Current collector assembly with curved interconnect portions

Abstract

Interconnection portions of the conductive layer may include different curvature distributions. Some of the interconnect portions include a curvature profile that allows the distance of the interconnect portions across the plurality of tabs of the conductive layer. The interconnection portion across the distance of the plurality of tabs allows a battery pack with a reduced number of modules to have the same or similar voltage output as a battery pack with a larger number of battery modules.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 649,265, filed May 17, 2024, entitled “CURRENT COLLECTOR ASSEMBLY WITHCURVED INTERCONNECT PORTIONS”, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Batteries are commonly used as a power source, including for electric vehicles that include wheels driven by electric motors that receive power from the battery. A battery may comprise multiple battery cells housed within a module and / or carrier.

[0004] Various aspects of the technologies in this subject matter can help improve the durability and / or lifespan of batteries in electric vehicles, which can help mitigate climate change by reducing greenhouse gas emissions. Summary of the Invention

[0005] The current collector assembly (CCA) for a battery module may include a conductive layer with several interconnect portions, some of which are connected to multiple interconnect portions. Specifically, some interconnect portions include a different curvature distribution (e.g., a different radius of curvature) than the others. Some interconnect portions include relatively small radii of curvature and are therefore flexible enough to extend around and / or between multiple tabs for connection to battery cells. Some battery modules are designed to provide output (e.g., voltage output) based on the series and parallel electrical connections between the battery cells of the battery module. However, when the number of battery modules decreases, the number of battery cells also decreases. This can cause a change in voltage output (e.g., a decrease). However, based on the interconnect portions, the desired output can be achieved with fewer battery cells (e.g., achieving a previous voltage output with a larger battery module), and other features of the conductive layer (e.g., tabs, other interconnect portions) do not need to be rearranged.

[0006] According to one or more embodiments of this disclosure, an apparatus is described. The apparatus may include a current collector assembly including a conductive layer. The conductive layer may include a first interconnect portion connected to a first and a second insert. The conductive layer may also include a second interconnect portion. The conductive layer may further include a third interconnect portion connected to the first and second interconnect portions. The third interconnect portion may extend from at least the first insert to the second insert. The first insert may be spaced apart from the second insert by a first distance, and the third interconnect portion may extend across a second distance greater than the first distance. The third interconnect portion may have a first width and a second width different from the first width.

[0007] The first interconnect portion may include a third insert. The third interconnect portion may span from at least the first insert, the second insert, and the third insert. The second interconnect portion may include a fourth insert, and the third interconnect portion may be positioned between the third insert and the fourth insert.

[0008] The second interconnect portion may include a fifth insert, the fourth insert may be spaced apart from the fifth insert by a first distance, and the third interconnect portion may span a second distance greater than the first distance.

[0009] The third interconnect portion can be positioned between the third and fifth inserts. The third interconnect portion can be positioned between the second and fifth inserts.

[0010] According to one or more embodiments of this disclosure, a battery sub-assembly is described. The battery sub-assembly may include a current collector assembly electrically coupled to one or more battery cells. The current collector assembly may include a conductive layer including a first tab extending from a first interconnect portion. The conductive layer may also include a second tab extending from a second interconnect portion. The conductive layer may also include a third interconnect portion. The third interconnect portion may include a first segment extending from the first interconnect portion. The third interconnect portion may also include a second segment extending from the second interconnect portion. The third interconnect portion may also include a third segment connected to the first segment and the second segment. The third segment may be positioned between the first tab and the second tab and extends at least from the first tab to the second tab. The first interconnect portion may be parallel to the second interconnect portion.

[0011] The third interconnect portion may also have a first width and a second width different from the first width. The conductive layer may also include a third tab extending from the first interconnect portion. The first tab and the third tab may be spaced apart by a first distance, and the third interconnect portion may span a second distance greater than the first distance.

[0012] The conductive layer may further include a fourth interconnect portion positioned between the first interconnect portion and the second interconnect portion. The conductive layer may also include a fifth interconnect portion. The conductive layer may further include a sixth interconnect portion connected to the fourth and fifth interconnect portions. The third interconnect portion may be a first distance away, and the sixth interconnect portion may span a second distance less than the second distance. The fourth interconnect portion may be parallel to the first interconnect portion and to the second interconnect portion.

[0013] The battery sub-assembly of claim 13 further includes a third tab extending from the fourth interconnect portion. The one or more battery cells may include a first battery cell electrically connected to the first tab. The one or more battery cells may further include a second battery cell electrically connected to the second tab. The second battery cell may be connected in parallel with the first battery cell. The one or more battery cells may further include a third battery cell electrically connected to the second tab. The third battery cell may be connected in series with the first and second battery cells. The first tab may be configured to be electrically connected to the positive terminal of the first battery cell, and the third tab may be configured to be electrically connected to the negative terminal of the third battery cell.

[0014] According to one or more embodiments of this disclosure, a vehicle is described. The vehicle may include a current collector assembly comprising a conductive layer. The conductive layer may include a first interconnect portion connected to a first and a second lamination. The conductive layer may also include a second interconnect portion. The conductive layer may further include a third interconnect portion connected to the first and second interconnect portions. The third interconnect portion may extend at least from the first lamination to the second lamination.

[0015] The third interconnect portion may include a first segment extending from the first interconnect portion. The third interconnect portion may also include a second segment extending from the second interconnect portion. The third interconnect portion may further include a third segment connected to the first segment and the second segment. The third segment may be positioned between the first tab and the second tab. The first segment may include a first width, and the third segment may have a second width different from the first width.

[0016] The conductive layer may further include a fourth interconnect portion positioned between the first interconnect portion and the second interconnect portion. The conductive layer may also include a fifth interconnect portion. The conductive layer may further include a sixth interconnect portion connected to the fourth interconnect portion and the fifth interconnect portion. The third interconnect portion may be a first distance away, and the sixth interconnect portion may span a second distance less than the second distance.

[0017] The conductive layer may further include a third insert extending from the fourth interconnect portion. The one or more battery cells may include a first battery cell electrically connected to the first insert. The one or more battery cells may further include a second battery cell electrically connected to the second insert. The second battery cell may be connected in parallel with the first battery cell. The one or more battery cells may further include a third battery cell electrically connected to the second insert. The second battery cell may be connected in series with the first battery cell and the second battery cell. Attached Figure Description

[0018] Certain features of the subject matter are set forth in the appended claims. However, for illustrative purposes, several embodiments of the subject matter are illustrated in the following figures.

[0019] Figure 1A and Figure 1B A schematic perspective side view of an example embodiment of a vehicle with a battery pack according to one or more embodiments of this disclosure is shown.

[0020] Figure 1C A schematic perspective view of a building with a battery pack according to one or more specific embodiments of this disclosure is shown.

[0021] Figure 2A A schematic perspective view of a battery pack according to one or more specific embodiments of the present disclosure is shown.

[0022] Figure 2B A schematic perspective view is shown of various battery modules that may be included in a battery pack according to one or more specific embodiments of the present disclosure.

[0023] Figure 2C A cross-sectional end view of a battery cell according to one or more embodiments of the present disclosure is shown.

[0024] Figure 2D A cross-sectional perspective view of a cylindrical battery cell according to one or more specific embodiments is shown.

[0025] Figure 2E A cross-sectional perspective view of a prismatic battery cell according to one or more embodiments of the present disclosure is shown.

[0026] Figure 2F A cross-sectional perspective view of a pouch cell according to one or more embodiments of the present disclosure is shown.

[0027] Figure 3 A perspective view of a cover for a battery module according to one or more specific embodiments of the present disclosure is shown.

[0028] Figure 4 One or more specific embodiments according to this disclosure are shown. Figure 3 The exploded perspective view of the battery module shown.

[0029] Figure 5 A perspective view of an example battery cell according to one or more specific embodiments of this disclosure is shown.

[0030] Figure 6A , Figure 6B and Figure 6C A perspective view of an example battery pack according to one or more specific embodiments of this disclosure is shown.

[0031] Figure 7 A plan view of a current collector assembly for a battery module according to one or more specific embodiments is shown.

[0032] Figure 8 One or more specific embodiments according to this disclosure are shown. Figure 7 An enlarged plan view showing additional features of the current collector assembly in section A of the diagram.

[0033] Figure 9 One or more specific embodiments according to this disclosure are shown. Figure 8 An additional enlarged plan view showing additional features of the current collector assembly is shown.

[0034] Figure 10 One or more specific embodiments according to this disclosure are shown. Figure 7 An additional enlarged plan view showing the characteristics of the voltage sensing harness of the current collector assembly shown.

[0035] Figure 11 A flowchart illustrating an example of a process executable to form a current collector assembly according to one or more specific embodiments of the present disclosure is shown. Detailed Implementation

[0036] The specific embodiments described below are intended to illustrate various configurations of the subject matter and are not intended to represent the only configuration in which the subject matter can be practiced. The accompanying drawings are incorporated herein and form part of the specific embodiments. The specific embodiments include particular details in order to provide a thorough understanding of the subject matter. However, those skilled in the art will clearly understand that the subject matter is not limited to the particular details set forth herein and can be practiced without these particular details. In some instances, well-known structures and components are shown in block diagram form to avoid confusion with the concepts of the subject matter.

[0037] This technical subject matter relates to CCAs with a conductive layer having different interconnect portions with varying curvature distributions. For example, some interconnect portions include a small radius of curvature allowing the interconnect portion to extend around and / or between several tabs. To enable the battery cells of a battery module to provide a desired output (e.g., voltage output), the battery cells can be electrically connected in series and parallel in a specific manner. However, when the number of battery modules (having several battery cells) changes, the desired output changes. To maintain the desired output, the interconnect portions described herein provide connections for electrically connecting different battery cells in series and parallel. Furthermore, the use of the interconnect portions described herein minimizes design changes to other features (e.g., tabs connected to the battery cells, other interconnect portions). Furthermore, it also minimizes changes to manufacturing, as molds and welding lines may undergo minimal changes (if any). Advantageously, when the number of battery cells decreases, the interconnect portions described herein can be used to maintain the desired output while also minimizing overall manufacturing costs.

[0038] Figure 1A An example implementation of the movable device as described herein is shown. Figure 1A In the example, the mobile device is implemented as a vehicle 100. As shown, the vehicle 100 may include one or more battery packs, such as battery pack 110. Battery pack 110 may be coupled to one or more electrical systems of the vehicle 100 to provide power to the electrical systems.

[0039] In one or more embodiments, vehicle 100 may be an electric vehicle having one or more electric motors that use electricity from battery pack 110 to drive the wheels 102 of vehicle 100. In one or more embodiments, vehicle 100 may also or alternatively include one or more engines or motors, including chemically powered engines such as gas-powered engines or fuel cell-powered motors. For example, in one or more embodiments, vehicle 100 may include one or more electric motors, and vehicle 100 may take the form of a fully electric or partially electric (e.g., hybrid or plug-in hybrid) vehicle.

[0040] exist Figure 1A In the example, vehicle 100 is implemented as a truck (e.g., a pickup truck) with battery pack 110. As shown, battery pack 110 may include one or more battery modules 115, which may include one or more battery cells 120. Figure 1A As shown, the battery pack 110 may also or alternatively include one or more battery cells 120 directly mounted within the battery pack 110 (e.g., in a cell-to-cell configuration). In one or more embodiments, the provided battery pack 110 may not have a battery module 115, but instead have battery cells 120 directly mounted within the battery pack 110 (e.g., in a cell-to-cell configuration) and / or other battery devices disposed within the battery pack 110. The battery pack 110 may include multiple energy storage devices that can be arranged as battery modules or battery devices. The battery devices or modules may include battery assemblies capable of being combined with other elements (e.g., structural frames, thermal management devices) that can protect the battery assembly from heat, shock, and / or vibration.

[0041] Each battery cell in battery cell 120 may include a battery, battery device, battery module, and / or battery pack to power components of vehicle 100. For example, the battery cell housing of battery cell 120 may be disposed in battery module 115, battery pack 110, battery array, or other battery device disposed in vehicle 100.

[0042] As discussed in further detail below, battery cell 120 may be provided with a battery cell housing, which may be provided with 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 be or alternatively shaped as a pouch or other flexible or stretchable housing for the battery cell. In various other embodiments, the battery cell housing may be provided with 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, battery pack 110 may not include modules (e.g., the battery pack may be module-free). For example, battery pack 110 may have a module-free or battery cell-battery pack configuration, wherein battery cells 120 are arranged directly as battery pack 110 without being assembled into battery modules 115. In one or more embodiments, vehicle 100 may include one or more busbars, electrical connectors, or other charge harvesting, current harvesting, and / or coupling components to supply power from battery pack 110 to various systems or components of vehicle 100. In one or more embodiments, vehicle 100 may include control circuitry such as power stage circuitry for converting DC power from battery pack 110 into AC power for one or more components and / or systems of vehicle (e.g., one or more power outlets including vehicle). The power stage circuitry may be located within vehicle 100 as part of battery pack 110 or separately from battery pack 110.

[0043] Figure 1B Another specific embodiment is shown, in which the vehicle 100 is implemented as a sport utility vehicle (SUV), such as an electric sport utility vehicle. Figure 1B In one example, vehicle 100 may include a cargo storage area enclosed within vehicle 100 (e.g., behind a row of seats in the passenger compartment of vehicle 100). In other embodiments, vehicle 100 may be implemented as another type of electric truck, electric van, electric car, electric motorcycle, electric scooter, electric bicycle, electric passenger vehicle, electric passenger or commercial truck, hybrid vehicle, aircraft, ship, and / or any other mobile device having a battery pack 110 (e.g., a battery pack or other battery device that powers the propulsion or drive components of the mobile device).

[0044] In one or more specific embodiments, the 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 110a implemented in a building 180 is shown. Building 180 can be a residential building, a commercial building, or any other building. As shown, in one or more specific embodiments, the battery pack 110a may be mounted to a wall of building 180.

[0045] As shown in the figure, a battery pack 110a housed in building 180 may be coupled (e.g., electrically coupled) to battery pack 110b in vehicle 100 via cable / connector 106, an electric vehicle power supply unit 170 (EVSE), power stage circuitry 172, and / or cable / connector 174, which can be connected to a charging port 130 of vehicle 100. For example, cable / connector 106 may be coupled to EVSE 170, which may be coupled to battery pack 110a via power stage circuitry 172, and / or coupled to an external power source 190. In this way, in some applications, external power source 190 or battery pack 110a may be used as an external power source to charge battery pack 110b. In one or more embodiments, battery pack 110a may also be coupled (e.g., via cable / connector 174, power stage circuitry 172, and EVSE 170) to external power source 190. External power source 190 may take the form of solar power, wind power, and / or a power grid for a city, town, or other geographic area (e.g., a grid supplied by a remote power plant). For example, if battery pack 110b is not coupled to battery pack 110a, battery pack 110a may be coupled (e.g., using power stage circuitry 172) to external power source 190 to charge and store electrical energy. In some applications, this stored electrical energy in battery pack 110a may later be used to charge battery pack 110b (e.g., during times when solar or wind power is unavailable, in the event of a regional or localized power outage at building 180, and / or during high-rate periods for grid connection).

[0046] In one or more embodiments, power stage circuitry 172 may electrically couple battery pack 110a to the electrical system of building 180. For example, power stage circuitry 172 may convert DC power from battery pack 110a into AC power for one or more loads in building 180. Exemplary loads coupled to battery pack 110a via one or more electrical outlets may include one or more lights, luminaires, appliances, fans, heaters, air conditioners, and / or any other electrical components or electrical loads. Power stage circuitry 172 may include control circuitry operable to switchably couple battery pack 110a between external power source 190 and one or more electrical outlets and / or other electrical loads in the electrical system of building 180. In one or more embodiments, vehicle 100 may include power stage circuitry (… Figure 1C(Not shown in the image), the power stage circuit can be used to convert the power received from the EVSE 170 into DC power for powering / charging the battery pack 110b, and / or to convert the DC power from the battery pack 110 into AC power for one or more electrical systems, components and / or loads of the vehicle 100.

[0047] In one or more use cases, battery pack 110a may be used as a power source for building 180, such as during periods when solar or wind power is unavailable, in the event of a regional or localized power outage at building 180, and / or during high-rate periods for grid connection (as non-limiting examples). In one or more other use cases, battery pack 110b may be used to charge battery pack 110a and / or to supply power to the electrical system of building 180 (e.g., in cases where the stored energy of battery pack 110a is insufficient or depleted and solar or wind power is unavailable, a regional or localized power outage occurs at building 180, and / or during high-rate periods for grid connection (as non-limiting examples)).

[0048] Figure 2A An example of a battery pack 110 is shown. As illustrated, the battery pack 110 may include a battery pack frame 203 (e.g., a battery pack housing or pack frame). The battery pack frame 203 may house or enclose one or more battery modules and / or one or more battery cells and / or other battery pack components of the battery pack 110. In one or more embodiments, the battery pack frame 203 may include or form a shielding structure on its outer surface (e.g., its bottom and / or under one or more battery modules, battery devices, batteries and / or battery cells) to protect the battery modules, battery devices, batteries and / or battery cells from external conditions (e.g., if the battery pack 110 is housed in a vehicle and the vehicle is driven on rough terrain such as off-road terrain, ditches, rocks, rivers, streams, etc.).

[0049] Battery pack 110 may include battery cells (e.g., directly housed within battery pack 110, or housed within batteries, battery devices, and / or battery modules, as described herein) and / or battery modules, and for coupling the voltage generated by the battery cells to a device such as vehicle 100. Figure 1A , Figure 1B and Figure 1C (as shown in the diagram) and / or the electrical system of building 180 ( Figure 1COne or more conductive coupling elements of the power-consuming components (shown in the figure). For example, the conductive coupling elements may include internal connectors and / or contactors that couple multiple battery cells, battery devices, batteries, and / or multiple battery modules together within the battery pack frame 203 to generate the 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 205 (e.g., high-voltage terminals or connectors). As shown, the battery pack 110 may include electrical contacts 205 that can electrically couple external loads (e.g., the electrical system of a vehicle or building) to the battery modules and / or battery cells in the battery pack 110. At this point, power cables (e.g., cable / connector 106) may be connected between the electrical contacts 205 and the electrical system of the vehicle or building to provide power to the vehicle or building.

[0050] In one or more embodiments, 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 structure 207 may couple thermal control structures and / or fluids to battery modules, battery devices, batteries, and / or battery cells within the battery pack frame 203, such as by distributing fluids through the battery pack 110. The thermal control structure 207 may form part of a thermal / temperature control or heat exchange system including one or more thermal components 209, which may include plates or bladders configured to thermally contact one or more battery modules and / or battery cells disposed within the battery pack frame 203. The one or more thermal components 209 may be positioned to contact one or more battery modules, battery devices, batteries, and / or battery cells within the battery pack frame 203. One or more thermal control structures 207 may be provided for each of a plurality of top and bottom battery module pairs.

[0051] Figure 2B It describes a configuration that can be set in a battery pack (e.g., Figure 2A Examples of battery modules within the battery pack frame 203 of the battery pack 110 shown in the diagram. Figure 2BIn one example, a battery module 115a is shown, which includes a battery module housing 211 having a rectangular cubic shape with a length approximately similar to its width. In this example, battery module 115a includes battery cells 120 implemented as cylindrical battery cells. Battery module 115a also includes rows and columns of cylindrical battery cells coupled together by interconnection structures 213 (e.g., current collector assemblies or CCAs). For example, interconnection structures 213 may couple the positive terminals of battery cells 120 together and / or couple the negative terminals of battery cells 120 together. As shown, battery module 115a may also include a bus 215 serving as a charge collector. For example, bus 215 may be electrically coupled to interconnection structures 213 to collect the charge generated by battery cells 120, thereby providing a high voltage output from battery module 115a.

[0052] Figure 2B A battery module 115b with an elongated shape is also shown. Battery module 115b may include a battery module housing 211, wherein the length of the battery module housing 211 (e.g., extending in a direction from front to rear end) is substantially greater than the width of the battery module housing 211 (e.g., in a lateral direction from front to rear end). At this point, battery module 115b (representing one or more similar battery modules) may span the entire front-to-back length of the battery pack within the battery pack frame. As shown, battery module 115b may also include an interconnect structure 213 electrically coupled to a bus 215, allowing the bus 215 to be electrically coupled to the interconnect structure 213 to collect the charge generated by the battery cells 120 of battery module 115b, thereby providing a high voltage output from battery module 115b.

[0053] In specific embodiments of battery module 115a, battery cell 120 is implemented as a cylindrical battery cell. However, in other embodiments, the battery module may include battery cells with other shape factors, such as battery cells with a right prism external shape (e.g., prism-shaped cells), or pouch-shaped battery cell embodiments. As an example, Figure 2BA battery module 115c with a battery module housing 211 is also shown. This housing has a rectangular-cubic shape with a length approximately equal to its width and includes battery cells 120 implemented as prismatic battery units. In this example, battery module 115c includes rows and columns of battery cells 120 coupled together via an interconnection structure 213 (e.g., a current collector assembly or CCA). For example, the interconnection structure 213 may couple the positive terminals of battery cells 120 together and / or couple the negative terminals of battery cells 120 together. As shown, battery module 115c may include a bus 215 serving as a charge collector. For example, bus 215 may be electrically coupled to interconnection structure 213 to collect the charge generated by battery cells 120, thereby providing a high voltage output from battery module 115c.

[0054] Figure 2B A battery module 115d is also shown, which includes prismatic battery cells and has an elongated shape. For example, battery module 115d includes a battery module housing 211, wherein the length of battery module housing 211 is substantially greater than the width of battery module housing 211. At this point, battery module 115d (representing one or more similar battery modules) may span the entire front-to-back length of the battery pack within the battery pack frame. As shown, battery module 115d may also include an interconnection structure 213 and a bus 215 electrically coupled to the interconnection structure 213. For example, bus 215 may be electrically coupled to the interconnection structure 213 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from battery module 115d.

[0055] As another example, Figure 2B A battery module 115e with a battery module housing 211 having a rectangular-cubic shape with a length approximately equal to its width is also shown. The battery module housing 211 can house battery cells 120, each of which is implemented as a pouch-like battery cell. In this example, the battery module 115e includes rows and columns of pouch-like battery cells coupled together via an interconnection structure 213 (e.g., a current collector assembly or CCA). For example, the interconnection structure 213 can couple the positive terminals of the battery cells 120 together and the negative terminals of the battery cells 120 together. As shown, the battery module 115e may also include a bus 215 electrically coupled to the interconnection structure 213. For example, the bus 215 can be electrically coupled to the interconnection structure 213 to collect the charge generated by the battery cells 120, thereby providing a high-voltage output from the battery module 115e.

[0056] Figure 2BBattery module 115f is also shown, which includes pouch-shaped battery cells and has an elongated shape. For example, battery module 115d includes a battery module housing 211, wherein the length of the battery module housing 211 is substantially greater than the width of the battery module housing 211. At this point, battery module 115d (representing one or more similar battery modules) may span the entire front-to-back length of the battery pack within the battery pack frame. At this point, battery module 115f (representing one or more similar battery modules) may span the entire front-to-back length of the battery pack within the battery pack frame. As shown, battery module 115f may also include an interconnect structure 213 and a bus 215 electrically coupled to the interconnect structure 213. For example, bus 215 may be electrically coupled to the interconnect structure 213 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from battery module 115f.

[0057] In various specific implementations, the battery pack (e.g., Figure 2A The battery pack 110 shown may have any one or more battery modules 115a, 115b, 115c, 115d, 115e, and 115f. In one or more other embodiments, the battery pack may be without any of the battery modules 115a, 115b, 115c, 115d, 115e, and 115f (e.g., in a battery cell-battery pack embodiment).

[0058] In one or more specific implementations, Figure 2B In any specific implementation, the battery module may be coupled (e.g., in series) to the current collector of the battery pack. In one or more implementations, the current collector may be coupled via a high-voltage wiring harness to one or more external connectors on the battery pack (e.g., Figure 2A The electrical contacts 205 of the battery pack 110 are shown in the diagram. In one or more embodiments, the battery pack may not have any battery modules 115. For example, in a battery cell-battery pack configuration, battery cells 120 are arranged directly as a battery pack without being assembled into battery modules (e.g., excluding battery module housings 211). For example, the battery pack frame of the battery pack (e.g., Figure 2A The battery pack frame 203 of the battery pack 110 shown may include or define a plurality of structures for directly positioning the battery cells 120 within the battery pack frame.

[0059] Figure 2CA cross-sectional end view of a portion of a battery cell 120 is illustrated. As 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 copper foil or other metal foil). Furthermore, the cathode 212 may include or be electrically coupled to a second current collector 214 (e.g., a metal layer, such as an aluminum foil or other metal foil). The battery cell 120 may also include a terminal 216 (e.g., a negative terminal) coupled to the anode 208 (e.g., via the first current collector 206) and a terminal 218 (e.g., a positive terminal) coupled to the cathode (e.g., via the second current collector 214). In various embodiments, the electrolyte 210 may be in the form of a liquid electrolyte layer or a solid electrolyte layer. In one or more embodiments (where the electrolyte 210 is a liquid electrolyte layer), the battery cell 120 may include a separator layer 220 separating the anode 208 from the cathode 212. In one or more embodiments where the electrolyte 210 is a solid electrolyte layer, the electrolyte 210 can be used as both a separator layer and an electrolyte layer.

[0060] In one or more embodiments, the battery cell 120 may be implemented as a lithium-ion battery cell, wherein the anode 208 is formed of a carbon-containing material (e.g., graphite or silicon-carbon). In these embodiments, lithium ions may move from the anode 208 to the cathode 212 via the electrolyte 210 during the discharge of the battery cell 120 (e.g., and from the cathode 212 to the anode 208 via 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 embodiments, 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. In embodiments in which the battery cell 120 is implemented as a lithium-ion battery cell, the electrolyte 210 may comprise a lithium salt in an organic solvent.

[0061] 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 prevents contact between the anode 208 and the cathode 212 and is permeable to the electrolyte 210 and / or ions within the electrolyte 210. In one or more embodiments, 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.

[0062] While this document describes some examples in which battery cell 120 is implemented as a lithium-ion battery cell, battery cell 120 can 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-hydroxide. In examples of nickel-metal hydride battery cells, in one or more examples, the electrolyte 210 may be formed of an aqueous solution of potassium hydroxide.

[0063] In one or more other embodiments, battery cell 120 may be implemented as a lithium-sulfur battery cell. For example, in a lithium-sulfur battery cell, anode 208 may be at least partially formed of lithium, cathode 212 may be at least partially formed of sulfur, and electrolyte 210 may be formed of cyclic ethers, short-chain ethers, glycol ethers, ionic liquids, supersaturated salt solvent mixtures, polymer gel organic media, solid polymers, solid inorganic glasses, and / or other suitable electrolyte materials. In various embodiments, anode 208, electrolyte 210, and cathode 212 may be encapsulated in a battery cell housing having any of a variety of shapes and / or sizes and / or being formed of any of a variety of suitable materials. For example, battery cell 120 may include cylindrical, rectangular, square, cubic, flat, pouch-like, elongated, or prismatic external shapes.

[0064] like Figure 2D As depicted, for example, battery cell 120 may be implemented as a cylindrical cell. Therefore, battery cell 120 includes dimensions 222a (e.g., cylinder diameter, cell diameter) and 222b (e.g., cylinder length). Battery cell 120 and other battery cells described herein may include dimensional information derived from a 4-digit code. For example, in some embodiments, battery cell 120 includes an XXYY battery cell, where “XX” refers to dimension 222a in millimeters (mm) and “YY” refers to dimension in mm. Thus, when battery cell 120 includes a “2170” battery cell, dimension 222a is 21 mm and dimension 222b is 70 mm. Alternatively, when battery cell 120 includes a “4680” battery cell, dimension 222a is 46 mm and dimension 222b is 80 mm. The foregoing examples of dimensional characteristics of battery cell 120 should not be construed as limiting, and battery cell 120 and other battery cells with a cylindrical shape factor described herein may include a variety of dimensions. For example, dimensions 222a and 222b can be larger than 46mm and 80mm, respectively.

[0065] Figure 2DA battery cell 120 is shown, which includes a cell housing 224 having a cylindrical external shape. As shown in the enlarged view, an anode 208, an electrolyte 210, and a cathode 212 can be wound into one or more windings 221. As a non-limiting example, the one or more windings 221 may include one or more generally cylindrical windings. As shown, one or more windings 221 of the anode 208, electrolyte 210, and cathode 212 (e.g., and / or one or more separator layers, such as...) Figure 2C The partition layer 220 shown may be disposed within the unit housing 224. For example, the partition layer may be disposed between adjacent windings in one or more windings 221. Additionally, Figure 2D The cylindrical cell 120 in this embodiment includes terminals 216 and 218. Terminal 218 may include a first polarity terminal, such as a positive terminal, coupled to a cathode 212. Terminal 216 may include a second polarity terminal, such as a negative terminal, coupled to an anode 208. Terminals 216 and 218 may be made of a conductive material to carry current from the cell 120 directly or indirectly (e.g., via current-carrying components, buses, and / or other electrical coupling structures) to electrical loads, such as components or systems of vehicles or buildings shown and / or described herein. However, Figure 2D The cylindrical unit implementation is merely illustrative, and other implementations of the battery unit 120 are envisioned.

[0066] Figure 2E An example is shown in which the battery cell 120 is implemented as a prismatic cell. As shown, the battery cell 120 may include a cell housing 224 having a straight prismatic external shape. Furthermore, one or more layers of an anode 208, a cathode 212, and an electrolyte 210 disposed between them may be disposed (e.g., with a separating material between the layers) within the cell housing 224. As an example, multiple layers of the anode 208, electrolyte 210, and cathode 212 may be stacked (e.g., with a separating material between each layer), or a single layer of the anode 208, electrolyte 210, and cathode 212 may be formed in a flat helical shape and provided within the cell housing 224. The cell housing 224 may include a relatively thick cross-sectional width 217 formed of a rigid material. For example, the cell housing 224 may be formed from welded, stamped, deep-drawn, and / or impact-extruded metal sheets, such as welded, stamped, deep-drawn, and / or impact-extruded aluminum sheets. The cross-sectional width 217 of the cell housing 224 can be up to or greater than 1 millimeter (mm) to provide a rigid housing for the prismatic battery cell. In one or more embodiments, Figure 2E In the specific implementation of the prismatic unit, terminals 216 and 218 may be formed by a feed conductor that passes through to the unit housing 224 to expose terminals 216 and 218 to the outside of the unit housing 224 for contact with interconnect structures (e.g., Figure 2B The interconnection structure 213 shown is insulated from the cell housing 224 (e.g., glass-to-metal feedthrough). However, Figure 2E This specific implementation is also exemplary, and other specific implementations of the battery cell 120 are envisioned.

[0067] Figure 2F An example in which the battery cell 120 is implemented as a pouch-like cell is shown. As shown, the battery cell 120 may include a cell housing 224, which is formed into a flexible or stretchable pouch-like housing. One or more layers of an anode 208, a cathode 212, and an electrolyte 210 disposed between them may be disposed (e.g., with a separating material between the layers) within the cell housing 224. Figure 2F In a specific implementation, the unit housing 224 may include a relatively thin cross-sectional width 219. For example, Figure 2F In a specific embodiment, the cell housing 224 may be formed of a flexible or stretchable material (e.g., foil, such as metal foil, or film, such as aluminum-coated plastic film). The cross-sectional width 219 of the cell housing 224 may 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 embodiments, Figure 2F In specific embodiments of the pouch-like unit, terminals 216 and 218 may be formed of conductive tabs (e.g., foil tabs) that are coupled (e.g., soldered) to the anode 208 and cathode 212, respectively, and sealed to the pouch that forms the unit housing 224 in these embodiments. Figure 2C , Figure 2E and Figure 2F In the example, terminals 216 and 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 embodiments, terminals 216 and 218 may be formed on two different sides (e.g., opposite sides, such as the top and bottom sides) of the battery cell 120. In various embodiments, terminals 216 and 218 may be formed on... Figure 2D On the same or different sides of the cylindrical unit.

[0068] In one or more embodiments, the battery module, battery pack, battery device, or any other battery may include some battery cells implemented as solid-state battery cells and other battery cells implemented with a liquid electrolyte for lithium ions or other battery cells having a liquid electrolyte. In one or more embodiments, one or more battery cells may be included in a battery module or battery pack, such as to provide power to components of a vehicle and / or the previously described building or any other electric component or device. The cell housing of the battery cell may be disposed in a battery module, disposed in a battery pack, or disposed in any of the vehicle, building, or any other electric component or device.

[0069] Figure 3 A perspective view of a cover 302a for a battery module 115 according to one or more specific embodiments of this disclosure is shown. Cover 302a may represent additional covers that will be shown and described below. Figure 3 In the example shown, battery module 115 includes submodule 304a and submodule 304b. Based on Figure 3 The positions and orientations of submodules 304a and 304b are shown; they may be referred to as the top submodule and bottom submodule, respectively. As shown, submodules 304a and 304b may each include unit carriers 308a and 308b. In one or more embodiments, each of unit carriers 308a and 308b may take the form of a monolithic body (e.g., a molded body formed of plastic and / or other materials) and may include structural features 310a and 310b, respectively, along its sidewalls. Structural features 310a and 310b may respectively enhance the strength of the sidewalls of unit carriers 308a and 308b, thereby reducing or eliminating the need for additional structural reinforcement components of the battery module 115, such as shear walls attached to unit carriers 308a and 308b. Furthermore, a cold plate 312 is provided between submodules 304a and 304b. The cold plate 312 may be connected to the battery cells (in...) in submodule 304a... Figure 3 (not visible in) and the battery cell in submodule 304b (in) Figure 3 (Invisible) thermal contact (e.g., thermal coupling) is used to provide thermal control for the respective battery cells of both submodules 304a and 304b.

[0070] Cover 302a may be disposed on the top of battery module 115, and an additional cover (shown below, similar to cover 302a) may be disposed on the bottom of battery module 115. Furthermore, a Balanced Voltage and Temperature (BVT) module 314 may be communicatively coupled to thermistor assemblies 316a and 316b. BVT module 314 may take the form of a modular assembly of various electrical components to monitor or control components of the battery sub-assembly. For example, BVT module 314 may include a circuit board attached to a housing of BVT module 314. As a non-limiting example, BVT module 314 may include various connectors for coupling with, for example, thermistors, voltage sensors, and / or communication devices. Thermistors may measure the temperature of battery module 115, battery sub-assemblies, and / or their battery cells. Voltage sensors or balancers may sense or control the voltage flowing through battery module 115, battery sub-assemblies, and / or their battery cells. Communication devices may receive, transmit, or analyze data associated with battery module 115, battery sub-assemblies, and / or their battery cells. Several buses can be integrated. For example, bus 318 (e.g., positive bus) can be electrically coupled to the respective first terminal (e.g., positive terminal) of the battery cell of submodule 304a and submodule 304b, and bus 320 (e.g., negative bus) can be electrically coupled to the respective second terminal (e.g., negative terminal) of the battery cell of submodule 304a and submodule 304b.

[0071] Figure 4 It shows Figure 3 An exploded perspective view of battery module 115 is shown, illustrating battery cells 120 of submodule 304a and submodule 304b. As shown, cover 302a is provided for submodule 304a, and cover 302b is provided for submodule 304b. In one or more examples described herein, battery module 115, Figure 3 and / or Figure 4 A subset of the components of the battery module 115 shown (e.g., submodule 304a, submodule 304b and / or another subset of the components of the battery module 115) or any other group of battery cells (e.g., a battery pack including multiple battery modules and / or other battery sub-assemblies) may be referred to as a battery sub-assembly.

[0072] exist Figure 4 In the example shown, CCA 400a and CCA 400b are also visible. As discussed in further detail below, when assembling battery module 115, CCA 400a and 400b can each take the form of a device that connects the corresponding terminals of the battery cells 120 of submodules 304a and 304b to busbars 318 and 320. Figure 4As shown, a series bus 406 may also be provided (e.g., on the ends of unit carriers 308a and 308b opposite to the ends of the respective unit carriers on which buses 318 and 320 are mounted). For example, the series bus 406 may electrically couple the battery cell 120 of submodule 304a to the battery cell 120 of submodule 304b.

[0073] The battery cell 120 of submodule 304a can be inserted into a crate-like structure formed by the unit carrier 308a of submodule 304a, and the battery cell 120 of submodule 304b can be inserted into a crate-like structure formed by the unit carrier 308b of submodule 304b. For example... Figure 3 and Figure 4 As shown, the orientation of the unit carrier 308a and battery cell 120 of submodule 304a can be substantially opposite to that of the unit carrier 308b and battery cell 120 of submodule 304b (e.g., upside down relative to the orientation of the unit carrier 308b and battery cell 120 of submodule 304b). In this way, CCA 400a and CCA 400b can be respectively disposed on or near the outer layer of submodules 304a and 304b for connection to the corresponding terminals of the battery cells 120 disposed in submodules 304a and 304b. In addition, the cold plate 312 can be thermally coupled to the battery cells 120 of submodule 304a and the battery cells 120 of submodule 304b. At this point, the cold plate 312 can dissipate heat energy from the battery cells 120 of submodule 304a and the battery cells 120 of submodule 304b.

[0074] Figure 5 A perspective view is shown of an example of a battery cell 520 according to one or more specific embodiments, the battery cell being implemented as a cylindrical cell having a cylindrical cell housing 524. Figure 5 In one example, battery cell 520 includes a cover 500 that includes a central portion 502 and a peripheral edge 504. In one or more embodiments, the central portion 502 may be implemented as a terminal, such as the positive terminal of battery cell 520. In one or more embodiments, the peripheral edge 504 may be implemented as a terminal, such as the negative terminal of battery cell 520. In one or more embodiments, battery cell 520 may include a gasket 506 at least partially disposed below the peripheral edge 504. For example, gasket 506 may isolate the internal cavity of battery cell 520 (e.g., closed by cylindrical cell housing 524 and cover 500) from the external environment of battery cell 520.

[0075] Figure 6A , Figure 6B and Figure 6C A perspective view of an example battery pack according to one or more specific embodiments of this disclosure is shown. Figures 6A to 6C Each battery pack shown may include several battery modules in a battery frame. Figures 6A to 6C Each battery module shown may include those described herein for battery modules (e.g., Figure 4 (The battery module shown in the diagram) and / or any of the features shown and / or described. Figures 6A to 6C Each battery module in the battery modules shown may be disposed in a battery pack frame, which may include, as described herein, a battery pack frame (e.g., Figure 2A The battery pack frame 203 shown in the diagram may have any of the features shown and / or described.

[0076] refer to Figure 6A The battery pack 610 includes battery modules 615a, 615b, 615c, 615d, 615e, 615f, 615g, 615h, and 615i. Each of these battery modules is disposed within a battery pack frame 603. (See reference...) Figure 6B The battery pack 710 includes battery modules 715a, 715b, 715c, 715d, 715e, 715f, and 715g. Each of these battery modules is disposed within the battery pack frame 603. (See reference...) Figure 6C The battery pack 810 includes battery modules 715a, 715b, 715d, 715e, 715f, and 715g. Each of these battery modules is disposed within the battery pack frame 603.

[0077] based on Figure 6A Battery pack 610 in Figure 6B Battery pack 710 and Figure 6C The different numbers of battery modules in battery packs 810, 610, 710, and 810 can provide different energy outputs, including different voltages and / or different energy storage capacities. For example, battery pack 610 with more battery modules can provide higher voltages and / or larger energy storage capacities. However, while the number of battery modules used in a battery pack may vary, the specific energy outputs of battery packs 610, 710, and 810 can also vary. Figure 6A and Figure 6BThe battery packs 610 and 710 differ, but the battery pack frame (e.g., battery pack frame 603) can include the same size and shape. In this respect, a battery pack frame of a single size and shape can be used with different numbers of battery modules. Advantageously, vehicles integrating battery pack frame 603 can be equipped with different numbers of battery modules, thus providing users with different options based on user preferences, including but not limited to acceleration (dependent on voltage), driving range (dependent on energy storage capacity), and cost (dependent on the number of battery modules).

[0078] Figure 7 A plan view of a CCA 800 for a battery module (e.g., battery module 115) according to one or more specific embodiments is shown. CCA 800 may represent other CCAs shown and / or described herein, such as... Figure 4 The CCA 400a and CCA 400b are shown. As shown, the CCA 800 may include a connector 804. As a non-limiting example, the connector 804 may be connected to another battery module or drive unit (e.g., a motor) of a vehicle (e.g., a mechanical and electrical connection). The CCA 800 may also include one or more edge portions 808, and one or more notches 812 (e.g., strain relief notches) in each of the one or more edge portions 808. Figure 7 Although not explicitly marked, the CCA 800 may include one or more inserts and one or more interconnects.

[0079] Figure 8 One or more specific embodiments according to this disclosure are shown. Figure 7 An enlarged plan view showing additional features of the CCA 800 in section A is shown. The CCA 800 is designed to work with a battery module ( Figure 8 Multiple battery cells (not shown) are connected (e.g., mechanically and electrically). As shown, the CCA 800 includes a conductive layer 820. The conductive layer 820 may be in the form of a metal layer (e.g., aluminum, aluminum foil) having a thickness in the range of approximately 100 micrometers to 200 micrometers.

[0080] The conductive layer 820 may include a plurality of interconnect portions or interconnects and inserts. For example, the conductive layer 820 may include interconnect portions 822a and 822b. In one or more embodiments, interconnect portions 822a and 822b are parallel or at least substantially parallel to each other. Additionally, the conductive layer 820 may include interconnect portion 822c, which is connected to and positioned between interconnect portions 822a and 822b. Furthermore, the conductive layer 820 may include interconnect portions 822d, 822e, and interconnect portion 822f, which is connected to and positioned between interconnect portions 822d and 822e. Interconnect portions 822d and 822f may be parallel to each other.

[0081] Several interconnect portions may include one or more tabs extending therefrom. For example, interconnect portion 822a includes tabs 824a and 824b. Additionally, interconnect portion 822b includes tabs 824c and 824d. Tabs 824a, 824b, 824c, and 824d represent several additional tabs of conductive layer 820.

[0082] At least some interconnect portions may include different features, including different curvatures (e.g., radii of curvature at different locations). For example, interconnect portions 822c and 822f (each of which is connected to and positioned between a corresponding interconnect portion) include different curvatures. Based on the difference in their respective curvatures, interconnect portion 822c, having a relatively smaller radius of curvature, includes larger / sharper bends compared to those bends in interconnect portion 822f, which has a relatively larger radius of curvature. Furthermore, each interconnect portion in interconnect portions 822c and 822f includes both an X component and a Y component (in Cartesian coordinates). Additionally, the X component of interconnect portion 822c (e.g., the component in one direction) is greater than the X component of interconnect portion 822f. In other words, interconnect portion 822c spans a greater distance along the same axis (e.g., the X-axis) than interconnect portion 822f. Furthermore, based on the difference in curvatures, interconnect portion 822c can be positioned between more inserts than interconnect portion 822f. For example, interconnect portion 822c is located between inserts 824a and 824c, and between inserts 824b and 824d. Conversely, interconnect portion 822f is located between inserts 824e and 824f.

[0083] Partly based on the interconnection portion, the CCA 800 can electrically connect some battery cells in series with each other, and also electrically connect some battery cells in parallel with each other. For example, in one or more embodiments, the CCA 800 can electrically connect six groups of battery cells in series with each other, and can also electrically connect seventy-two battery cells in parallel with each other. Additionally, in one or more embodiments, the CCA 800 can electrically connect eight groups of battery cells in series with each other, and can also electrically connect fifty-four battery cells in parallel with each other. Some battery cells electrically connected in series with some battery cells can also be electrically connected in parallel with other battery cells.

[0084] The desired number of battery cells connected in series and parallel can be adjusted based on interconnecting portions such as interconnecting portions 822c and 822f (and similar interconnecting portions). For example, a CCA utilizing interconnecting portions similar to interconnecting portion 822f (e.g., without using interconnecting portions similar to interconnecting portion 822c) can electrically connect six battery cells in series and seventy-two battery cells in parallel. Conversely, a CCA utilizing interconnecting portions similar to both interconnecting portions 822c and 822f (e.g., CCA 800) can electrically connect eight battery cells in series and fifty-four battery cells in parallel. Advantageously, the number of battery modules in the battery pack can be changed (e.g., reduced) while the voltage output remains constant. Furthermore, based on the use of interconnect portion 822c, various inserts (e.g., inserts 824a, 824b, 824c and 824d, representing additional inserts) and other interconnect portions (e.g., interconnect portions 822a, 822b, 822d and 822e, representing additional interconnect portions) do not need to be repositioned, resized and / or reshaped, while CCA (e.g., CCA 800) can change the number of battery cells in series and the number of battery cells in parallel.

[0085] Figure 9 One or more specific embodiments according to this disclosure are shown. Figure 8 The diagram shows an enlarged plan view illustrating additional features of the CCA 800. Interconnect portion 822c (represented by...) Figure 8The interconnect portion shown may include a segment 826a connected (e.g., electrically and mechanically) to interconnect portion 822a. Interconnect portion 822c may also include a segment 826b connected (e.g., electrically and mechanically) to interconnect portion 822b. Interconnect portion 822c may also include a segment 826c connected (e.g., electrically and mechanically) to segments 826a and 826b. Based on its location, segment 826c may be characterized as an intermediate segment or a central segment. Dashed lines superimposed on interconnect portion 822c represent boundaries or approximate boundaries between adjacent segments of interconnect portion 822c (e.g., segments 826a, 826b, and 826c). Partly based on the diagonal positioning of segment 826c relative to segments 826a and 826b, interconnect portion 822c may bypass some inserts (e.g., inserts 824a and 824d) and may extend between some inserts (e.g., 824a, 824b, 824c and 824d).

[0086] The corresponding intermediate or central section of the interconnection part 822f ( Figure 8 Compared to the interconnect portion 822f (shown in the diagram), segment 826c of interconnect portion 822c may include a larger dimension (e.g., longer) than the size of the intermediate segment of interconnect portion 822f. For example, segment 826c includes a dimension 830 (e.g., width along the X-axis). Based on dimension 830, segment 826c may at least span a dimension 832a defined as the distance between inserts 824a and 824b (including the outer edges of inserts 824a and 824b (e.g., adjacent inserts)). Additionally, segment 826c may at least span a dimension 832b defined as the distance between inserts 824c and 824d (e.g., adjacent inserts) (including the outer edges of inserts 824c and 824d). In this respect, dimension 830 of segment 826c may be larger than dimension 832a, and dimension 830 of segment 826c may be larger than dimension 832b. Furthermore, segment 826c allows the dimensions (represented by dimension 830) to be spaced along the X-axis at least from insert 824a to insert 824d. Similarly, segment 826c allows the dimensions (represented by dimension 830) to be spaced along the X-axis at least from insert 824c to insert 824b. Conversely, the corresponding intermediate segment of interconnect portion 822f ( Figure 8 As shown, the interconnect portion 822c may not span the dimensions of two adjacent inserts, and therefore the interconnect portion 822c spans a greater distance (along the same axis) than the interconnect portion 822f.

[0087] The conductive layer 820 may further include a tab 824e connected to and extending from the interconnect portion 822a, and a tab 824f connected to and extending from the interconnect portion 822d. As shown, a segment 826c of the interconnect portion 822c is positioned between tabs 824e and 824f. The tabs may be oriented in different directions. For example, tabs 824a, 824b, 824c, and 824d may be oriented in one direction (e.g., the positive direction of the Y-axis), and tabs 824e and 824f may be oriented in another direction (e.g., the negative direction of the Y-axis). In this respect, tabs 824a, 824b, 824c, and 824d may be oriented in a direction opposite to that of tabs 824e and 824f.

[0088] The conductive layer 820 may further include a tab 824g positioned between tabs 824a and 824b. Tabs 824a, 824b, and 824g may be electrically connected to a battery cell. For example, battery cell 834a (as shown by the dashed line) may include a positive terminal connected to tab 824a. Figure 9 (not shown in the image) and the negative terminal connected to the insert 824g ( Figure 9 (Not shown in the image). Additionally, battery cell 834b (shown as dashed) may include a positive terminal connected to insert 824b. Figure 9 (not shown in the image) and the negative terminal connected to the insert 824g ( Figure 9 (Not shown in the image). Additionally, it can be seen that insert 824g is positioned between inserts 824a and 824b. In this respect, segment 826c of interconnect portion 822c may span the distance of at least three inserts (e.g., inserts 824a, 824b, and 824g) based on dimension 830.

[0089] To further accommodate the interposer and other relatively small spaces, segment 826c of interconnect portion 822c may include different dimensions. For example, segment 826c may include dimension 836a (e.g., width) and dimension 836b (e.g., width). As shown, dimensions 836a and 836b are different because dimension 836a is smaller than dimension 836b. Advantageously, the interconnect portion (e.g., interconnect portion 822c) may also be adapted to the existing architecture of CCA 800 (e.g., the location of interposers 824c and 824d).

[0090] Figure 10 One or more specific embodiments according to this disclosure are shown. Figure 7 The attached enlarged plan view of the CCA 800 shows the features of the voltage sensing harness 840. The voltage sensing harness 840 is designed to supply power to the battery management system (BMS). Figure 10(Not shown) provides information such as voltage and current. In one or more embodiments, the number of electrical traces in the voltage sensing harness 840 may change as the number of battery modules in the battery pack changes.

[0091] Figure 11 A flowchart illustrating an example of a process 900 executable to form a current collector assembly according to one or more specific embodiments of the present disclosure is shown. For purposes of explanation, this document primarily refers to... Figure 4 and Figures 7 to 9 The CCA shown is used to describe the process. However, the process is not limited to... Figure 4 and Figures 7 to 9 The CCA shown herein, and one or more boxes (or operations) of the process may be performed by one or more other components of other suitable movable devices, equipment, or systems. Further, for illustrative purposes, some boxes of the process are described herein as occurring sequentially or linearly. However, multiple boxes of the process may occur in parallel. Furthermore, the boxes of the process do not need to be performed in the order shown, and / or one or more boxes of the process do not need to be performed and / or may be replaced by other operations.

[0092] At box 902, a conductive layer is provided. The conductive layer may include a metal (e.g., aluminum). At least some portions of the conductive layer may be covered by one or more electrically insulating layers.

[0093] At frame 904, a first interconnect portion is formed in the conductive layer. The first interconnect portion (e.g., Figure 8 The interconnect portion 822a shown may include one or more tabs (extending from the first interconnect portion), such as tabs 824a and 824b. Figure 8 (As shown in the diagram). The insert can be connected (e.g., electrically and mechanically) to one or more battery cells.

[0094] At frame 906, a second interconnect portion is formed in the conductive layer. The second interconnect portion (e.g., Figure 8 The interconnect portion 822b shown may also include one or more inserts (extending from the second interconnect portion), such as inserts 824c and 824d. Figure 8 (as shown in the image).

[0095] At frame 908, a third interconnect portion is formed in the conductive layer. The third interconnect portion (e.g., Figure 8 The interconnect portion 822c shown may be connected to the first interconnect portion and the second interconnect portion. The third interconnect portion may include a dimension (e.g., segment 826c) that spans from the tab extending at least from the first interconnect portion. The third interconnect portion may include a dimension that spans from the tab extending at least from the second interconnect portion.

[0096] Various aspects of the technologies in this topic can help extend the lifespan of batteries in transportation vehicles. This can help promote the operation and / or widespread use of batteries, which can have a positive impact on the climate by reducing greenhouse gas emissions.

[0097] As used herein, the phrase “at least one of” following a series of items, along with the terms “and” or “or” used to separate any items, modifies the entire list, not each member of the list (i.e., each item). The phrase “at least one of” does not require selection of at least one of each of the listed items; rather, it allows for the inclusion of meanings such as: at least one of any of these items, and / or at least one of any combination of these items, and / or at least one of each of these items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” respectively refer to 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.

[0098] When a component is referred to herein as “connected” or “coupled” to another component, it should be understood that the component may be directly connected to that other component, or that there may be intermediate components between these components. Conversely, when a component is referred to herein as “directly connected” or “directly coupled” to another component, it should be understood that there are no intermediate components in the “direct” connection between these components. However, the presence of a direct connection does not preclude the possibility of other connections with intermediate components.

[0099] The predicates “constructed as,” “operable to,” and “programmed to” do not imply any particular tangible or intangible modification of the subject matter, but are intended to be used interchangeably. In one or more embodiments, a processor constructed to monitor and control operations or components may also mean that the processor is programmed to monitor and control operations or that the processor is operable to monitor and control operations. Similarly, a processor constructed to execute code can be interpreted as a processor programmed to execute code or operable to execute code.

[0100] Phrases such as "aspect," "that aspect," "on the other hand," "some aspects," "one or more aspects," "one embodiment," "that embodiment," "another embodiment," "some embodiments," "one or more embodiments," "an implementation scheme," "that implementation scheme," "another implementation scheme," "some implementation schemes," "one or more implementation schemes," "a configuration," "that configuration," "another configuration," "some configurations," "one or more configurations," "the subject matter," "the disclosure," "this disclosure," and other variations thereof are used for convenience and do not imply that the disclosure associated with such phrases is necessary for the subject matter or that such disclosure applies to all configurations of the subject matter. The disclosure associated with such phrases may apply to all configurations or one or more configurations. One or more examples of the disclosure associated with such phrases may be provided. Phrases such as "aspect" or "some aspects" may refer to one or more aspects, and vice versa, and this similarly applies to other foregoing phrases.

[0101] The term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” or “example” is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, with regard to the use of terms such as “comprising,” “having,” etc., in the specification or claims, such terms are intended to be inclusive in a manner similar to the term “including,” as interpreted when “including” is used as a transitional word in the claims.

[0102] All structural and functional equivalents of elements of the various aspects described throughout this disclosure that are known to or will later become known to a person skilled in the art are expressly incorporated herein by reference and are intended to be covered by the claims. Furthermore, nothing disclosed herein is intended to serve the public, whether or not such disclosure is expressly stated in the claims. No claim element should be construed under paragraph 6 of 35 U.S.SC § 112 unless the element is expressly stated using the phrase “means for…” or, in the case of a method claim, using the phrase “step for…”.

[0103] The foregoing description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects. Therefore, the claims are not intended to be limited to the aspects shown herein, but are to be consistent with the full scope of the language claims, wherein elements referred to in the singular are not intended to mean “one and only one”, but rather “one or more” unless specifically stated otherwise. Unless otherwise specifically stated, the term “some” refers to one or more. Male pronouns (e.g., his) include female and neutral pronouns (e.g., her and its), and vice versa. Titles and subheadings (if any) are used for convenience only and do not limit this disclosure.

Claims

1. An apparatus, the apparatus comprising: Current collector assembly, the current collector assembly including a conductive layer, the conductive layer including: A first interconnect portion is connected to a first insert and a second insert; Second interconnection section; and A third interconnect portion is connected to the first interconnect portion and the second interconnect portion, wherein the third interconnect portion extends at least from the first insert to the second insert.

2. The apparatus according to claim 1, wherein: The first insert and the second insert are spaced apart by a first distance, and The third interconnection portion spans a second distance greater than the first distance.

3. The apparatus of claim 1, wherein the third interconnect portion comprises: First width, and A second width that is different from the first width.

4. The apparatus according to claim 1, wherein: The first interconnect portion includes a third insert. The third interconnect portion spans at least the first insert, the second insert, and the third insert.

5. The apparatus according to claim 4, wherein: The second interconnect portion includes a fourth insert, and The third interconnect portion is positioned between the third insert and the fourth insert.

6. The apparatus according to claim 5, wherein: The second interconnect portion includes a fifth insert. The fourth insert and the fifth insert are spaced apart by a first distance, and The third interconnection portion spans a second distance greater than the first distance.

7. The apparatus of claim 6, wherein the third interconnect portion is positioned between the third insert and the fifth insert.

8. The apparatus of claim 6, wherein the third interconnect portion is positioned between the second insert and the fifth insert.

9. A battery sub-assembly, the battery sub-assembly comprising: Current collector assembly, electrically coupled to one or more battery cells, the current collector assembly including a conductive layer comprising: A first insert, the first insert extending from a first interconnect portion; The second insert extends from the second interconnect portion; and The third interconnection portion includes: The first segment extends from the first interconnect portion. The second segment extends from the second interconnect portion, and A third segment connects the first segment and the second segment, wherein the third segment is positioned between the first insert and the second insert and extends at least from the first insert to the second insert.

10. The battery subassembly of claim 9, wherein the first interconnect portion is parallel to the second interconnect portion.

11. The battery subassembly of claim 9, wherein the third interconnect portion further comprises: First width, and A second width that is different from the first width.

12. The battery sub-assembly according to claim 9, wherein: The conductive layer further includes a third insert extending from the first interconnect portion. The first insert and the third insert are spaced apart by a first distance, and The third interconnection portion spans a second distance greater than the first distance.

13. The battery sub-assembly of claim 9, wherein the conductive layer further comprises: A fourth interconnect portion is positioned between the first interconnect portion and the second interconnect portion; Fifth interconnection section; and A sixth interconnect portion, which is connected to the fourth interconnect portion and the fifth interconnect portion, wherein: The third interconnect portion spans the first distance, and The sixth interconnect portion spans a second distance that is less than the second distance.

14. The battery subassembly of claim 13, wherein the fourth interconnect portion is parallel to the first interconnect portion and to the second interconnect portion.

15. The battery sub-assembly according to claim 13, wherein: The conductive layer further includes a third insert extending from the fourth interconnect portion, and the one or more battery cells include: A first battery cell, wherein the first battery cell is electrically connected to the first insert; A second battery unit, electrically connected to the second insert, and electrically connected in parallel with the first battery unit; and The third battery unit is electrically connected to the second insert and is connected in series with the first battery unit and the second battery unit.

16. The battery sub-assembly according to claim 15, wherein: The first insert is configured to be electrically connected to the positive terminal of the first battery cell, and The third insert is configured to be electrically connected to the negative terminal of the third battery cell.

17. A means of transport, the means of transport comprising: Current collector assembly, the current collector assembly including a conductive layer electrically coupled to one or more battery cells, the conductive layer comprising: A first interconnect portion is connected to a first insert and a second insert; Second interconnection section; and A third interconnect portion is connected to the first interconnect portion and the second interconnect portion, wherein the third interconnect portion extends at least from the first insert to the second insert.

18. The vehicle of claim 17, wherein the third interconnecting portion comprises: The first segment extends from the first interconnect portion. The second segment extends from the second interconnect portion, and A third segment, connected to the first segment and the second segment, positioned between the first insert and the second insert, wherein the first segment has a first width and the third segment has a second width different from the first width.

19. The vehicle according to claim 17, wherein the conductive layer further comprises: A fourth interconnect portion is positioned between the first interconnect portion and the second interconnect portion; Fifth interconnection section; and A sixth interconnect portion, which is connected to the fourth interconnect portion and the fifth interconnect portion, wherein: The third interconnect portion spans the first distance, and The sixth interconnect portion spans a second distance that is less than the second distance.

20. The means of transport according to claim 19, wherein: The conductive layer further includes a third insert extending from the fourth interconnect portion, and the one or more battery cells include: A first battery cell, wherein the first battery cell is electrically connected to the first insert; A second battery unit, electrically connected to the second insert, and electrically connected in parallel with the first battery unit; and The third battery unit is electrically connected to the second insert and is connected in series with the first battery unit and the second battery unit.

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