidewall may extend from the base main wall at a second substantially perpendicular angle. The substantially zero radius may include a radius less than 1 mm. All internal corners defined between the cover and the sidewall structure and between the base and the sidewall structure include a substantially zero radius. The internal volume may be further defined by all internal corners. The cover main wall may include a second cover sidewall extending laterally from the cover main wall and transverse to the first cover sidewall, and the base main wall may include a second base sidewall extending laterally from the base main wall and transverse to the first base sidewall. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A further understanding of the nature and advantages of the various embodiments can be realized by referring to the following drawings. In the drawings, like components or features may have the same reference numerals. Additionally, various components of the same type can be distinguished by adding a dash and a second label used to differentiate between like components after the reference numeral. If only the first reference numeral is used in the specification, the description applies to any one of the like components having the same first reference numeral, regardless of the second reference numeral.

[0008] Figure 1 A partial cross-sectional view of an exemplary battery according to one aspect of the present disclosure is depicted.

[0009] Figure 2A An isometric view of an exemplary battery according to one aspect of the present disclosure is depicted.

[0010] Figure 2B Depicts Figure 2A an exploded view of the battery.

[0011] Figure 2C Depicts Figure 2A a partial cross-sectional view of the battery along cross-section 2C-2C.

[0012] Figure 2D Depicts Figure 2A a partial cross-sectional view of the battery along cross-section 2D-2D.

[0013] Figure 3A An isometric view of an exemplary battery according to one aspect of the present disclosure is depicted,

[0014] Figure 3B Depicts Figure 3A a partial cross-sectional view of the battery along cross-section 3B-3B.

[0015] Figure 3C Depicts Figure 3A a partial cross-sectional view of the battery along cross-section 3C-3C.

[0016] Figure 4A An isometric view of an exemplary battery according to one aspect of the present disclosure is depicted,

[0017] Figure 4B Depicts Figure 4A a partial cross-sectional view of the battery along cross-section 4B-4B.

[0018] Figure 4C Depicts Figure 4A a partial cross-sectional view of the battery along cross-section 4C-4C.

[0019] Figure 5A An exemplary sidewall structure according to one aspect of the present disclosure is depicted.

[0020] Figure 5B depicts Figure 5A A partial view of a sidewall member of the sidewall structure of

[0021] Figure 6 depicts an example sidewall structure according to one aspect of the present disclosure.

[0022] Figure 7A depicts a partial cross-sectional view of an example battery according to one aspect of the present disclosure.

[0023] Figure 7B depicts an example battery Figure 7A coupled between a base and a lid.

[0024] Figure 8 depicts an example flow chart for forming a battery according to one aspect of the present disclosure. DETAILED DESCRIPTION

[0025] When a battery is coupled in a battery pack or an electronic device, the battery may occupy an effective volume defined by the volume of the main dimensions of the battery within the battery pack or the electronic device. However, the specific shapes and dimensions of certain features of the battery (e.g., the battery housing) may effectively prevent other components (e.g., battery cells, electrode tabs, or other components) from occupying space within the effective volume. In other words, certain features of the battery may have shapes and / or dimensions that make certain portions of the effective volume into dead space (e.g., space that is not easily occupied by another component other than the battery). Therefore, it is desirable to maximize the amount of space available for use by the battery by minimizing the dead space within the effective volume.

[0026] Figure 1 Examples of batteries with excessive dead space can be seen in Figure 1 depicts a partial cross-sectional view of an example battery 100. The battery 100 may have a lid 110 and a base 130 coupled together via welding, brazing, soldering, gluing, etc. The lid 110 and the base 130 may have main dimensions (e.g., a main height 162 and a main width 161) that define the battery 100 as having an effective volume 163. The lid 110 and the base 130 may define an internal volume 150 therebetween. The battery 100 may include a battery cell stack 101 (e.g., one or more of a cathode layer, an anode layer, a separator, and a current collector) positioned within the internal volume 150. The portion of the effective volume 163 that is not occupied by the internal volume 150 or the battery 100 may be dead space 164. When the battery 100 is coupled within a battery pack or an electronic device, due to certain features of the battery 100, the battery 100 may have a large amount of dead space 164.

[0027] For example, the lid 110 may include a lid main wall 117 and a lid side wall 114, with a circular corner 115 defined therebetween. The corner 115 may have a circular shape, such as by forming the lid 110 through a deep-drawing metal stamping process. This circular shape of the corner 115 may increase the dead space 164 in the effective volume 163 by reducing the size of the internal volume 150 and defining a space just outside the corner 115 that is not easily occupied by another component. Although the radius of the corner 115 may be reduced by decreasing the radius of the imprint during the stamping process, there is a lower limit to the radius of the corner 115 because a too-small radius increases the risk that the lid 110 will tear along the corner 115 during the stamping process or during use. Thus, the circular shape of the corner 115 may increase the dead space 164 within the effective volume 163 of the battery 100.

[0028] In addition, the lid 110 may include a lid extension portion 116 extending from the lid side wall 114 to outside the internal volume 150, and the base 130 may include a base extension portion 136 extending past the lid side wall 114 to outside the internal volume 150. The lid 110 and the base 130 may be coupled to each other at the lid extension portion 116 and the base extension portion 136. The lengths of the extension portions 116, 136 may correspond to the minimum lengths required for the lid 110 and the base 130 to be sufficiently coupled to each other along the extension portions 116, 136 (e.g., the sufficient length required for the extension portions 116, 136 to be seam-welded together). However, this length and the height of the combined extension portions 116, 136 may increase the effective volume 163 occupied by the battery 100 while increasing the dead space 164 within the effective volume 163 of the battery 100 because the dimensions of the extension portions 116, 136 create a space within the effective volume 163 that is not easily occupied by other components.

[0029] The battery 100 may include an insulating member 180 (e.g., a gasket) and an electrical contact 182 (e.g., a rivet), which are received through a hole 121 defined along the lid sidewall 114. The battery cell stack 101 may be electrically coupled to the electrical contact 182 through a conductive member 102. The electrical contact 182 and the conductive member 102 may be made of a conductive material (e.g., aluminum, copper, nickel, etc.) such that electric charge may be transmitted from the battery cell stack 101 through the conductive member 102 to the electrical contact 182 to provide power to one or more electronic components coupled to the electrical contact 182. The method of coupling the battery cell stack 101 within the internal volume 150 may cause certain components (e.g., the conductive member 102) to occupy a large amount of space. Specifically, after the lid 110 is formed and the electrical contact 182 and the insulating member 180 are coupled in the hole 121, the battery cell stack 101 and the conductive member 102 may be coupled to the electrical contact 182 while the battery cell stack 101 is positioned outside the internal volume 150. After the conductive member 102 is coupled to the electrical contact 182, the battery cell stack 101 may be rotated into the internal volume 150 about the coupling point between the conductive member 102 and the electrical contact 182 such that the conductive member 102 defines a first bend 103 and a second bend 104 along the conductive member 102. These bends 103, 104 may occupy space within the internal volume 150 that could otherwise be used by a larger battery cell stack 101. Accordingly, the battery 100 may have a reduced energy density.

[0030] The present disclosure relates to a battery having a housing with internal corners having a substantially zero radius. Specifically, a lid and a base may be coupled to a sidewall structure such that the internal corners defined between the lid and the sidewall structure and between the base and the sidewall structure of the battery may have a substantially zero radius. This configuration minimizes the amount of dead space in the effective volume of the battery, e.g., by increasing the internal volume of the battery to store more components (e.g., larger battery cells), thus increasing the energy density of the battery. Additionally, this configuration provides a reduced extension (or no extension at all), which may reduce the dead space within the effective volume of the battery. This configuration may also include shorter conductive members (e.g., conductive members with fewer bends), which allows a larger battery cell stack to be positioned within the internal volume, thus further increasing the energy density of the battery.

[0031] Although the remainder of the specification will routinely refer to lithium-ion battery cells, those skilled in the art will readily understand that the technology is not limited thereto. The design of the present invention can be used with any number of batteries or energy storage devices, including other rechargeable and primary, or non-rechargeable battery types, as well as electrochemical capacitors, also known as supercapacitors or ultracapacitors, electrolyzers, fuel cells, and other electrochemical devices. Additionally, the technology can be applied to battery cells and energy storage devices that can be used in any number of technologies, which may include, but are not limited to, telephones and mobile devices, handheld electronic devices, wearable devices, laptop computers and other computers, appliances, heavy machinery, transportation equipment, spacecraft electronic payloads, vehicles, and any other device that can use a battery cell or benefit from the design discussed. Accordingly, the present disclosure and claims should not be considered limited to any specific example discussed, but rather can be widely utilized with any number of devices, any number of which may exhibit some or all of the electrical or chemical characteristics of the examples discussed.

[0032] Figures 2A to 2D An example battery 200 is depicted. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. As Figure 2A shown, the battery 200 may include a lid 210, a sidewall structure 220, a base 230, and a battery cell stack 201 (e.g., the battery cell stack includes one or more of a cathode active material layer, an anode active material layer, a separator, and a current collector). The lid 210, the sidewall structure 220, and the base 230 may form a housing of the battery 200. The housing may be in the form of a "can" (e.g., a thin-walled container), and each can may be made of metal (e.g., aluminum, aluminum alloy such as 3003 aluminum, stainless steel, steel, etc.), such that the housing can be rigid. However, in other embodiments, the housing may be any other suitable configuration, such as cylindrical, octagonal, can-like, pouch-like, etc. The battery cell stack 201 may be positioned within an internal volume (e.g., internal volume 250) of the housing.

[0033] Turning to Figure 2B, the lid 210 may include a lid main wall 217, a first lid side wall 260 that extends laterally from a first lid edge 212 of the lid main wall 217, and a second lid side wall 262 that extends laterally from a second lid edge 214 of the lid main wall 217. The base 230 may include a base main wall 237, a first base side wall 270 that extends laterally from a first base edge 232 of the base main wall 237, and a second base side wall 272 that extends laterally from a second base edge 234 of the base main wall 237. However, in other embodiments, the lid side wall and the base side wall may extend from their respective main walls at an intermediate portion of the main wall (e.g., extend from a portion of the main wall that is spaced apart from the edge of the main wall). The lid 210 may be coupled to a first end 221 of the side wall structure 220, and the base 230 may be coupled to a second end 227 of the side wall structure 220 that is opposite to the first end. The side wall structure 220 may include a first structural side wall 222, a second structural side wall 224, a third structural side wall 226, a fourth structural side wall 228, and a fifth structural side wall 229, which together form the shape of the side wall structure 220. The lid side wall 260 and the first base side wall 270 may be coupled to the first structural side wall 222, and the second lid side wall 262 and the second base side wall 272 may be coupled to the second structural side wall 224. The lid 210 and the base 230 may be coupled to the side wall structure 220 by welding, brazing, soldering, gluing, etc. Specifically, the lid 210 and the base 230 may be coupled to the side wall structure 220 by laser welding to provide lap welding, edge welding, wire welding, stitch welding, etc.

[0034] The main walls 217, 237 and the side wall structure 220 may define a plurality of internal corners. For example, referring to Figure 2C , the lid main wall 217 and the first structural side wall 222 may be coupled together to define a first internal corner 240 therebetween, the lid main wall 217 and the second structural side wall 224 may be coupled together to define a second internal corner 242 therebetween, the base main wall 237 and the first structural side wall 222 may be coupled together to define a third internal corner 244 therebetween, and the base main wall 237 and the second structural side wall 224 may be coupled together to define a fourth internal corner 246 therebetween. Referring to Figure 2D, the cover main wall 217 and the third structural side wall 226 may be joined together to define a fifth internal corner 241 therebetween, the cover main wall 217 and the fourth structural side wall 228 may be joined together to define a sixth internal corner 243 therebetween, the base main wall 237 and the third structural side wall 226 may be joined together to define a seventh internal corner 245 therebetween, and the base main wall 237 and the fourth structural side wall 228 may be joined together to define an eighth internal corner 247 therebetween. The cover main wall 217, the base main wall 237, the side wall structure 220, and the internal corners 240, 241, 242, 243, 244, 245, 246, 247 together define an internal volume 250 for storing electronic components within the battery 200 (e.g., the battery cell stack 201).

[0035] Additionally or alternatively, the internal corners 240, 241, 242, 243, 244, 245, 246, 247 may include corners between two components joined to each other, where only the planes of the surfaces of these two components intersect rather than the planes of the surfaces of three components. For example, the internal corners 240, 241, 242, 243, 244, 245, 246, 247 may be the corresponding corners where only the X-Y plane of the cover 210 and the base 230 intersects the Y-Z and Y-X planes of the side wall structure 220, rather than the corresponding corners where multiple planes of the side wall structure 220 intersect the plane of the cover 210 or the base 230. An example of the latter corner may be a three-sided corner defined between two of the structural side walls 222, 224, 226, 228, 229 in the structural side walls and the cover 210 or the base 230. Thus, the internal corners 240, 241, 242, 243, 244, 245, 246, 247 may have a radius that is substantially zero, while the three-sided corner may not have a radius that is substantially zero. However, in some embodiments, the three-sided corner may also include a radius that is substantially zero such that all corners defining the internal volume have a radius that is substantially zero. The internal corners 240, 241, 242, 243, 244, 245, 246, 247 may also include corners defined by the intersection of two planes of the innermost surfaces of the cover 210 and the side wall structure 220 and the base 230 and the side wall structure 220. For example, the internal corners 240, 241, 242, 243, 244, 245, 246, 247 may include the corresponding corners of the intersection defined between the X-Y plane of the innermost surfaces of the cover 210 and the base 230 and the Y-Z plane and the Y-X plane of the innermost surface of the side wall structure 220.

[0036] As discussed above, rounded corners can increase the dead space in the effective volume of the battery housing. Thus, forming a battery housing with a smaller radius can reduce this dead space by increasing the amount of space available within the internal volume of the battery housing. The battery 200 provides this benefit by providing internal corners 240, 241, 242, 243, 244, 245, 246, 247 having a radius that is substantially zero. In other words, the internal corners 240, 241, 242, 243, 244, 245, 246, 247 can have a radius of less than about 1 mm, such as less than about 0.75 mm, such as less than about 0.5 mm, such as less than about 0.25 mm, or having a radius that is exactly zero. Since the internal volume 250 does not include rounded corners, the internal volume 250 can be greater than the internal volume of a conventional battery having a similar effective volume (e.g., the volume 150 of the battery 100), which allows more components (such as a larger battery cell stack 201) to be accommodated within the internal volume 250. Thus, compared to other conventional batteries, the substantially zero radius of the internal corners 240, 241, 242, 243, 244, 245, 246, 247 can reduce the dead space within the effective volume of the battery 200 and increase the energy density of the battery 200.

[0037] When the structural sidewalls 222, 224, 226, 228 are substantially planar, the lid main wall 217 and the structural sidewalls 222, 224, 226, 228 are substantially perpendicular to each other, and the base main wall 237 and the structural sidewalls 222, 224, 226, 228 are substantially perpendicular to each other, a dead space starting from a substantially zero radius at the internal corners 240, 241, 242, 243, 244, 245, 246, 247 within the effective volume can be further shown to decrease. In other words, when the internal corners 240, 241, 242, 243, 244, 245, 246, 247 are substantially perpendicular angles and the structural sidewalls 222, 224, 226, 228 are substantially planar. Substantially perpendicular can mean that the angles of the internal corners 240, 241, 242, 243, 244, 245, 246, 247 can be between about 75° and 105°, such as between about 80° and 100°, such as between about 85° and 95°, or about 90°. When the internal corners 240, 241, 242, 243, 244, 245, 246, 247 have substantially perpendicular angles, the internal corners 240, 241, 242, 243, 244, 245, 246, 247 can have a substantially zero radius. The internal corners defined between the lid 210 and the fifth structural sidewall 229 and between the lid 210 and the fifth structural sidewall 229 can also have a substantially zero radius as described above. Substantially planar can mean that the structural sidewalls 222, 224, 226, 228 have a radius less than about 0.06 rad / m, such as less than about 0.03 rad / m, such as less than about 0.02 rad / m, or are substantially flat.

[0038] In this configuration, the internal volume 250 can define a substantially rectangular cross-sectional shape. In cases where the structural sidewalls have a non-planar shape and / or the internal corners are not substantially perpendicular angles, the housing can have protruding features that have shapes and dimensions that prevent other components from being occupied within the effective volume of the battery (i.e., increase the dead space within the effective volume), which can reduce the energy density of the battery. The substantially perpendicular angles of the internal corners 240, 241, 242, 243, 244, 245, 246, 247 and the substantially planar structural sidewalls 222, 224, 226, 228 address this issue by maximizing the available space within the effective volume. However, in other embodiments, the internal corners can have any other angle (e.g., greater than or less than substantially perpendicular) and the structural sidewalls can have any other shape (e.g., curved, angled, irregular shape, etc.).

[0039] In an assembled configuration, the lid sidewalls 260, 262 and the base sidewalls 270, 272 may be flush against the structural sidewalls 222, 224, 226, 228. For example, in the case where the lid sidewalls 260, 262 and the base sidewalls 270, 272 and the structural sidewalls 222, 224, 226, 228 have similar shapes (e.g., both are substantially planar), the lid sidewalls 260, 262 and the base sidewalls 270, 272 extend at an angle from the lid main wall 217 and the base main wall 237, respectively, such that substantially all of the sidewalls 260, 262 and the base sidewalls 270, 272 contact the structural sidewalls 222, 224, 226, 228, and the lid sidewalls 260, 262 and the base sidewalls 270, 272 may be flush against the structural sidewalls 222, 224, 226, 228. In this configuration, the lid sidewalls 260, 262 and the base sidewalls 270, 272 may reduce the effective volume of the battery 200 without affecting the amount of dead space within the effective volume, and thus reduce the proportion of dead space within the effective volume of the battery 200. Additionally, this configuration may allow for a stronger connection between the lid sidewalls 260, 262 and the base sidewalls and the structural sidewalls 222, 224, 226, 228.

[0040] The lid sidewalls 260, 262 may be transverse to each other, and the base sidewalls 270, 272 may be transverse to each other. For example, the lid sidewalls 260, 262 may be substantially perpendicular to each other, and the base sidewalls 270, 272 may be substantially perpendicular to each other. Specifically, the angle between the lid sidewalls 260, 262 and the angle defined between the base sidewalls 270, 272 may correspond to the angle between the specific structural sidewalls (e.g., the first structural sidewall 222 and the third structural sidewall 226) to which the lid sidewalls 260, 262 and the base sidewalls 270, 272 are to be coupled. When coupling the lid 210 and the base 230 to the sidewall structure 220, this configuration may be used to align the lid 210 and the base 230 to the sidewall structure 220, respectively. As will be discussed further below, this alignment may be achieved by moving the lid 210 and the base 230 and the sidewall structure 220 relative to each other until the sidewall structure 220 abuts against both of the lid sidewalls 260, 262 and until the sidewall structure 220 abuts against both of the base sidewalls 270, 272. In this way, the lid 210 and the base 230 may be positioned relative to the sidewall structure 220 in a specific orientation and position. However, in other embodiments, the angle between the lid sidewalls and the base sidewalls may not correspond to the angle between the corresponding structural sidewalls to which the lid sidewalls and the base sidewalls are to be coupled, and may include other angles (e.g., an angle greater than or higher than the angle between the corresponding structural sidewalls).

[0041] Although the lid sidewalls 260, 262 and the base sidewalls 270, 272 are depicted as extending from the main walls 217, 237 at equal angles to each other, in other embodiments, one or more of these sidewalls may extend from their respective main walls at an angle different from that of one or more of the other sidewalls. For example, the first lid sidewall may extend from the lid main wall at a greater angle than the angle at which the second lid sidewall extends from the lid main wall, the first base sidewall may extend from the base main wall at a greater angle than the angle at which the second base sidewall extends from the base main wall, the first lid sidewall may extend from the lid main wall at a greater angle than the angle at which the first base sidewall extends from the base main wall, and so on.

[0042] Although each of the lid 210 and the base 230 includes two sidewalls 260, 262, 270, 272, in other embodiments, each of the lid and the base may include more or fewer than two sidewalls extending therefrom, such as one, three, four, etc. For example, at least one of the lid and the base may include sidewalls extending from each edge of the lid and the base. In the case where there are a plurality of sidewalls extending from one or more edges of the base and the lid, the sidewalls on each edge may be spaced apart from each other (e.g., having a gap therebetween) or be continuous with each other. Additionally, although the lid 210 and the base 230 include one sidewall 260, 262, 270, 272 extending from the edges 212, 214, 232, 234, respectively, in other embodiments, there may be more than one sidewall extending from one or more of these edges, such as two sidewalls, three sidewalls, four sidewalls, etc. In yet another embodiment, the lid and the base may not have an equal number of sidewalls, but may each have a different number of sidewalls.

[0043] The lid main wall 217 may include a first lid extension portion 211 that extends a first distance d1 externally of the second structure sidewall 224 in the X direction. The base main wall 237 may include a first base extension portion 231 that extends a first distance d1 externally of the second structure sidewall 224 in the X direction. The lid main wall 217 may include a second lid extension portion 219 that extends a distance d2 externally of the fourth structure sidewall 228 in the Y direction. The base main wall 237 may include a second base extension portion 239 that extends a distance d2 externally of the fourth structure sidewall 228 in the Y direction.

[0044] The extensions 211, 219, 231, 239 may allow the cover 210 and the base 230 to be more easily coupled to the second structural wall 224 and the fourth structural wall 228, respectively. Specifically, when welding the cover 210 and the base 230 to the sidewall structure 220, the extensions 211, 219, 231, 239 may allow the weld seams to be positioned slightly outside the second structural sidewall 224 (e.g., in the X direction) and the fourth structural sidewall 228 (e.g., in the Y direction). In this way, the cover 210 and the base 230 can be welded to the sidewall structure 220 without the weld seams being directly positioned along the centerlines of the second structural sidewall 224 and the fourth structural sidewall 228. Thus, the extensions 211, 219, 231, 239 may allow the cover 210 and the base 230 to be coupled to the second structural wall 224 and the fourth structural wall 228, respectively, with a greater margin of error. Additionally, the extensions 211, 219, 231, 239 may allow for a greater margin of error when forming the cover 210 and the base 230, such that the dimensions of the cover 210 and the base 230 do not need to be precisely aligned with the edges of the sidewall structure 220.

[0045] The distances d1, d2 may be less than the distances of the corresponding features of a conventional battery (e.g., less than the extensions 116, 136 of the battery 100). This smaller distance may reduce the dead space in the effective volume of the battery 200, thus allowing for a greater internal volume 250 within the effective volume of the battery 200 to store more components (e.g., a larger battery cell stack). At the same time, the distances d1, d2 allow for sufficient material of the cover 210 to extend past the sidewall structure 220 to allow the cover 210 to be coupled to (e.g., welded to) the sidewall structure 220. The substantially zero radius of the internal corners 240, 241, 242, 243, 244, 245, 246, 247 and the reduced distances d1, d2 of the extensions 211, 219, 231, 239 may provide a 2.5% volume increase. This may be particularly important where a volume increase of 0.1% to 0.2% is considered significant.

[0046] The extensions 211, 219, 231, 239 may extend in substantially the same plane as the respective cover main walls 217 and base main walls 237. For example, the extensions 211, 219, 231, 239 may extend from the respective cover main walls 217 and base main walls 237 at respective angles relative to each other that are less than or about 20°, such as less than or about 10°, such as less than or about 5°, or are completely planar with respect to each other.

[0047] Although the extension portions 211, 219 are depicted as extending the same distance d1 past the second structure sidewall 224 and the extension portions 231, 239 are depicted as extending the same distance d2 past the fourth structure sidewall 228, in other embodiments, the extension portions may extend different lengths past the corresponding structure sidewalls. In other embodiments, one or more of the lid and the base may not include extension portions. In this example, the edges of the lid and the base may be substantially flush with the outer surfaces of the corresponding structure sidewalls.

[0048] The battery cell stack 201 can be any suitable type of rechargeable battery, including but not limited to: dry cells, wet cells, NiCd (nickel-cadmium), NiMH (nickel metal hydride), Li-ion (lithium-ion), nickel-zinc (NiZn), lithium-ion polymer (LiPO), lithium iron phosphate battery (LiFePO), or lead-acid batteries. In some embodiments, the battery cell stack 201 may have any suitable geometry, including but not limited to prismatic battery cells (e.g., cubes), vertically stacked battery cells, cylindrical battery cells, etc. In some embodiments, the battery cell stacks 201 may be connected together within the battery 200 to provide a "high" voltage that may be suitable for powering the main traction motor of an electric vehicle or providing power to other electronic devices. The battery 200 may have a voltage range between 20V and 600V, between 200V and 500V, or between 300V and 450V. In some embodiments, one or more of the battery cell stacks in the battery cell stack 201 may be connected together to form a "low" voltage battery 200 (e.g., which may be integrated with the high voltage battery 200 or may be separate), and the "low" voltage battery may be suitable for powering auxiliary systems. The low voltage battery 200 may have a voltage range between 2V and 5V, between 10V and 19V, between 11V and 15V, or approximately 12V.

[0049] In some embodiments, the sidewall structure may not have a rectangular cross-sectional shape. Instead, the sidewall structure may have an irregular shape. For example, Figures 3A to 3C An example battery 300 is depicted. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. The sidewall structure 220 may include a first protrusion 392 extending along the X-axis from the first structure sidewall 322, a second protrusion 394 extending along the X-axis from the second structure sidewall 324, a third protrusion 396 extending along the Y-axis from the third structure sidewall 326, and a fourth protrusion 398 extending along the Y-axis from the fourth structure sidewall 328. The protrusions 392, 394, 396, 398 may improve the distribution of shear stress to the structure sidewalls 322, 324, 326, 328. Additionally, the protrusions 392, 394, 396, 398 may increase the internal volume 350.

[0050] The first protrusion 392 can be positioned along the Z-axis between the first lid sidewall 360 and the first base sidewall 370. The second protrusion 396 can be positioned along the Z-axis between the first lid sidewall 362a and the second sidewall 362b and between the first base sidewall 372a and the second base sidewall 372b. Although the first protrusion 392 and the third protrusion 396 are depicted as being positioned equidistantly from each of the sidewalls 360, 370, 362a, 362b, 372a, 372b, in other embodiments, the protrusions can be closer or farther from one sidewall to another. In other embodiments, there can be more than one protrusion on each structural sidewall, such as two, three, four, etc. Although the protrusions 392, 394 are depicted as having a length less than the length of the corresponding structural sidewalls 322, 324, in other embodiments, the protrusions can have any length relative to their corresponding sidewalls, including extending the entire length of the structural sidewalls. In yet another embodiment, the protrusions can have any cross-sectional shape, such as a curved shape, an irregular shape, etc.

[0051] In some embodiments, the protrusions 392, 394, 396, 398 can extend a certain distance from the structural sidewalls 322, 324, 326, 328 such that the outer surfaces of the protrusions 392, 394, 396, 398 are substantially flush with the outer surfaces of the sidewalls 360, 362a, 362b, 370, 372a, 372b and the extension portions 311, 319, 331, 339. In this way, the protrusions 392, 394, 396, 398 can increase the structural support provided to the battery 300 while minimizing the dead space occupied by the battery 300. In another embodiment, the protrusions can have dimensions and shapes corresponding to the distances between each of these sidewalls. In this way, the protrusions can provide even more structural support to the battery while minimizing the dead space of the battery. In other embodiments, the height of one or more of these protrusions along the Z-axis can be greater than the distance between the adjacent lid sidewall and the base sidewall. For example, if the structural sidewall has multiple lid sidewalls and base sidewalls, the protrusion can be positioned between the sidewalls and have a height greater than the distance between the lid sidewall and the base sidewall.

[0052] In some embodiments, the sidewall structure may not include any extension portions. For example, Figures 4A to 4CIllustrates an example battery 400. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. The sidewall structure 420 defines recesses at each end of the structural sidewalls 422, 424, 426, 428 to receive the cover 410 and the base 420. Specifically, the first structural sidewall 422 defines a first recess 492 at the first top end 422a and a second recess 494 at the first bottom end 422b, the second structural sidewall 424 defines a third recess 496 at the second top end 424a and a fourth recess 498 at the second bottom end 424b, the third structural sidewall 426 defines a fifth recess 493 at the third top end 426a and a sixth recess 495 at the third bottom end 426b, and the fourth structural sidewall 428 defines a seventh recess 497 at the fourth top end 428a and an eighth recess 499 at the fourth bottom end 428b. Although the recesses 492, 492, 494, 495, 496, 497, 498, 499 are depicted as having an arcuate cross-sectional shape, in other embodiments, the recesses can have any other shape, such as rectangular, linear, stepped, irregular, etc.

[0053] The ends of the cover 410 and the base 430 can be received in the recesses 492, 492, 494, 495, 496, 497, 498, 499. For example, the cover 410 can include a first cover end 411 received in the first recess 492, a second cover end 412 received in the third recess 496, a third cover end 413 received in the fifth recess 493, and a fourth cover end 414 received in the seventh recess 497. The base 430 can include a first base end 431 received in the second recess 494, a second base end 432 received in the fourth recess 498, a third base end 433 received in the sixth recess 495, and a fourth base end 434 received in the eighth recess 499. Since the example battery 400 does not include any extensions, the proportion of dead space in the effective volume of the battery 400 can be reduced as more effective volume is available for storing larger electrodes, for example, within the internal volume 450.

[0054] In some embodiments, the sidewall structure can be made of more than one piece. For example, Figure 5A and Figure 5BDepicts an example sidewall structure 520. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. The sidewall structure 520 may include a first sidewall member 523 and a second sidewall member 525. The first sidewall member 523 may include a first end 552 and a second end 556. The second sidewall member 525 may include a first end 554 and a second end 558. The sidewall members 523, 525 may be joined to each other at the respective first ends 552, 554 and second ends 556, 558. Specifically, the first ends 552, 554 and the second ends 556, 558 may be shaped to at least partially receive each other before being joined together (e.g., welded, brazed, soldered, glued, etc.). Although two sidewall members 523, 525 are depicted, in other embodiments, there may be more than two sidewall members, such as three, four, five, etc.

[0055] For example, Figure 5B Depicts the first ends 552, 554 joined to each other. It should be understood that the second ends 556, 558 include a structure similar to the first ends 552, 554. The first end 552 may include a first flange 551 and may define a first slot 555. The second end 554 may include a second flange 553 and may define a second slot 557. The size and shape of the slots 555, 557 may be configured to receive the corresponding flanges 551, 553. For example, the size and shape of the first slot 555 may be configured to receive the second flange 553, and the size and shape of the second slot 557 may be configured to receive the first flange 551. In this configuration, the inner and outer surfaces of the ends 552, 554 are substantially aligned. When the flanges 551, 553 are received in the slots 555, 557, the ends 552, 554 may be joined to each other by the flanges 551, 553 (e.g., welded). In other embodiments, the ends may be joined together by a different configuration. For example, one of the ends may include one or more pointed tips that define one or more slots therebetween, and the other end may include one or more flanges sized and shaped to be received in the slots. In other embodiments, other configurations are envisioned.

[0056] In other embodiments, the ends may not be rectangular but may have any other shape. For example, the ends may have an irregular shape, such as a single line, a serrated edge, etc. Figure 6Depicts the ends 652, 654 of the sidewall structure 620. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. As shown, the ends 652, 654 may each include a curved shape corresponding to each other. Such a shape may facilitate minimizing the gap between the ends 652, 654 when the ends 652, 654 are fitted together to achieve a stronger connection (e.g., stronger welding) between the ends 652, 654.

[0057] As will be further described below, the method of forming the battery of the present disclosure may allow larger battery cells to be positioned in the battery of the present disclosure. Figure 7A and Figure 7B Depicts a partial cross-sectional view of an exemplary battery 700. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. Figure 7A Depicts the process of coupling the sidewall structure 720 to the base 730 such that the conductive member 702 defines only one bend 703, as will be further described below. Figure 7B Depicts the battery 700 after the sidewall structure 720 is coupled to the lid 710 and the base 730. Specifically turning to Figure 7B , the battery 700 may include an insulating member 780 and an electrical contact 782 that are received through a hole 721 defined along the sidewall structure 720 such that the insulating member 780 and the electrical contact 782 extend from the internal volume 750 to the outside of the sidewall structure 720. The battery cell stack 701 may be electrically coupled to the electrical contact 782 through the conductive member 702. The conductive member 702 may be electrically coupled to the electrode tabs of each current collector of the battery cell stack 701. In some embodiments, the conductive member 702 may be a single integral member that collects all the current from the electrode tabs of the battery cell stack 701. The electrical contact 782 and the conductive member 702 may be made of a conductive material (e.g., aluminum, copper, nickel, etc.) such that charge can be transferred from the battery cell stack 701 through the conductive member 702 to the electrical contact 782 to provide power to one or more electronic components coupled to the electrical contact 782. Although the battery cell stack 701 is depicted as including a plurality of current collectors coupled to the conductive member 702, in other embodiments, the battery cell stack may include only a single current collector coupled to the conductive member (e.g., a top current collector adjacent to the lid). A plurality of current collectors may be beneficial for providing more power within the internal volume 750.

[0058] As described above, in a conventional battery, the conductive component can occupy space within the internal volume that would otherwise be occupied by the cell stack (e.g., conductive component 102). This configuration of the conventional battery may result from forming the lid using a stamping process that forms both the lid main wall and the lid side wall together. In such a conventional configuration, the cell stack can be electrically connected to an electrical component (e.g., a rivet) external to the lid and then flipped into the lid before joining the base and the lid together. This assembly can cause components that are not part of the cell stack to occupy an unnecessary amount of space within the internal volume of the battery (e.g., the bend 103 of the conductive component 102).

[0059] Battery 700 addresses these issues by providing a shorter conductive component 702. Specifically, the conductive component 702 can include fewer than two bends along its length. For example, the conductive component 702 can include only one bend 703 instead of multiple bends (e.g., bends 103, 104 of the conductive component 102). Since there is only one bend 703 along the electrical component 702, more space within the internal volume 750 can be occupied by the cell stack 701. Accordingly, battery 700 can have an increased energy density compared to a conventional battery (such as battery 100).

[0060] In some embodiments, the electrical contact 782 can be a rivet. The conductive component 702 can be a current collector or a part of a current collector made of a conductive material. The insulating component 780 can include an electrically insulating material such as rubber, plastic (e.g., polybutene (PB), perfluoroalkoxy (PFA), polypropylene, and / or polybutylene succinate (PBS)), etc. In this way, the insulating component 780 can insulate the side wall structure from the charge from the electrical contact 782. Electrical component.

[0061] Figure 8 An example flow chart 800 of forming a battery is depicted. It should be understood that features ending with the same reference numerals as the features discussed above are similar, except as described below. Starting from step 802, a side wall structure can be formed. In the case where the side wall structure is a monolithic piece, a blank can be stamped to form a stamped component. For example, go to Figure 1, the stamping part can be similar to the cover 110. To form a sidewall structure (e.g., sidewall structure 220) from the cover 110, the cover main wall 117 and the circular corner 115 can be cut (e.g., using a rotary cutter, laser, etc.) to form an edge of the sidewall structure (e.g., the first end 221 of the sidewall structure 220). Then, the cover extension 116 can be cut to form the opposite edge of the sidewall structure (e.g., the second end 227 of the sidewall structure 220). The cover extension 116 or either of the cover main wall 117 and the circular corner 115 can be cut in any order. After cutting these parts, holes (e.g., hole 621) can be cut in the sidewall structure to form the sidewall structure 220.

[0062] In some embodiments, protrusions can be formed in the sidewall structure. For example, referring to Figures 3A to 3C , protrusions 392, 394, 396, 398 can be formed (e.g., stamped, machined, etc.) in the structural sidewalls 322, 324, 326, 328. However, in other embodiments, the protrusions can be formed in the sidewall structure in other ways, such as cutting an opening in the sidewall structure and attaching the protrusion to (e.g., welding to, brazing to, soldering to, etc.) the sidewall structure. In other embodiments, recesses can be formed in the top and bottom ends of the sidewall structure. For example, referring to Figures 4A to 4C , recesses 492, 492, 494, 495, 496, 497, 498, 499 can be formed (e.g., by machining, etc.) in the sidewall structure.

[0063] In another embodiment, referring to Figure 5A and Figure 5B, the sidewall structure 520 can be formed by multiple components. Specifically, multiple blanks having a desired height of the sidewall structure can be cut. Before bending each of these blanks to form sidewall components 523, 525, each end 552, 554, 556, 558 of the blank can be machined or otherwise cut to form flanges 551, 553 and define slots 555, 557. Then each of these blanks can be bent into a desired shape to form sidewall components 523, 525. In other embodiments, the ends can be machined after the blanks are bent. In some embodiments, holes (e.g., hole 721) can be drilled along one or more of these blanks. Once the sidewall components 523, 525 are formed, the first ends 552, 554 and the second ends 556, 558 can be coupled to each other respectively. For example, turning to the first ends 552, 554, the first flange 551 can be received in the second slot 557, and the second flange 553 can be received in the first slot 555. Then, the first ends 552, 554 can be coupled to each other by coupling (e.g., welding) the overlapping flanges 551, 553 together. A similar process can then be performed on the second ends 556, 558. Once the first ends 552, 554 and the second ends 556, 558 are coupled to each other respectively, the sidewall structure 520 can be formed. A similar process can be used for the structural sidewall 620.

[0064] Turning to step 804, the battery cell stack can be coupled to the sidewall structure. Specifically, the battery cell stack can be coupled to the sidewall structure 620 before the sidewall components 523, 525 (or the sidewall components 623, 625 of the sidewall structure 520) are coupled together. For example, turning to Figure 7A, the insulating member 780 and the electrical contact 782 can be coupled through the hole 721. Before the sidewall members are fully coupled together to form the sidewall structure 720 (or after only one of the ends of the sidewall members is coupled together), the battery cell stack 701 can be positioned between the sidewall members. The battery cell stack 701 can be electrically coupled to the electrical contact 782 by coupling the conductive member 702 to the electrical contact 782. After the conductive member 702 is coupled to the electrical contact 782, the portion of the sidewall structure 720 including the electrical contact 782 rotates in the direction of arrow A. Then, the sidewall structure 720 can be formed by coupling another set of ends of the sidewall members together. Since the battery cell stack 701 has been positioned between the sidewall members before the cover 710 and the base 730 are coupled to the sidewall structure 720, the electrical contact 782 can define only one bending portion 703 to electrically couple the battery cell stack 701 to the electrical contact 782. The battery cell stack 701 does not need to be rotated and flipped into place relative to the electrical contact 782 as in a conventional battery design (e.g., the battery cell stack 101 in the sidewall structure 120). In this way, the conductive member 702 can include only one bending portion 703 along its length instead of more bending portions (e.g., as in the conductive member 102), thus allowing a larger battery cell stack 701 to be positioned in the internal volume 750, thereby increasing the energy density of the battery 700. The battery cell stack 701 can be electrically coupled to the electrical contact 782 before being positioned on the base 730 (e.g., before the base 730 is formed, as described below). However, in other embodiments, the base 730 may already be formed, and the battery cell stack 701 can be electrically coupled to the electrical contact 782 as described above after the base 730 is formed (e.g., when the battery cell stack 701 is on the base 730).

[0065] Go to step 806, the cover and the base can be formed. Return to Figures 2A to 2D , the first blank can be cut to include the cover main wall 217, where the first cover sidewall 260 and the second cover sidewall 262 extend from the cover main wall. The second blank can be cut to include the base main wall 237, where the first base sidewall 270 and the second base sidewall 272 extend from the base main wall. The cover sidewalls 260, 262 can be bent relative to the cover main wall 217 to a desired angle (e.g., at a substantially perpendicular angle) to form the cover 210. The base sidewalls 270, 272 can be bent relative to the base main wall 237 to a desired angle (e.g., at a substantially perpendicular angle) to form the base 230. The cover and the base can be formed simultaneously or sequentially one after another.

[0066] Proceed to step 808, where the lid and the base can be coupled to the sidewall structure. The lid 210 and the base 230 can be aligned with the sidewall structure 220. Specifically, the lid 210 can be moved relative to the sidewall structure 220 until the first lid sidewall 260 abuts against and adjoins the first structure sidewall 222 and the second lid sidewall 262 abuts against and adjoins the third structure sidewall 226. The base 230 can also be moved relative to the sidewall structure 220 until the first base sidewall 270 abuts against and adjoins the first structure sidewall 222 and the second base sidewall 272 abuts against and adjoins the third structure sidewall 226. Once the lid 210 and the base 230 are aligned to the sidewall structure 220, the lid 210 and the base 230 can be coupled to the sidewall structure 220. For example, one or more welds can be applied through the first lid sidewall 260 and the first structure sidewall 222, the first base sidewall 270 and the first structure sidewall 222, the second lid sidewall 262 and the third structure sidewall 226, and the second base sidewall 272 and the third structure sidewall 226. Another set of welds can be applied through the lid 210 and the base 230 to the edge of the sidewall structure 220. For example, welds can be applied through the first lid extension 211 and the second structure sidewall 224, the first base extension 231 and the second structure sidewall 224, the second lid extension 219 and the fourth structure sidewall 228, and the second base extension 239 and the fourth structure sidewall 228. Additional welds can be applied between the sidewall structure 220 and the lid 210 and the base 230. In other embodiments, either the lid or the base can be coupled to the sidewall structure before the other, rather than both the lid and the base being coupled to the sidewall structure simultaneously. Once the lid 210 and the base 230 are coupled to the sidewall structure 220, the battery 200 can be formed.

[0067] In other embodiments, proceed to Figures 4A to 4C , the ends of the lid 410 and the base 430 can be coupled to the sidewall structure 420. For example, the lid ends 411, 412, 413, 414 of the lid 410 can be received in the recesses 492, 493, 496, 497, and the base ends 431, 432, 433, 434 can be received in the recesses 494, 495, 498, 499. In this position, the lid ends 411, 412, 413, 414 and the base ends 431, 432, 433, 434 can be coupled to (e.g., welded to, brazed to, soldered to, glued to, etc.) the structure sidewall 420 to form the battery 400.

[0068] In the foregoing specification, embodiments of the present disclosure have been described with reference to numerous specific details that can vary from one specific implementation to another. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. The scope of the present disclosure and the sole and exclusive indication of what the applicant anticipates as the scope of the present disclosure is the literal and equivalent scope of a set of claims issued from this patent application in the specific form in which such claims are issued, including any subsequent corrections. The specific details of a particular embodiment can be combined in any suitable manner without departing from the essence and scope of the embodiments of the present disclosure.

[0069] In addition, spatially relative terms, such as “bottom” or “top” and the like, may be used to describe the relationship of one element and / or feature to another or other elements and / or other features, as illustrated, for example, in the figures. It should be understood that spatially relative terms are intended to encompass different orientations of the device in use and / or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, an element described as the “bottom” surface could then be oriented “above” other elements or features. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and the spatially relative descriptors used herein are to be interpreted accordingly.

[0070] As used herein, the terms “and,” “or,” and “and / or” can include a variety of meanings, which are also expected to depend at least in part on the context in which such terms are used. Generally, if used to associate a list (such as A, B, or C), “or” is intended to mean A, B, and C (used here in an inclusive sense) as well as A, B, or C (used here in an exclusive sense). In addition, as used herein, the term “one or more” can be used to describe any feature, structure, or characteristic in the singular, or can be used to describe some combination of features, structures, or characteristics. However, it should be noted that this is merely an illustrative example and the claimed subject matter is not limited to this example. In addition, if used to associate a list (such as A, B, or C), the term “at least one of...” can be interpreted to mean any combination of A, B, and / or C, such as A, B, C, AB, AC, BC, AA, AAB, ABC, AABBCCC, etc.

[0071] As used throughout this specification, the phrases "one example", "an example", "certain examples", or "exemplary embodiments" refer to a particular feature, structure, or characteristic described in connection with the feature and / or example that may be included in at least one feature and / or example of the claimed subject matter. Thus, the phrases "in one example", "an example", "in certain examples", or "in certain embodiments", or other similar phrases that occur throughout the specification do not necessarily all refer to the same feature, example, and / or limitation. Additionally, these particular features, structures, or characteristics may be combined in one or more examples and / or features.

[0072] In some embodiments, an operation or process may involve the physical manipulation of physical quantities. Typically, but not necessarily, such quantities may take the form of electrical or magnetic signals that can be stored, transferred, combined, compared, or otherwise manipulated. For reasons of general utility, it has proven convenient at times to refer to such signals as bits, data, values, elements, symbols, characters, items, numbers, numerical values, and the like. However, it should be understood that all such or similar terms are to be associated with the appropriate physical quantity and are merely convenient labels. Unless otherwise specifically stated, as will be apparent from the discussion herein, it should be understood that throughout this specification, discussions using terms such as "processing", "computing", "calculating", "determining", etc. refer to the actions or processes of a particular apparatus, such as a special purpose computer, a special purpose computing device, or a similar special purpose electronic computing device. In the context of this specification, therefore, a special purpose computer or similar special purpose electronic computing device is capable of manipulating or transforming signals that are typically represented as physical electronic or magnetic quantities within the memory, registers, or other information storage devices, transmission devices, or display devices of that special purpose computer or similar special purpose electronic computing device.

[0073] In the foregoing detailed description, numerous specific details have been set forth to provide a thorough understanding of the claimed subject matter. However, those skilled in the art will understand that the claimed subject matter may be practiced without these specific details. In other instances, methods and apparatuses known to one of ordinary skill in the art have not been described in detail so as not to obscure the claimed subject matter. Accordingly, the claimed subject matter is not intended to be limited to the specific examples disclosed, but rather the claimed subject matter may also include all aspects falling within the scope of the appended claims and their equivalents.

Claims

1. A battery, comprising: a cover comprising a cover main wall and a first cover side wall extending from the cover main wall at a first substantially perpendicular angle; a base comprising a base main wall and a first base side wall extending from the base main wall at a second substantially perpendicular angle; Side wall structure, wherein: A first end of the side wall structure is coupled against the cover main wall and the first cover side wall to define a first interior corner between the side wall structure and the cover main wall; The second end of the sidewall structure is coupled against the base main wall and the first base sidewall to define a second interior corner between the sidewall structure and the base main wall; The first interior corner and the second interior corner include a radius of substantially zero; and The cover, the base, the sidewall structure, the first interior corner, and the second interior corner define an interior volume; and A battery cell stack is positioned in the interior volume.

2. The battery of claim 1, wherein the substantially zero radius comprises a radius of less than 1 mm.

3. The battery according to claim 1, wherein: all interior corners defined between the cover and the sidewall structure, and between the base and the sidewall structure, include a radius of substantially zero; and The interior volume is further defined by all interior corners. 4 . The battery of claim 1 , wherein the first cover side wall and the first base side wall extend from an edge of the cover main wall and an edge of the base main wall, respectively.

5. The battery of claim 1, wherein the cover main wall includes a second cover side wall extending from the cover main wall transversely to the first cover side wall, and the base main wall includes a second base side wall extending from the base main wall transversely to the first base side wall.

6. The battery of claim 5, wherein the first cover sidewall and the second cover sidewall are substantially perpendicular to each other, and the first base sidewall and the second base sidewall are substantially perpendicular to each other.

7. The battery according to claim 1, wherein: The cover main wall includes a cover extension portion extending outwardly of the side wall structure, and the base main wall includes a base extension portion extending outwardly of the side wall structure; and The cover extension is disposed substantially along the same plane as the cover main wall, and the base extension is disposed substantially along the same plane as the base main wall.

8. The battery according to claim 1, wherein: The sidewall structure includes a plurality of sidewall components, each of the sidewall components including a first end and a second end; and The first ends of the sidewall members are coupled to each other and the second ends of the sidewall members are coupled to each other to define the sidewall structure.

9. The battery according to claim 8, wherein: The first end defines a first slot and includes a first flange, and the second end defines a second slot and includes a second flange; and The first flange is received in the second slot, and the second flange is received in the first slot.

10. The battery according to claim 1, The battery also includes: an electrical contact extending from the interior volume of the sidewall structure to an exterior of the sidewall structure; a conductive member electrically coupling the battery cell stack to the electrical contact; in: The battery cell stack is electrically coupled to the conductive member; and The conductive member includes less than two bends along the length of the conductive member.

11. A battery, comprising: a cover, the cover comprising a cover main wall and a first cover side wall extending laterally from the cover main wall; a base, the base comprising a base main wall and a first base side wall extending laterally from the base main wall; Side wall structure, wherein: A first end of the side wall structure is coupled against the cover main wall and the first cover side wall to define a first interior corner between the side wall structure and the cover main wall; A second end of the sidewall structure is coupled against the base main wall and the first base sidewall to define a second interior corner between the sidewall structure and the base main wall; The first interior corner and the second interior corner include a radius of substantially zero; and The cover, the base, the sidewall structure, the first interior corner, and the second interior corner define an interior volume; and A battery cell stack is positioned in the interior volume.

12. The battery of claim 11, wherein the substantially zero radius comprises a radius of less than 1 mm.

13. The battery of claim 11, wherein the first cover side wall extends substantially perpendicularly from the cover main wall, and the first base side wall extends substantially perpendicularly from the base main wall.

14. The battery of claim 11, wherein the cover main wall includes a second cover side wall extending from the cover main wall transversely to the first cover side wall, and the base main wall includes a second base side wall extending from the base main wall transversely to the first base side wall.

15. The battery according to claim 11, wherein: The sidewall structure includes a plurality of sidewall components, each of the sidewall components including a first end and a second end; and The first ends of the sidewall members are coupled to each other and the second ends of the sidewall members are coupled to each other to define the sidewall structure.

16. A battery, comprising: A rigid metal housing characterized by an internal volume, wherein the housing comprises: a cover, the cover comprising a cover main wall and a first cover side wall extending from the cover main wall; a base, the base comprising a base main wall and a first base side wall extending from the base main wall; a structural sidewall extending between the cover and the base to define a plurality of interior corners having a substantially zero radius, wherein the cover is coupled to the structural sidewall at the first cover sidewall and the base is coupled to the structural sidewall at the first base sidewall; and A battery cell stack is positioned in the interior volume.

17. The battery of claim 16, wherein the first cover side wall extends from the cover main wall at a first substantially perpendicular angle, and the first base side wall extends from the base main wall at a second substantially perpendicular angle.

18. The battery of claim 16, wherein the substantially zero radius comprises a radius less than 1 mm.

19. The battery according to claim 16, wherein: all interior corners defined between the cover and the sidewall structure, and between the base and the sidewall structure, include a radius of substantially zero; and The interior volume is further defined by all interior corners.

20. The battery of claim 16, wherein the cover main wall includes a second cover sidewall extending from the cover main wall transversely to the first cover sidewall, and the base main wall includes a second base sidewall extending from the base main wall transversely to the first base sidewall.

Images