System and method for improved battery assembly

Abstract

The invention discloses a battery pack. The battery pack comprises a first battery cell pair with a first cell and a second cell. The first battery cell is provided with a first terminal extending towards the second battery cell, and the second battery cell is provided with a second terminal extending towards the first battery cell. The first terminal is provided with a first terminating part which is folded towards the second terminal and extends back towards the first battery cell, and the second terminal is provided with a second terminating part which is folded towards the first terminal and extends back towards the second battery cell. The battery pack also includes a clip disposed in a space between the first terminal and the second terminal for biasing the first terminal and the second terminal toward each other.

Description

Technical Field

[0001] This disclosure relates to the field of battery pack components and thermal management systems, and more specifically, but not exclusively, to systems and methods for securing battery cell tabs within a battery pack, providing electrical connectivity, and managing the performance and efficiency of battery packs used in various applications, such as electric vehicles, portable electronic devices, and large energy storage systems. Background Technology

[0002] Battery packs are common power sources in a variety of applications, including electric vehicles, portable electronic devices, and large-scale energy storage systems. These battery packs typically consist of multiple individual battery cells that are electrically interconnected to provide the required voltage and current output. The individual battery cells are usually arranged in a specific configuration within the battery pack to optimize the pack's performance and efficiency.

[0003] The electrical interconnection of individual battery cells within a battery pack is typically achieved through busbars or similar conductive elements. These busbars are usually mechanically attached to the battery cells and provide conductive paths for the flow of electrical energy between the cells. Busbars are typically arranged in a specific configuration to achieve the required electrical interconnection between the cells.

[0004] In addition to the electrical interconnection of the cells, battery pack assembly also includes the mechanical connection of the cells. This is typically achieved by using mechanical clips or other similar devices to hold the cells in place within the battery pack. These mechanical clips also provide a way to physically connect the cells to busbars or other conductive components.

[0005] Thermal management is another consideration in battery pack design and assembly. The operation of battery cells generates heat. To manage this heat, battery packs typically include heat dissipation suppression devices. These devices are designed to absorb, reflect, or dissipate the heat generated by the battery cells, thereby improving the overall performance and lifespan of the battery pack.

[0006] The assembly and industrialization process of battery packs involves connecting cell terminals to high-voltage terminals, connecting sensing leads, and suppressing heat dissipation. This process is complex and time-consuming, requiring a high degree of precision and expertise. Summary of the Invention

[0007] According to one aspect of this disclosure, a battery pack includes a first battery cell pair, the first battery cell pair including, for example, a first cell and a second cell adjacent to or close to each other. In some examples, the first cell and the second cell are adjacent such that they share at least one common boundary, or are separated by a gap material. The first cell includes a first terminal extending away from the first cell and toward the second cell, and the second cell includes a second terminal extending away from the second cell and toward the first cell. The first terminal includes a first termination portion folded toward the second terminal and extending back toward the first cell, and the second terminal includes a second termination portion folded toward the first terminal and extending back toward the second cell.

[0008] In some examples, the battery pack may include clips for biasing a first terminal and a second terminal toward each other. The clips are positioned in the space between the first and second terminals. Located within the intermediate space separating the first and second terminals, the clips not only act as a physical bridge between them but also enhance the electrical connection by maintaining consistent pressure. The presence of the clips ensures that the terminals maintain their intended alignment and orientation, which is particularly beneficial in environments where the battery pack may be subject to vibration or movement. In some examples, the clips may be used to couple the first terminal to the second terminal and optionally to one or more additional terminals. In some examples, the clips may be configured to be detachable from the terminals. For example, after assembling the clips to connect the terminals, the clips can be removed in a manner that causes little or no damage to the terminals. In this way, battery cells can be removed from the battery array, for example, for maintenance purposes. Therefore, using the proposed clips to couple the terminals can provide enhanced maintainability of the battery pack. In some examples, the clips provide stress relief functionality, for example, allowing the terminals to move under vibration without breaking or being pulled out of the cells. For example, clips can be configured to facilitate coupling of multiple terminals without adding additional stress to the coupled terminal assemblies.

[0009] In some examples, the battery pack may include a second pair of battery cells adjacent to a first pair of battery cells and connection elements for electrically coupling the first pair of battery cells to the second pair of battery cells. This structure allows for the formation of a compact and efficient energy distribution system within the battery pack.

[0010] In some examples, the connecting element can be used to insert into a clip between the first and second terminals. The connecting element may include a structure that allows it to be securely held in place by the clip, such as a notch or protrusion that mates with a corresponding structure within the clip. This structure ensures that the connecting element remains in place during battery pack operation and maintains a consistent electrical connection between the terminals.

[0011] In some examples, the battery pack may include a welded joint that secures the engagement between the first terminal, clip, connecting element, and second terminal. This welded joint enhances the mechanical robustness and electrical reliability of the connection by forming a secure bond between these components. The welding process may incorporate techniques such as resistance welding, laser welding, or ultrasonic welding, selected based on factors such as the materials of the components, the required joint strength, and the thermal characteristics of the battery pack. Including a welded joint also contributes to the overall structural integrity of the battery pack, ensuring the connection remains stable under various operating conditions, including vibration, thermal cycling, and mechanical stress.

[0012] In some examples, the battery pack may include an insulating cover that can be attached to a connecting element. In some examples, the integrated insulating cover and connecting element are used to provide stress relief for the cell terminals during thermal expansion and contraction. This feature helps prevent mechanical stress and potential deformation of the cell terminals, thereby ensuring a reliable and effective connection.

[0013] In some examples, the battery pack may include sensing leads that connect to the clip. This connection is used to monitor operating parameters of the battery pack, such as voltage and current. The sensing lead connection may be integrated into the mechanical clip or connecting element assembly.

[0014] In some examples, the sensing lead connection includes a wireless transmitter. This transmitter allows for remote monitoring of the battery pack's operating parameters, providing real-time data on the battery pack's performance and condition.

[0015] In some examples, clips can be used to electrically couple a first terminal to a second terminal.

[0016] In some examples, the battery pack may include a heat dissipation suppression device disposed in the space between the first and second cells. This device is placed in the inter-cell platform region, i.e., the space between individual cells within the battery pack. The heat dissipation suppression device may be designed to absorb, reflect, or dissipate heat, thereby managing the heat generated within the battery pack and preventing overheating and localized expansion of the battery cells.

[0017] In some examples, the battery pack assembly method may include using a tool to install clips. This tool is used to open the clips a certain distance, allowing them to be mounted on the terminals and allowing connecting elements to be inserted into the clips. The tool is then removed, releasing the clips to provide bias forces on the terminals and connecting elements, holding them together. Sensing leads are then attached, and the components are soldered together.

[0018] According to another aspect of this disclosure, a battery pack system is provided that includes a plurality of cell terminals. These cell terminals are secured by mechanical clips designed to secure adjacent cell terminals. The system also includes an integrated insulating cover and a connecting element assembly. This assembly is used to electrically connect adjacent mechanical clips. For example, in a battery pack for an electric vehicle, the mechanical clips can be used to secure the cell terminals of individual battery cells, while the integrated insulating cover and connecting element assembly can provide electrical continuity between the cells.

[0019] In other examples, the mechanical clips are made of a conductive material. This material facilitates the transfer of electrical energy between the battery cell terminals. For example, the mechanical clips could be made of conductive metals such as copper or aluminum.

[0020] In other examples, the battery pack system includes a damping material. This material, located near the mechanical clamps, reduces mechanical stress transmitted to the cell terminals. This helps prevent mechanical wear on the cell terminals, thereby improving the battery pack's durability and lifespan.

[0021] According to one aspect of this disclosure, a method for providing a battery pack system is provided. The method includes securing a plurality of battery cell terminals using mechanical clips for securing adjacent cell terminals; and electrically connecting the secured mechanical clips to an integrated insulating cover and connecting element assembly.

[0022] According to another aspect of this disclosure, a method for managing thermal runaway in a battery pack system is provided. The method includes securing a plurality of battery cell terminals using mechanical clips for securing adjacent cell terminals; electrically connecting the secured mechanical clips to an integrated insulating cover and connection element assembly; and placing a thermal runaway suppression device in an inter-cell platform region between individual battery cells within the battery pack.

[0023] According to another aspect of this disclosure, a battery pack is provided, the battery pack including a pair of battery cells, each of the pair of battery cells including a terminal, the terminal including a body portion extending away from the battery cell and a termination portion adjacent to the body portion extending toward the battery cell.

[0024] In some examples, the termination portions of the terminals in a terminal pair are folded toward each other.

[0025] According to another aspect of this disclosure, a battery pack assembly is provided, the battery pack assembly including a battery pack and a reverse clamp device. The battery pack includes a first battery cell pair, the first battery cell pair including a first cell and a second cell adjacent to each other, the first cell including a first terminal extending away from the first cell and toward the second cell, and the second cell including a second terminal extending away from the second cell and toward the first cell. The first terminal includes a first termination portion folded back toward the first cell that engages with the reverse clamp, and the second terminal includes a second termination portion folded back toward the second cell that engages with the reverse clamp.

[0026] In some examples, the battery pack assembly including the reverse clamp device also includes a connecting element mechanically connected to the reverse clamp. The reverse clamp is disposed in the space between the first terminal and the second terminal. The reverse clamp is used to hold the first termination portion between the first portion of the reverse clamp and the connecting element, and to hold the second termination portion between the second portion of the reverse clamp and the connecting element. This provides an electrical connection between the first cell and the second cell in the assembly structure.

[0027] According to another aspect of this disclosure, a vehicle comprising at least one of the aforementioned battery packs is provided.

[0028] It should be understood that while the examples described herein relate to the coupling (e.g., physical and electrical coupling) of individual terminals of adjacent cells (e.g., the terminals of the first and second cells in a cell pair), this disclosure generally covers the coupling of any suitable number (e.g., 2, 3, 4…n) of cell terminals. For example, while the examples disclosed herein relate to 2P arrays, such as arrays with two cells in parallel, this disclosure extends to 3P arrays, 4P arrays, etc. Alternatively or concurrently, this disclosure covers the coupling of terminal battery cell terminals arranged in series in an array, such as 2S, 3S, etc. To avoid ambiguity, the scope of this disclosure extends to arrays having combinations of cells arranged in series and / or parallel, such as XP-YS arrays.

[0029] These examples, along with other aspects of this disclosure, will be clearly illustrated and explained in conjunction with the examples described below. It should also be understood that specific combinations of the various examples and features described above and below are generally illustrative, and any other possible combinations of these examples and features are also within the scope of this disclosure, although such combinations are clearly mutually exclusive.

[0030] The general description of the illustrative example above and the detailed description below are merely exemplary aspects of the teachings of this disclosure and are not limiting. Attached Figure Description

[0031] The above and other objects and advantages of this disclosure will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: Figure 1A-1C Various mechanical clip designs for securing cell terminals in a battery pack system are shown, according to some examples of this disclosure; Figure 2 An orthogonal view of a battery pack system in which mechanical clips secure cell terminals according to some examples of this disclosure is shown; Figure 3 An orthogonal view is shown of a battery pack system with insulating barriers on the top and bottom of a series of battery cells, according to some examples of this disclosure; Figure 4 A top view is shown of a battery pack assembly process including a first battery cell and a second battery cell, according to some examples of this disclosure; Figure 5 A top view is shown, according to some examples of this disclosure, focusing on a battery pack system assembly that uses mechanical clips to connect cell terminals; Figure 6 An isometric view of a battery pack assembly according to some examples of this disclosure is shown, wherein mechanical clips are used to mechanically attach and secure the cell terminals. Figures 7A-7B Flowcharts of some example battery pack assembly methods according to this disclosure are shown; and Figure 8 Side views of vehicles containing battery packs, according to some examples of this disclosure, are shown. Detailed Implementation

[0032] This disclosure provides a novel method for assembling and designing battery packs, with a particular focus on the connection of cell terminals. In some aspects, this disclosure introduces the use of mechanical clamps or similar devices to secure the cell terminals, providing an alternative to traditional methods such as welding or riveting. This method simplifies the assembly process, potentially reducing the time and effort required, and can enable more compact and efficient battery pack designs.

[0033] In some examples, this disclosure eliminates the traditional busbar, which typically requires inserting terminals into slots followed by soldering. Instead, mechanical clamps hold the cell terminals, potentially simplifying the assembly process and reducing space requirements for cell connection and power distribution.

[0034] In some examples, mechanical clamps can simplify the assembly of cell terminals and high-voltage (HV) terminals, potentially improving production efficiency. Battery pack systems may also include platforms between cells for assembly devices and / or thermal runaway (TP) suppression devices. These devices can help manage heat within the battery pack, thereby improving battery pack performance and lifespan.

[0035] In some examples, this disclosure introduces the use of thermal runoff suppression devices in the inter-cell platform region (i.e., the space between individual cells within a battery pack). These devices can help manage the heat generated within the battery pack, thereby potentially improving the overall performance and lifespan of the battery pack.

[0036] Furthermore, this disclosure provides interlocking between inter-cell thermal barriers and side insulation covers with specific cells or cell groups within a battery pack. This feature can help suppress thermal diffusion within a module, array, or pack.

[0037] In some examples, this disclosure also includes sensing lead connections for monitoring voltage and current within the battery pack, thereby ensuring efficient operation of the battery pack. This connection can be attached to a clip, thus providing a means of monitoring battery pack operation.

[0038] In some examples, battery pack systems can offer several advantages, including improved design and assembly simplicity, reduced number of main array components, and enhanced thermal runaway protection. Battery pack systems may also include sensing lead connections for monitoring voltage and current within the battery pack, as well as methods for suppressing thermal runaway.

[0039] like Figure 1A-1C As shown, various designs of the mechanical clip 112 can be used to secure cell terminals 122 (e.g., cell terminals) in a battery pack system. Figure 1A In the diagram, the mechanical clip 112 is shown engaging with the cell terminal piece 122. This engagement provides a secure, detachable, and efficient connection between the cell terminal piece 122 and the mechanical clip 112.

[0040] In some examples, the mechanical clips used to secure the battery cell terminals can resemble bulldog clips, a design widely recognized for its simplicity and effectiveness. Generally, the mechanical clips may comprise a pair of opposing arms biased towards each other, for example by a spring-loaded hinge and / or an inherent spring force in the shaped portion of at least one arm. These arms apply pressure to the battery cell terminals upon release, thereby ensuring a firm grip and maintaining a secure mechanical and electrical connection. This design facilitates application and removal, which is particularly beneficial during assembly or maintenance. In some examples, the triangular shape of clip 112 may allow for a tight grip on the battery cell terminals 122, potentially reducing the likelihood of disconnection or slippage (however, any other suitable shape may be considered where technically feasible).

[0041] Mechanical clamps provide technicians and assembly workers with a familiar and user-friendly interface. This familiarity can potentially shorten the learning curve associated with the assembly process, thereby improving efficiency and productivity. Furthermore, the use of mechanical clamps helps gain market acceptance and adoption for this innovative battery pack system.

[0042] Furthermore, the mechanical clips can be configured to flexibly accommodate battery cell terminals of different sizes or shapes. This is particularly advantageous for battery pack systems that integrate battery cells from different manufacturers or of different types. The ability to adapt to different battery cell terminals makes battery pack systems more versatile and adaptable, thereby potentially expanding their application range.

[0043] In some examples, mechanical clamps can provide a visual indication of the connection status of the battery cell terminals. For instance, when the clamp arm is released and pressure is applied to the battery cell terminals, this can indicate that a secure connection has been formed. This visual indication can provide technicians or assembly workers with a quick and easy way to verify the connection status, potentially reducing the time and effort required for quality control or troubleshooting.

[0044] like Figure 1B As shown, the circular mechanical clip 114 can also be designed to hold the cell connection piece 122. The circular design of the mechanical clip 114 can provide different shape factors and mechanisms for attaching to the cell connection piece 122, thus demonstrating the versatility of the connection system within the battery pack.

[0045] The circular mechanical clip 114 offers several advantages over conventional designs. In certain situations, the circular shape factor of the mechanical clip 114 can distribute pressure more evenly around the cell terminal piece 122, potentially reducing the likelihood of localized stress. This uniform pressure distribution is particularly beneficial in applications where battery packs undergo frequent vibration or thermal cycling, as it can improve the durability and lifespan of the connections.

[0046] Furthermore, due to its wraparound design, the circular mechanical clip 114 provides a more secure grip on the cell terminal piece 122. This can be particularly advantageous when securing cell terminal pieces with a small surface area or those made of materials that are easier to slide. The circular clip engages the cell terminal piece 122 in a manner that reduces the chance of accidental disconnection or loosening, which is crucial for maintaining the integrity of electrical connections within the battery pack system.

[0047] Furthermore, the circular mechanical clamp 114 can be designed to self-align with the cell terminal piece 122 during application, thereby simplifying the assembly process. This self-alignment feature reduces the time and precision requirements during installation, thus shortening the assembly time. Ease of application also contributes to improving the overall quality and consistency of the produced battery pack systems.

[0048] In some examples, the circular mechanical clip 114 can also be designed to provide a more aesthetically pleasing appearance, which can be an advantage in battery pack systems where visual design is a consideration. The smoothness and symmetry of the clip may appeal to designers and consumers, thereby increasing the marketability of the battery pack system.

[0049] Overall, the circular mechanical clamp 114 can serve as a robust and reliable alternative to traditional designs, offering advantages in uniform pressure distribution, secure clamping, and self-alignment during installation, which can help improve the performance and reliability of battery pack systems.

[0050] like Figure 1C As shown, the reverse mechanical clip 116 can be used in conjunction with the connecting element 132 and the insulating cover 134. The reverse mechanical clip 116 and the connecting element 132 can work together to secure the cell terminal piece 122, while the insulating cover 134 provides electrical insulation. This arrangement can provide different form factors and mechanisms for attachment to the cell terminal piece 122, thereby further demonstrating the versatility of the connection system within the battery pack.

[0051] In some examples, the design of the mechanical clip 112 can be varied to accommodate different types of battery cell terminals or to improve connection efficiency. For example, the mechanical clip 112 can be designed with wider or narrower openings to accommodate battery cell terminals of different sizes. Alternatively, the mechanical clip 112 can be designed with a locking mechanism to ensure a secure connection. These variations in the design of the mechanical clip 112 can allow for more flexible and adaptable battery pack systems.

[0052] In some examples, the insulating cover 134 can provide electrical insulation within the battery pack. The insulating cover 134 can be integrated with the connecting clip 132, potentially simplifying the assembly process and reducing space requirements within the battery pack.

[0053] These different clip designs demonstrate alternative methods for securing and connecting cell terminals 122 within the battery pack, each potentially offering its own advantages in terms of safety, efficiency, and adaptability.

[0054] like Figure 2 As shown, the battery pack system may include battery cell 222A, which is connected to adjacent battery cell 222B via cell terminals 122 (e.g., cell terminals). Cell terminals 122 can be secured by mechanical clips 112, ensuring mechanical and electrical connections between the cell terminals of the battery cells. An insulating cover 134 may be positioned near the cell terminals 122 to provide electrical insulation and physical isolation from other components.

[0055] In some examples, the battery pack system may include more than two battery cells. For example, a third battery cell 222C and a fourth battery cell 222D may be combined into the system. Similar to the first and second battery cells, the third and fourth battery cells can also be connected via a cell connector 122. This cell connector 122 is secured by another mechanical clip 112, thereby ensuring a stable and effective connection between the third and fourth battery cells.

[0056] In addition to the mechanical clamp 112, a connecting element 132 can be used to maintain the electrical continuity of the entire system. The connecting element 132 is used to connect the upper battery cell group (e.g., the first and second battery cells) and the lower battery cell group (e.g., the third and fourth battery cells). This arrangement ensures that electrical energy can flow seamlessly from one group of battery cells to another, thereby improving the overall efficiency of the battery pack system.

[0057] The use of multiple mechanical clips 112 and connecting elements 132 allows for the assembly of a larger number of battery cells into the battery pack system. This scalability is a significant advantage, as it enables the design and assembly of battery pack systems with different capacities to meet varying power requirements. Furthermore, the use of mechanical clips 112 and connecting elements 132 to secure the cell terminals and maintain electrical continuity simplifies the assembly process.

[0058] In some examples, the battery pack system may include multiple cell terminals 122. The number of cell terminals 122 may vary depending on the specific requirements of the battery pack system. For example, a larger battery pack system may require more cell terminals 122 to ensure efficient energy distribution.

[0059] In some examples, the battery pack system can use mechanical clips 112 to secure adjacent cell terminals 122. The mechanical clips 112 provide a robust and efficient connection between the cell terminals 122, eliminating the need for traditional welding or riveting methods. This innovative approach simplifies the assembly process and reduces the area required for cell connection and energy distribution.

[0060] In some examples, the battery pack system may include integrated insulating covers and connecting element assemblies 134, 132 for electrically connecting adjacent mechanical clips 112. The integrated insulating cover 134 provides electrical insulation, while the connecting element 132 provides a robust and efficient connection between the mechanical clips 112. This integrated design simplifies the assembly process and reduces space requirements, resulting in a more compact and efficient battery pack.

[0061] In some examples, the process of electrically connecting the fixed mechanical clip 112 to the integrated insulating cover and connecting element assembly 132 may include positioning the connecting element 132 near the mechanical clip 112. The connecting element 132 can then be secured to the mechanical clip 112, thereby forming a robust and efficient electrical connection. This process can simplify the assembly process.

[0062] like Figure 3 As shown, the battery pack system may include a battery pack 220 and isolation barriers 342 located on top and bottom of a series of battery cells. The series of battery cells may include a top battery cell 222A, a second battery cell 222B, a third battery cell 222C, a fourth battery cell 222D, a fifth battery cell 222E, a sixth battery cell 222F, a seventh battery cell 222G, and a bottom battery cell 222H. The battery cells may be displayed in pairs: A and B, C and D, E and F, G and H. Each pair of battery cells can be connected to an adjacent pair of cells via a connecting element 132.

[0063] In some examples, the connecting element 132 can be electrically and mechanically connected via an integrated insulating cover 134 that spans the battery cell to maintain electrical continuity and provide insulation. The arrangement of the connecting element 132 and the integrated insulating cover 134 can contribute to a compact and efficient battery pack design with enhanced thermal management and electrical connectivity.

[0064] In some examples, the integrated insulating cover 134 may include a heat-resistant material. The heat-resistant material can be selected based on its ability to withstand high temperatures without reducing or losing its insulating properties. This can enhance the thermal management capabilities of the battery pack system, potentially improving its performance and lifespan.

[0065] In some examples, integrated insulating caps and connecting element assemblies 134, 132 can be used to provide stress relief for the cell terminals 122 during thermal expansion and contraction. This can improve the reliability and lifespan of the battery pack system.

[0066] In some examples, heat-resistant materials can be incorporated into the integrated insulating cover 134. The heat-resistant material can be selected based on its ability to withstand high temperatures without reducing or losing its insulating properties. This can enhance the thermal management capabilities of the battery pack system, potentially improving its performance and lifespan.

[0067] like Figure 4As shown, the battery pack assembly process may include a first battery cell 222A and a second battery cell 222B. Mounting blocks and assembly fixtures 402 can be positioned to facilitate the assembly of the battery cells. Cell terminals 122 can extend from the first battery cell 222A. Mechanical clips 112 can be used to mechanically secure the cell terminals 122. Connecting elements 132 can be shown adjacent to the cell terminals 122, indicating a method of electrically connecting adjacent cell terminals. This arrangement suggests that the mechanical clips 112 and connecting elements 132 can work together to provide mechanical retention and electrical continuity between the battery cells.

[0068] The assembly process of a battery pack system may involve the use of mounting blocks and assembly fixtures 402. Mounting blocks provide a stable platform for the assembly process, thus providing secure and precise positioning of battery cells and other components. On the other hand, assembly fixtures 402 are used to handle and manipulate components during the assembly process. These fixtures are designed to firmly hold components, such as cell terminals and mechanical clamps, during positioning and securing. The use of mounting blocks and assembly fixtures 402 not only simplifies the assembly process but also improves its accuracy and reliability. This can potentially increase production efficiency. Furthermore, assembly fixtures 402 can be designed to accommodate different types of components, making the assembly process more flexible and adaptable.

[0069] In some examples, the process of securing multiple battery cell terminals may involve using mechanical clips 112. The mechanical clips 112 can be positioned on and secured in place to the cell terminals 122, thereby providing a robust and efficient connection between the cell terminals 122 and the mechanical clips 112. This process can eliminate the need for traditional welding or riveting methods, potentially simplifying the assembly process and reducing the area required for cell connection and energy distribution.

[0070] In some examples, the process of electrically connecting the fixed mechanical clip 112 to the integrated insulating cover and connecting element assembly 132 may involve positioning the connecting element 132 near the mechanical clip 112. The connecting element 132 can then be secured to the mechanical clip 112, thereby forming a robust and efficient electrical connection. This process can simplify the assembly process, potentially improving production efficiency.

[0071] In some examples, the process of securing multiple battery cell terminals may involve using mechanical clips 112. Mechanical clips 112 can be positioned on and secured in place to the cell terminals 122, thereby providing a robust and efficient connection between the cell terminals 122 and the mechanical clips 112. This process can eliminate the need for traditional welding or riveting methods, potentially simplifying the assembly process and reducing the area required for cell connection and energy distribution.

[0072] like Figure 5As shown, the top view of the battery pack system components focuses on the connection of cell terminals 122 using mechanical clips 112. The mechanical clips 112 are positioned on the cell terminals 122 and secured in place by soldering areas 502, ensuring a stable and conductive connection. Below the mechanical clips 112 and cell terminals 122, connecting elements 132 are shown, which may be used for electrical connection and mechanical fixation of adjacent cell terminals within the battery pack system. This arrangement indicates that the mechanical clips 112 and connecting elements 132 can work together to provide electrical continuity and mechanical stability to the cell terminals 122 within the battery pack.

[0073] The welding area 502 refers to the specific area where the mechanical clip 112 is securely attached to the cell terminal piece 122. This attachment is achieved through a welding process that involves applying heat or pressure, or both, to form a permanent bond between the mechanical clip 112 and the cell terminal piece 122. The welding area 502 can be a useful optional step in battery pack system assembly because it ensures a stable and conductive connection between the cell terminal piece 122 and the mechanical clip 112. This robust connection is crucial for the efficient transfer of electrical energy within the battery pack system. The welding process used to form the welding area 502 is designed to be robust and reliable, ensuring a durable connection capable of withstanding the operational demands of the battery pack system. Furthermore, the welding area 502 is strategically positioned to optimize the mechanical stability and electrical continuity of the connection, thereby contributing to the overall performance and efficiency of the battery pack system.

[0074] In some examples, the mechanical clip 112 may be made of a conductive material to facilitate the transfer of electrical energy. The conductive material can be selected based on its conductivity, which can improve the energy transfer efficiency between the cell terminals 122. This can improve the performance of the battery pack system.

[0075] In some examples, the mechanical clip 112 may be designed with a locking mechanism to ensure a secure connection. The locking mechanism can be used to engage with the cell terminal piece 122, thereby preventing it from shifting or disconnecting from the mechanical clip 112. This can improve the reliability and stability of the connection between the cell terminal piece 122 and the mechanical clip 112.

[0076] In some examples, the process of providing a locking mechanism for the mechanical clip 112 may involve integrating a latch, buckle, or similar device into the design of the mechanical clip 112. The locking mechanism may be designed to engage with the cell terminal 122 when the mechanical clip 112 is positioned on the cell terminal 122. This ensures a secure connection to the cell terminal 122, potentially improving the reliability and lifespan of the battery pack system.

[0077] In some examples, such as Figure 6As shown, the battery pack assembly may include mechanical clips 112 for mechanically attaching and securing the cell terminals 122 of battery cell A 222A to the corresponding cell terminals of battery cell B 222B. The mechanical clips 112 provide a robust and efficient connection between the cell terminals 122, eliminating the need for traditional welding or riveting methods. This innovative method simplifies the assembly process and reduces the area required for battery connection and energy distribution.

[0078] In some examples, electrical connection element 132 can provide electrical continuity between adjacent cell terminals. Connection element 132 can be positioned near and secured in place by mechanical clamp 112, thereby forming a robust and efficient electrical connection. This process can simplify assembly, potentially improving production efficiency.

[0079] In some examples, a thermal barrier 342 may be located between battery cells to provide insulation and prevent heat diffusion between cells. The thermal barrier 342 may be made of a heat-resistant material that can withstand high temperatures without reducing or losing its insulating properties. This can enhance the thermal management capabilities of the battery pack system, potentially improving its performance and lifespan.

[0080] In some examples, the battery pack system may include a heat dissipation suppression device placed in the inter-cell platform area between the individual cells within the battery pack. Depending on the specific requirements of the battery pack system, the heat dissipation suppression device may be designed to absorb, reflect, or dissipate heat. By managing the heat generated within the battery pack, the heat dissipation suppression device can prevent overheating, thereby improving the overall performance and lifespan of the battery pack.

[0081] In some examples, vibration damping material may be placed near the mechanical clip 112 to reduce mechanical stress transmitted to the cell terminal 122. The vibration damping material can be selected based on its ability to absorb or dissipate vibrations, which can improve the reliability and lifespan of the battery pack system.

[0082] In some examples, the process of placing a thermal diffusion suppression device in the inter-cell platform region between the individual cells within a battery pack may involve positioning the device in the space between the battery cells. The device can then be secured in place, thereby providing a barrier against thermal diffusion within the battery pack. This process can enhance the thermal management capabilities of the battery pack system, potentially improving its performance and lifespan.

[0083] refer to Figures 7A-7BThis document describes a flowchart of a battery pack assembly method according to some examples of this disclosure. The method comprises a series of steps to provide a robust and efficient connection for the cell terminals in the battery pack. The steps shown in processes 700 and 750 should not be considered mutually exclusive or performed in a specific order. References to specific clips or cells should be considered as examples, and the processes described herein can be performed on any other cell, cell terminal, or clip.

[0084] Special Reference Figure 7A In process 700, step 702 describes providing a first battery cell pair including a first cell and a second cell, the first cell including a first terminal extending away from the first cell, and the second cell including a second terminal extending away from the second cell. If the battery described herein has already been provided to a system for assembly, step 702 may be omitted, as described in more detail below.

[0085] In step 704, process 700 includes shaping a first terminal (which may be a cell connector 122) to extend toward a second cell (which may be a second battery cell 222B). This shaping of the first terminal may include bending or forming the cell connector 122 away from the first cell (which may be a first battery cell 222A) and toward the second battery cell 222B.

[0086] In step 706, process 700 includes folding the first terminal to define a first termination portion. This first termination portion can be folded toward a second terminal, which can be another cell terminal piece 122 extending from the second battery cell 222B and back toward the first battery cell 222A. This folding of the first terminal provides a robust and efficient connection between the first and second terminals, thereby ensuring electrical continuity and mechanical stability within the battery pack.

[0087] In step 708, process 700 includes shaping the second terminal to extend toward the first cell. Similar to shaping the first terminal, this may include bending or forming the cell terminal piece 122 away from the second battery cell 222B and toward the first battery cell 222A.

[0088] In step 710, process 700 includes folding the second terminal to define a second termination portion. This second termination portion can fold toward the first terminal and extend back toward the second battery cell 222B. This folding of the second terminal provides a robust and efficient connection between the first and second terminals, thereby ensuring electrical continuity and mechanical stability within the battery pack.

[0089] Special Reference Figure 7BIn process 750, step 752 includes securing multiple battery cell terminals with mechanical clips (such as triangular clips 112). Therefore, triangular clips 112 are used to secure adjacent cell terminals in the battery pack 220.

[0090] In step 754, process 750 includes electrically connecting the fixed mechanical clamp to the integrated insulating cover and connecting elements.

[0091] Process 700 or 750 may further include assembling a clip into the space between the first and second terminals on the battery pack. The clip can be any clip described herein, such as a triangular clip 112, a circular clip 114, or a reverse clip 116. The clip can be used to bias the first and second terminals toward each other, potentially providing a robust and efficient connection between the first and second terminals.

[0092] Process 700 or 750 may further include inserting a connecting element into a clip between the first terminal and the second terminal. The connecting element may be, for example, Figure 2 The connecting element 132 shown is used to electrically couple a first battery cell pair to a second battery cell pair. Inserting the connecting element 132 into the clip can facilitate electrical connection between the first and second battery cell pairs, thereby potentially improving the overall performance and efficiency of the battery pack.

[0093] Process 700 or 750 may also include connecting sensing leads to a clip (such as triangular clip 112). The sensing leads provide a means of monitoring voltage and current within the battery pack, thereby ensuring its efficient operation. This connection can be attached to triangular clip 112, thus providing a means of monitoring battery pack operation. Depending on the specific requirements of the battery pack, this step can be performed at any suitable point during the assembly process.

[0094] Process 700 or 750 may also include attaching an insulating cap (such as insulating cap 134) to the connecting element (which may be connecting element 132) before inserting the connecting element into the clip. Insulating cap 134 can provide electrical insulation, potentially preventing short circuits or other electrical problems within the battery pack. Insulating cap 134 can be integrated with connecting element 132, potentially simplifying the assembly process and reducing space requirements within the battery pack, thereby enabling a more compact and efficient battery pack design.

[0095] In some examples, the battery pack assembly process can be modified to improve efficiency or accommodate different types of cell terminals. For instance, this process can be automated to reduce the time and effort required for assembly. Alternatively, the process can be designed to be easily adaptable, allowing for the assembly of battery packs with different structures. This flexibility in the assembly process allows for the production of a wide variety of battery packs, potentially meeting diverse applications and requirements.

[0096] In some examples, the method described herein may involve the use of different types of clips, such as triangular clips 112, circular clips 114, or reverse clips 116, depending on the specific requirements of the battery pack. These different types of clips can offer various advantages in terms of stability, efficiency, and adaptability, thereby potentially improving the overall performance and efficiency of the battery pack.

[0097] In some examples, depending on the specific requirements of the battery pack, the method described herein may include the use of different types of connection elements, such as connection elements 132 of different designs or materials. These different types of connection elements can provide various advantages in terms of electrical continuity, mechanical retention, and thermal management, thereby potentially improving the overall performance and efficiency of the battery pack.

[0098] Overall, such as Figures 7A-7B The battery pack assembly method shown provides a robust and efficient way to connect the cell terminals in the battery pack. The use of the triangular clip 112, connecting element 132, insulating cover 134, and sensing lead, along with potential variations in the assembly process, can provide a robust and efficient connection between the cell terminals and the battery cells, thereby potentially improving the overall performance and efficiency of the battery pack.

[0099] like Figure 8 As shown, battery pack 220 is integrated into vehicle 800 as a practical demonstration of battery pack application. Vehicle 800 can be any type of land vehicle, including but not limited to cars, trucks, buses, and even specialized vehicles such as construction or agricultural machinery. In some cases, vehicle 800 can be an electric vehicle, a hybrid vehicle, etc., both of which rely on battery packs (such as battery pack 220) to provide propulsion and power auxiliary equipment.

[0100] In some examples, battery pack 220 provides power for the operation of vehicle 800. In the case of electric or hybrid vehicles, this power can be used to drive the vehicle's electric motor. In other cases, the power from battery pack 220 can be used to power auxiliary equipment of the vehicle, such as the vehicle's lights, radio, air conditioning system, and other electronic devices.

[0101] In some cases, battery pack 220 can be used to provide a specific supply voltage according to the needs of vehicle 800. For example, battery pack 220 can provide 12V power to auxiliary equipment in the vehicle, or provide 48V power to power the electric motor of a hybrid or electric vehicle.

[0102] Several terms are provided below, which are considered to be further non-limiting examples of this disclosure. Each term is accompanied by its own exemplary advantages.

[0103] Article 1: This clause describes a battery pack system including mechanical clips for securing adjacent cell terminals. The system also includes an integrated insulating cover and connecting element assembly for electrically connecting the adjacent mechanical clips.

[0104] A key advantage of point 1 is that it simplifies the battery pack system assembly process by eliminating traditional methods such as welding or riveting. This can potentially improve production efficiency.

[0105] Article 2: This article describes a battery pack system including a thermal diffusion suppression device placed in the inter-cell platform region between the individual cells within the battery pack.

[0106] A key advantage of point 2 is enhanced thermal management capabilities of the battery pack system. By managing the heat generated within the battery pack, the thermal runaway suppression device prevents overheating, thereby improving the overall performance and lifespan of the battery pack.

[0107] Article 3: This article describes a battery pack system in which mechanical clips are made of conductive material to facilitate the transfer of electrical energy.

[0108] The typical advantage of Article 3 is that it improves the energy transfer efficiency between the cell terminals, thereby improving the performance of the battery pack system.

[0109] Article 4: This clause describes a battery pack system in which the mechanical clips are designed with a locking mechanism to ensure a secure connection.

[0110] A typical advantage of Clause 4 is that it improves the reliability and stability of the connection between the battery cell terminals.

[0111] Article 5: This clause describes a battery pack system that includes sensing lead connections for monitoring battery pack operating parameters.

[0112] A key advantage of Article 5 is that it allows for real-time monitoring of the battery pack's operating parameters, thereby providing valuable data on the battery pack's performance and condition.

[0113] Article 6: This article describes a battery pack system in which the integrated insulating cover comprises a heat-resistant material.

[0114] A typical advantage of Article 6 is that it enhances the thermal management capabilities of the battery pack system, thereby helping to improve the overall performance and lifespan of the battery pack.

[0115] Article 7: This clause describes a battery pack system in which an integrated insulating cover and connecting element assembly provides stress relief for the cell terminals during thermal expansion and contraction.

[0116] A typical advantage of Article 7 is that it helps prevent mechanical stress and potential deformation of the battery cell terminals, thereby ensuring a reliable and effective connection.

[0117] Article 8: This clause describes a battery pack system that includes damping material located near mechanical clips to reduce mechanical stress transmitted to the cell terminals.

[0118] A typical advantage of Article 8 is that it helps prevent mechanical wear on the cell terminals, thereby improving the durability and lifespan of the battery pack.

[0119] Article 9: This clause describes a method of providing a battery pack system, which includes using mechanical clips to secure multiple battery cell terminals and electrically connecting the secured mechanical clips to an integrated insulating cover and connecting element assembly.

[0120] A key advantage of Article 9 is that it simplifies the assembly process of battery pack systems, thereby potentially improving production efficiency.

[0121] Article 10: This article describes a method for managing thermal runaway in a battery pack system, the method comprising securing multiple battery cell terminals with mechanical clips, electrically connecting the secured mechanical clips to an integrated insulating cover and connecting element assembly, and placing a thermal runaway suppression device in the inter-cell platform area between the individual cells within the battery pack.

[0122] A typical advantage of Article 10 is that it enhances the thermal management capabilities of the battery pack system, thereby potentially improving its performance and lifespan.

[0123] Article 11: This article describes a battery pack system that uses clips to secure the cell terminals instead of a traditional busbar.

[0124] A key advantage of Article 11 is that it simplifies the assembly process and reduces the area for cell connection and energy distribution, thereby enabling a more compact and efficient battery pack design.

[0125] Article 12: This article describes a battery pack system that includes an integrated insulating cover and connecting clips, replacing the conventional busbar frame and insulating cover.

[0126] A key advantage of Article 12 is that it simplifies the design and reduces space requirements, resulting in a more compact and efficient battery pack.

[0127] Article 13: This article describes a battery pack system that incorporates a combination of thermal barriers and insulating covers to separate logic cell groups, thereby limiting heat diffusion.

[0128] A key advantage of Article 13 is that it allows the battery pack to operate more efficiently.

[0129] Article 14: This article describes a battery pack system including sensing lead connections for monitoring voltage and current within the battery pack.

[0130] A key advantage of Article 14 is that it allows for real-time monitoring of the battery pack's operating parameters, thus providing valuable data on the battery pack's performance and condition.

[0131] Article 15: This article describes a battery pack system that includes a method for suppressing thermal diffusion.

[0132] A key advantage of Article 15 is that it enhances the thermal management capabilities of the battery pack system, thereby potentially improving its performance and lifespan.

[0133] Article 16: This article describes a battery pack system that eliminates the bus or battery management assembly (BMA) traditionally used in battery packs.

[0134] A typical advantage of Article 16 is that it simplifies the design and assembly process, thereby reducing the number of components and potentially increasing production efficiency.

[0135] Article 17: This article describes a battery pack system that eliminates the slots for inserting cell terminals. Instead, mechanical clips or similar devices are used to secure the cell terminals.

[0136] A key advantage of Article 17 is that it simplifies the assembly process, thereby eliminating the time-consuming and complex process of inserting the terminals into the slots.

[0137] Article 18: This article describes a battery pack system that abandons traditional welding methods. Instead, the cell terminals are secured using mechanical clips, providing a robust and efficient connection.

[0138] A typical advantage of Article 18 is that it simplifies the assembly process, thereby reducing the time and effort required and potentially increasing productivity.

[0139] Article 19: This article describes a battery pack system designed to reduce and enhance the bending or folding of cell terminals.

[0140] A key advantage of Article 19 is that it enables more efficient and reliable connections between cell terminals, thereby improving the overall performance of the battery pack.

[0141] Article 20: This article describes a battery pack system using floating clips.

[0142] A typical advantage of Article 20 is that the floating clips allow for a secure and efficient connection between the cell terminals, while also providing flexibility to accommodate changes in the size or shape of the cell terminals.

[0143] Article 21: This article describes a battery pack system that reduces the number of array components.

[0144] A key advantage of Article 21 is that this reduction simplifies the design and assembly process, resulting in more compact and efficient battery packs.

[0145] Article 22: This article describes a battery pack system that improves the quality of the battery pack by using mechanical clips to secure the cell terminals, while eliminating traditional components such as busbars or BMAs.

[0146] A key advantage of Article 22 is that it enables more reliable and efficient battery packs.

[0147] Article 23: This article describes a battery pack system comprising an integrated insulating cover and connecting clips. The insulating cover provides electrical insulation, while the connecting clips provide a secure and efficient connection between the cell terminals.

[0148] A key advantage of Article 23 is that this integrated design simplifies the assembly process and reduces space requirements, resulting in more compact and efficient battery packs.

[0149] Article 24: This article describes a battery pack system including a sensing lead connection attached to a clip. This connection provides a means of monitoring voltage and current within the battery pack.

[0150] A key advantage of Article 24 is that it allows for real-time monitoring of the battery pack's operating parameters, thereby providing valuable data on the battery pack's performance and condition.

[0151] Article 25: This article describes a battery pack system that includes an interlocking thermal barrier and insulating cover. This interlocking helps manage heat generated within the battery pack, thereby preventing overheating and improving the overall performance and lifespan of the battery pack.

[0152] A key advantage of Article 25 is that it enhances the thermal management capabilities of the battery pack system, thereby potentially improving its performance and lifespan.

[0153] Article 26: This article describes a battery pack system that includes a platform area between cells, i.e., the space between the individual cells within the battery pack. This space is used to house thermal diffusion (TP) suppression devices, which help manage the heat generated within the battery pack.

[0154] A key advantage of Article 26 is that by utilizing this space and reducing the possibility of heat diffusion, the battery pack can operate more efficiently.

[0155] Article 27: This article describes a battery pack system that has several advantages, including improved ease of design and assembly, reduced number of main array components, and enhanced thermal runaway protection.

[0156] A key advantage of Article 27 is that it provides a comprehensive solution for battery pack design and assembly, thereby potentially improving production efficiency.

[0157] Article 28: This article describes a battery pack system including sensing lead connections for monitoring voltage and current within the battery pack and a method for suppressing thermal diffusion.

[0158] A key advantage of Article 28 is that it improves the efficiency of the battery pack system by providing real-time monitoring of operating parameters and managing the heat generated within the battery pack.

[0159] Article 29: This article describes a battery pack system that includes mechanical clamps or similar devices, replacing traditional methods such as welding or riveting. This method simplifies the assembly process, reduces the area for cell connection and energy distribution, and enables a more compact and efficient battery pack design.

[0160] A key advantage of Article 29 is that it simplifies the assembly process of battery pack systems by eliminating traditional methods such as welding or riveting. This can potentially improve production efficiency.

[0161] Article 30: This article describes a battery pack system that includes interlocking between cell thermal barriers and side insulation covers with specific cells or cell groups within the battery pack, thereby helping to suppress heat diffusion and reduce the likelihood of overheating.

[0162] A typical advantage of Article 30 is that it enhances the thermal management capabilities of the battery pack system, thereby potentially improving its performance and lifespan.

[0163] Article 31: This article describes a battery pack comprising a first battery cell pair having a first cell and a second cell. The first cell has a first terminal extending toward the second cell, and the second cell has a second terminal extending toward the first cell. The first terminal has a first termination portion folded toward the second terminal and extending back toward the first cell, and the second terminal has a second termination portion folded toward the first terminal and extending back toward the second cell.

[0164] A key advantage of Article 31 is that it provides a compact and efficient design for battery packs, thereby potentially improving the overall performance and lifespan of the battery packs.

[0165] Article 32: This article describes a battery pack including a clip disposed in a space between a first terminal and a second terminal for biasing the first terminal and the second terminal toward each other.

[0166] A key advantage of Article 32 is that it simplifies the assembly process and provides a robust and efficient connection between the cell terminals, thereby potentially improving production efficiency.

[0167] Article 33: This article describes a battery pack including a second pair of battery cells adjacent to a first pair of battery cells and a connection element for electrically coupling the first pair of battery cells to the second pair of battery cells.

[0168] A key advantage of Article 33 is that it allows for a tight and efficient energy distribution system within the battery pack, potentially improving the overall performance and efficiency of the battery pack.

[0169] Article 34: This article describes a battery pack in which a connecting element is inserted into a clip between a first terminal and a second terminal.

[0170] A key advantage of Article 34 is that it further simplifies the assembly process and ensures a secure connection between the cell terminals, thereby potentially improving production efficiency.

[0171] Article 35: This article describes a battery pack including a welded joint for securing a joint between a first terminal, a clip, a connecting element, and a second terminal.

[0172] A key advantage of Clause 35 is that it provides a robust and reliable connection between the cell terminals, thereby potentially improving the overall performance and efficiency of the battery pack.

[0173] Article 36: This article describes a battery pack that includes an insulating cover that can be attached to a connecting element.

[0174] A key advantage of Article 36 is that it provides electrical insulation and physical isolation between battery cells.

[0175] Article 37: This article describes a battery pack that includes sensing leads that are connected to clips.

[0176] A key advantage of Article 37 is that it provides a means of monitoring the voltage and current within the battery pack, thereby ensuring its efficient operation.

[0177] Article 38: This article describes a battery pack in which clips are used to electrically couple a first terminal to a second terminal.

[0178] A key advantage of Article 38 is that it simplifies the assembly process and provides a robust and efficient connection between the cell terminals, thereby potentially improving production efficiency.

[0179] Article 39: This article describes a battery pack including a thermal diffusion suppression device disposed in the space between a first cell and a second cell.

[0180] A typical advantage of Article 39 is that it helps manage the heat generated within the battery pack, thereby preventing overheating and improving the overall performance and lifespan of the battery pack.

[0181] Article 40: This clause describes a vehicle that includes a battery pack pursuant to any of the foregoing clauses.

[0182] A key advantage of Article 40 is that it demonstrates the practical application of battery packs, thereby potentially improving vehicle performance and efficiency.

[0183] Article 41: This article describes a method for assembling a battery pack, wherein the battery pack includes a first battery cell pair, the first battery cell pair including a first cell and a second cell adjacent to each other in an assembly structure, the method including shaping a first terminal to extend toward the second cell, and shaping a second terminal to extend toward the first cell.

[0184] A key advantage of Article 41 is that it provides a method for efficiently and securely assembling battery packs, thereby potentially improving the overall performance and efficiency of the battery packs.

[0185] Article 42: This article describes a method of assembling a battery pack, wherein the method includes assembling clips into the space between a first terminal and a second terminal on the battery pack such that the first terminal and the second terminal are biased toward each other.

[0186] A typical advantage of Clause 42 is that it simplifies the assembly process and provides a robust and efficient connection between the cell terminals, thereby potentially improving production efficiency.

[0187] Clause 43: This clause describes a method of assembling a battery pack, wherein the method includes inserting a connecting element into a clip between a first terminal and a second terminal, wherein the connecting element is used to electrically couple a first battery cell pair to a second battery cell pair.

[0188] A typical advantage of Article 43 is that it facilitates electrical connection between the first battery cell pair and the second battery cell pair, thereby potentially improving the overall performance and efficiency of the battery pack.

[0189] Article 44: This article describes a method for assembling a battery pack, wherein the method includes connecting sensing leads to clips.

[0190] A key advantage of Article 44 is that it provides a method for monitoring the voltage and current within a battery pack, thereby ensuring its efficient operation.

[0191] Article 45: This article describes a method for assembling a battery pack, wherein the method includes welding a connector to secure a joint between a first terminal, a clip, a connecting element, and a second terminal.

[0192] A key advantage of Clause 45 is that it provides a robust and reliable connection between the cell terminals, thereby potentially improving the overall performance and efficiency of the battery pack.

[0193] Article 46: This article describes a method for assembling a battery pack, wherein the method includes securing sensing leads to the battery pack using solder joints.

[0194] A key advantage of Article 46 is that it ensures a reliable connection for monitoring the operation of the battery pack, thereby ensuring its efficient and reliable operation.

[0195] Article 47: This article describes a method for assembling a battery pack, wherein the method includes installing a thermal diffusion suppression device in the space between a first cell and a second cell.

[0196] A typical advantage of Article 47 is that it helps manage the heat generated within the battery pack, thereby preventing overheating and improving the overall performance and lifespan of the battery pack.

[0197] Article 48: This article describes a method of assembling a battery pack, wherein the method includes attaching an insulating cap to the connecting element before inserting the connecting element into the clip.

[0198] A key advantage of Article 48 is that it provides electrical and physical insulation between cells, thereby improving the efficiency of the battery pack.

Claims

1. A battery pack comprising: a first pair of battery cells, the first pair of battery cells comprising a first cell and a second cell adjacent to each other, the first cell comprising a first terminal extending away from the first cell and towards the second cell, the second cell comprising a second terminal extending away from the second cell and towards the first cell, wherein the first terminal comprises a first terminal termination portion folded towards the second terminal and extending back towards the first cell, and wherein the second terminal comprises a second terminal termination portion folded towards the first terminal and extending back towards the second cell.

2. The battery pack of claim 1, comprising a clip disposed in a space between the first terminal and the second terminal for biasing the first and second terminals towards each other.

3. The battery pack of claim 1 or 2, comprising: a second pair of battery cells adjacent to the first pair of battery cells; and a connecting element for electrically coupling the first pair of battery cells to the second pair of battery cells. the connecting element for insertion into the clip between the first terminal and the second terminal.

4. The battery pack of claim 3, wherein, 5. The battery pack of claim 4, comprising a weld joint securing a junction between the first terminal, the clip, the connecting element and the second terminal.

6. The battery pack of any one of claims 1 to 5, comprising an insulating cover attachable with the connecting element.

7. The battery pack of any one of claims 2 to 6, comprising a sense lead connected with the clip. the clip for electrically coupling the first terminal with the second terminal.

8. The battery pack according to any one of claims 2 to 7, wherein, 9. The battery pack of any one of the preceding claims, comprising a thermal dissipation inhibiting device disposed in a space between the first cell and the second cell.

10. A vehicle comprising the battery pack of any one of claims 1 to 9.

11. A battery pack assembly method, the battery pack comprising a first pair of battery cells, the first pair of battery cells comprising a first cell and a second cell adjacent to each other in an assembled configuration, the first cell comprising a first terminal extending away from the first cell, the second cell comprising a second terminal extending away from the second cell, the method comprising: shaping the first terminal to extend towards the second cell in the assembled configuration and to define a first terminal termination portion folded towards the second terminal and extending back towards the first cell; and shaping the second terminal to extend towards the first cell in the assembled configuration and to define a second terminal termination portion folded towards the first terminal and extending back towards the second cell.

12. The method of claim 11, comprising: assembling a clip into a space between the first terminal and the second terminal on the battery pack to bias the first and second terminals towards each other.

13. The method of claim 11 or 12, comprising: ​ ​ inserting a connection element into the clip between the first terminal and the second terminal, wherein the connection element is to electrically couple the first battery cell pair to a second battery cell pair.

14. The method of any of claims 12-13, the method comprising: connecting a sense lead to the clip.

15. The method of claim 14, the method comprising: welding a joint to secure a junction between the first terminal, the clip, the connection element, and the second terminal.

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