Battery module assembly

Abstract

The battery module may include features for supporting and protecting components thereof from external stresses and certain electrical conditions. In particular, the battery module may be provided with means to direct forces away from the electrical connection area, such as at the terminals of the battery cells. Such forces may be directed towards other structures that do not define electrical connection regions. The battery module may also be provided with features that enhance protection against a particular electrical condition, such as a series bus that electrically connects a plurality of groups of battery cells. An assembly for such a battery module may provide guidance to align and secure the assembled components, as well as to hold them with potting material during assembly.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefits of U.S. Provisional Application No. 63 / 684,233 entitled “BATTERY MODULE ASSEMBLY”, filed August 16, 2024, and U.S. Provisional Application No. 63 / 807,457 entitled “BATTERY MODULE ASSEMBLY”, filed May 16, 2025, the entire contents of each 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] Battery modules may include features for supporting and protecting their components from external stresses and certain electrical conditions. Specifically, battery modules may be provided with components that direct forces away from areas of electrical connection, such as at the terminals of the battery cells. Such forces may be directed to other structures that do not define areas of electrical connection. Battery modules may also include features that enhance protection against specific electrical conditions, such as series buses that electrically connect multiple sets of battery cells. Components used in such battery modules may provide guidance for aligning and securing assembled components, as well as for holding them in place with potting material during assembly.

[0006] According to one or more embodiments of this disclosure, a battery sub-assembly is described. The battery sub-assembly may include a cover, a frame for abutting a peripheral edge of a battery cell, and a current collector assembly located between the frame and the cover, wherein the cover is configured to direct forces applied thereto away from an encapsulating agent between the cover and a central portion of the battery cell and to the peripheral edge of the battery cell.

[0007] The current collector assembly may include a first interconnect portion and a second interconnect portion. The encapsulant may be configured to include a first region and a second region, wherein in the first region, the first interconnect portion is connected to a first terminal of the battery cell, and in the second region, the second interconnect portion is connected to a second terminal of the battery cell.

[0008] The frame may define an opening for exposing (i) a central portion of the battery cell for connection to a first interconnect portion, and (ii) a portion of a peripheral edge for connection to a second interconnect portion. The cap may form an inner surface defining a concave shape facing the encapsulant and the central portion of the battery cell. The encapsulant may have an elastic modulus less than that of the cap and the frame. The battery subassembly may include a foam layer on the side of the cap opposite the frame. The battery subassembly may include a base, a potting dam extending along an end of the frame to the base, and a potting material between the cap and the base.

[0009] The battery cell may be one of the cells in a first group of battery cells. The battery sub-assembly may include a series bus for electrically connecting the first group of battery cells to a second group of battery cells, wherein the series bus occupies a plane occupied by the current collector assembly. The frame may be a first frame, and the battery sub-assembly may also include a second frame, wherein each of the first and second frames is used to cover a corresponding portion of the first and second group of battery cells.

[0010] The first frame may include a first connector for forming a four-way reference with the first group of battery cells and a second connector for forming a two-way reference with the first group of battery cells. The first frame may include a third connector for forming a four-way reference with the current collector assembly. The first frame may include a fourth connector for forming a four-way reference with the cover.

[0011] According to one or more embodiments of this disclosure, a series busbar is described. The series busbar may include a first terminal, a second terminal, and a plurality of fuse elements connected in parallel to the first terminal and the second terminal, wherein each of the plurality of fuse elements has a different cross-sectional size.

[0012] The fusible element may include: a first fusible element on a first side of the series busbar, the first fusible element being configured to connect to a current collector assembly and having a first cross-sectional dimension; and a second fusible element on a second side of the series busbar opposite to the first side, the second fusible element being configured to face away from the current collector assembly and having a second cross-sectional dimension larger than the first cross-sectional dimension. The first terminal, the second terminal, and the plurality of fusible elements may form an integral structure. A non-conductive container may surround the plurality of fusible elements.

[0013] According to one or more embodiments of this disclosure, a method for assembling a battery sub-assembly is described. The method may include: providing a first set of battery cells and a second set of battery cells, wherein each battery cell in the first and second sets of battery cells defines a central portion including a first terminal and a peripheral edge including a second terminal; providing one or more frames adjacent to the peripheral edge of each battery cell; connecting a current collector assembly to the first and second terminals of each battery cell; providing an encapsulant over the central portion of each battery cell; and providing a cap over the current collector assembly and each encapsulant.

[0014] A series busbar can be connected to a first group of battery cells and a second group of battery cells, with a cover extending above the series busbar. A base can be provided to support the first group of battery cells and the second group of battery cells. One or more potting dams can be provided, each potting dam extending along a corresponding end of one or more frames to the base. A potting material can be provided between the cover and the base. Attached Figure Description

[0015] Certain features of the present subject matter are set forth in the appended claims. However, for purposes of explanation, several embodiments of the present subject matter are illustrated in the following figures.

[0016] 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.

[0017] 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.

[0018] Figure 2A A schematic perspective view of a battery pack according to one or more specific embodiments of the present disclosure is shown.

[0019] 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.

[0020] Figure 2C A cross-sectional end view of a battery cell according to one or more embodiments of the present disclosure is shown.

[0021] Figure 2D A cross-sectional perspective view of a cylindrical battery cell according to one or more specific embodiments is shown.

[0022] Figure 2E A cross-sectional perspective view of a prismatic battery cell according to one or more embodiments of the present disclosure is shown.

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

[0024] Figure 3 A perspective view of an example battery cell according to one or more specific embodiments of this disclosure is shown.

[0025] Figure 4 An exploded perspective view of a battery module according to one or more embodiments of this disclosure is shown.

[0026] Figure 5 A cross-sectional side view of a portion of a battery module according to one or more embodiments of this disclosure is shown.

[0027] Figure 6 A top view of multiple frames on a battery cell of a battery module according to one or more embodiments of the present disclosure is shown.

[0028] Figure 7 A bottom view is shown of a first portion of a frame on a battery cell of a battery module according to one or more embodiments of the present disclosure.

[0029] Figure 8 A bottom view is shown of the second part of the frame on the battery cell of a battery module according to one or more embodiments of the present disclosure.

[0030] Figure 9 A top view of the frame of a battery module and the current collector assembly on the battery cell according to one or more embodiments of the present disclosure is shown.

[0031] Figure 10 A top view of a portion of the frame on a battery cell of a battery module according to one or more embodiments of the present disclosure is shown.

[0032] Figure 11 One or more specific embodiments according to this disclosure are shown. Figure 10 A top view of the frame and a portion of the current collector assembly on the battery cell.

[0033] Figure 12 A top view of the frame of a battery module and the encapsulant on the battery cells according to one or more embodiments of the present disclosure is shown.

[0034] Figure 13A A perspective view of a cover according to one or more specific embodiments of this disclosure is shown.

[0035] Figure 13B A perspective view of a cover according to one or more specific embodiments of this disclosure is shown.

[0036] Figure 13CA perspective view of a cover according to one or more specific embodiments of this disclosure is shown.

[0037] Figure 13D A top view of a cover according to one or more specific embodiments of this disclosure is shown.

[0038] Figure 13E One or more specific embodiments according to this disclosure are shown. Figure 13D A perspective view of a portion of the cover.

[0039] Figure 13F A perspective view of a cover according to one or more specific embodiments of this disclosure is shown.

[0040] Figure 13G A bottom view of the cover according to one or more specific embodiments of this disclosure is shown.

[0041] Figure 13H A perspective view of a cover according to one or more specific embodiments of this disclosure is shown.

[0042] Figure 14A An exploded perspective view is shown of a cover above the current collector assembly of a battery module according to one or more embodiments of the present disclosure.

[0043] Figure 14B A top view of a cover on the frame of a battery module according to one or more embodiments of this disclosure is shown.

[0044] Figure 15A A perspective view of the busbar of a battery module according to one or more embodiments of this disclosure is shown.

[0045] Figure 15B The illustration shows a housing according to one or more specific embodiments of this disclosure. Figure 15A Perspective view of the busbar.

[0046] Figure 16A A perspective view of a portion of the busbar of a battery module according to one or more embodiments of this disclosure is shown.

[0047] Figure 16B A perspective view of the first portion of a container for a busbar according to one or more embodiments of this disclosure is shown.

[0048] Figure 16C A perspective view of the second part of a container for a busbar according to one or more specific embodiments of this disclosure is shown.

[0049] Figure 16D A perspective view of a portion of a busbar and a first portion of a container according to one or more embodiments of this disclosure is shown.

[0050] Figure 17 A perspective view of a potting dam of a battery module according to one or more embodiments of the present disclosure is shown.

[0051] Figure 18 A perspective view of a portion of a battery module having a potting dam, according to one or more embodiments of the present disclosure, is shown.

[0052] Figure 19 A perspective view of a portion of a battery module having a potting dam, according to one or more embodiments of the present disclosure, is shown.

[0053] Figure 20 A perspective view of a portion of a battery module having multiple potting dams according to one or more embodiments of the present disclosure is shown.

[0054] Figure 21 A perspective view of a portion of a battery module having a base and a frame containing battery cells, according to one or more specific embodiments of the present disclosure, is shown.

[0055] Figure 22 A bottom view of a portion of a battery module having a base supporting battery cells, according to one or more embodiments of the present disclosure, is shown.

[0056] Figure 23 A cross-sectional view of a portion of a battery module having a base supporting battery cells, according to one or more embodiments of the present disclosure, is shown.

[0057] Figure 24 A perspective view of a portion of a battery module having a base supporting battery cells, according to one or more embodiments of the present disclosure, is shown.

[0058] Figure 25 A perspective view of a portion of a battery module having a base supporting battery cells, according to one or more embodiments of the present disclosure, is shown.

[0059] Figure 26 A perspective view of a portion of a battery module having a voltage and temperature equalization (“BVT”) module according to one or more specific embodiments of the present disclosure is shown.

[0060] Figure 27 A top view of a portion of a battery module having a current collector assembly connected to a battery cell, according to one or more specific embodiments of the present disclosure, is shown.

[0061] Figure 28 A top view of a portion of a current collector assembly according to one or more specific embodiments of this disclosure is shown.

[0062] Figure 29A top view of a portion of a current collector assembly according to one or more specific embodiments of this disclosure is shown.

[0063] Figure 30 A top view of a portion of a current collector assembly according to one or more specific embodiments of this disclosure is shown.

[0064] Figure 31 A top view of a portion of a current collector assembly according to one or more specific embodiments of this disclosure is shown.

[0065] Figure 32 A top view of a portion of a current collector assembly according to one or more specific embodiments of this disclosure is shown.

[0066] Figure 33 A top view of a portion of a current collector assembly according to one or more specific embodiments of this disclosure is shown.

[0067] Figure 34 A cross-sectional view of a portion of a current collector assembly and a voltage sensing assembly according to one or more embodiments of the present disclosure is shown.

[0068] Figure 35 A cross-sectional view of a portion of a current collector assembly according to one or more embodiments of this disclosure is shown.

[0069] Figure 36 A perspective view of a portion of a battery module according to one or more embodiments of the present disclosure is shown, wherein the current collector assembly and the frame are stacked on top of each other and located above the battery cells.

[0070] Figure 37 A cross-sectional view of a portion of a battery module having a cover, current collector assembly, and frame aligned with a conical tool, according to one or more embodiments of this disclosure, is shown.

[0071] Figure 38 A flowchart illustrating an example of a process executable for assembling a battery module according to one or more specific embodiments of this disclosure is shown.

[0072] Figure 39 A flowchart illustrating an example of a process executable for assembling a battery module according to one or more specific embodiments of this disclosure is shown.

[0073] Figure 40 A perspective view of a facility for assembling a battery module according to one or more specific embodiments of this disclosure is shown.

[0074] Figure 41 A top view of a facility for assembling battery modules according to one or more specific embodiments of this disclosure is shown.

[0075] Figure 42 A flowchart illustrating an example of a process executable for assembling a battery module according to one or more specific embodiments of this disclosure is shown. Detailed Implementation

[0076] The detailed description set forth below is intended as a description of various configurations of the subject matter and is 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 detailed description. The detailed description includes specific 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 specific details set forth herein and can be practiced without these specific 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.

[0077] Battery modules may be provided with features for supporting and protecting their components from external stresses and certain electrical conditions. Specifically, battery modules may be provided with components that direct forces away from areas of electrical connection, such as at the terminals of the battery cells. Such forces may be directed to other structures that do not define areas of electrical connection. Battery modules may also be provided with features that enhance protection against specific electrical conditions, such as series buses that electrically connect multiple sets of battery cells. Components used in such battery modules may provide guides for aligning and securing assembled parts, as well as for holding them in place with potting material during assembly.

[0078] 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.

[0079] In some 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 some 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 some embodiments, vehicle 100 may include one or more electric motors, and vehicle 100 may be in the form of a fully electric or partially electric (e.g., hybrid or plug-in hybrid) vehicle.

[0080] exist Figure 1AIn 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 some 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 cell components capable of being combined with other elements (e.g., structural frames, thermal management devices) that can protect the cell components from heat, shock, and / or vibration.

[0081] 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.

[0082] 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 into battery pack 110 without being assembled into battery modules 115. In some 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 some 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.

[0083] 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).

[0084] In some 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 1CAn 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 some embodiments, the battery pack 110a may be mounted to a wall of building 180.

[0085] 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 some 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).

[0086] In some embodiments, power stage circuitry 172 can electrically couple battery pack 110a to the electrical system of building 180. For example, power stage circuitry 172 can 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 power 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 power outlets and / or other electrical loads in the electrical system of building 180. In some 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.

[0087] 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)).

[0088] Figure 2A An example battery pack 110 according to one or more specific embodiments is depicted. As shown, the battery pack 110 may include an energy volume housing 205 (e.g., a battery pack housing, sometimes referred to herein as a casing). For example, the energy volume housing 205 may contain or enclose an energy volume 207 for the battery pack 110, the energy volume 207 including one or more battery modules 115 and / or one or more battery cells 120, and / or other battery pack components. In one or more specific embodiments, the energy volume housing 205 may include or form a shielding structure on its outer surface (e.g., its bottom and / or under one or more battery modules 115, battery units, batteries and / or battery cells 120) to protect the battery modules 115, battery units, batteries and / or battery cells 120 from external conditions (e.g., if the battery pack 110 is installed in a vehicle 100 and the vehicle 100 is driven on rough terrain such as off-road terrain, ditches, rocks, rivers, streams, etc.).

[0089] The battery pack 110 may include multiple battery cells 120 (e.g., directly mounted within the battery pack 110, or mounted within batteries, battery devices, battery sub-assemblies, and / or battery modules 115, as described herein) and / or battery modules 115 within the energy volume 207 and energy volume housing 205, as well as one or more conductive coupling elements for coupling the voltage generated by the battery cells 120 to power-consuming components of an electrical system such as vehicle 100 and / or building 180. For example, the conductive coupling elements may include internal connectors and / or contactors that couple multiple battery cells 120, battery devices, batteries, battery sub-assemblies, and / or multiple battery modules 115 together within the energy volume housing 205 to generate a desired output voltage for the battery pack 110.

[0090] As shown, the battery pack 110 may further include a modular power component assembly 290 (e.g., including a modular electronics housing or a modular power component housing) mounted to the energy volume housing 205. In one or more embodiments, the modular power component assembly 290 may include one or more conductive coupling elements for routing power from the battery cells 120 and / or battery modules 115 within the energy volume housing 205 (e.g., within energy volume 207) to one or more external connection ports, such as electrical contacts 203 (e.g., high-voltage terminals, ports, or connectors). For example, power cables or harnesses may be connected between the electrical contacts 203 and the electrical system of the vehicle 100 or building 180 to provide power to the vehicle 100 or building 180. The energy volume housing 205 may have a front end 267 and a rear end 269. In one or more embodiments, when the battery pack 110 is installed in the vehicle 100, the battery pack 110 may be arranged with a front end 131 closer to the vehicle and a rear end 133 closer to the vehicle. As shown in the figure, in one or more specific embodiments, the modular power component assembly 290 may be mounted to the energy volume housing 205 at or near the rear end 269 (e.g., a cover 277 mounted to the energy volume housing 205).

[0091] In one or more embodiments, the battery pack 110 may include one or more additional features, such as thermal control structures (e.g., cooling lines and / or plates and / or heating lines and / or plates). For example, the thermal control structures may couple thermal control structures and / or fluids to the battery module 115, battery device, battery and / or battery cell 120 within the energy volume housing 205, such as by distributing fluids through the battery pack 110.

[0092] For example, a thermal control structure may form part of a thermal / temperature control or heat exchange system that includes one or more thermal components, such as plates or bladders, configured to thermally contact one or more battery modules 115 and / or battery cells 120 disposed within an energy volume housing 205. For example, the thermal components may be positioned to contact one or more battery modules 115, battery devices, batteries, and / or battery cells 120 within the energy volume housing 205. In one or more embodiments, the battery pack 110 may include one or more thermal control structures and / or other thermal components for each of several top and bottom pairs of battery modules. As shown, the battery pack 110 may include electrical contacts 203 (e.g., high-voltage connectors or ports) through which external loads (e.g., the electrical system of vehicle 100 or building 180) may be electrically coupled to the battery modules and / or battery cells in the battery pack 110.

[0093] As shown in the figure, the energy volume housing 205 of the battery pack 110 may include a cover 277. For example, the cover 277 may cover and extend over one or more battery modules 115, battery cells 120, and / or other battery sub-assemblies within the energy volume housing 205. Figure 2A In the example, the cover 277 may be a deep-drawn structure forming the top 257 and one or more sidewalls 259 (e.g., four sidewalls) of the energy volume housing 205. As discussed in further detail below, the energy volume housing 205 may also include a tray or other housing structure (e.g., at the bottom of the energy volume housing) that engages with the cover 277 to enclose one or more battery modules 115, battery cells 120, and / or other battery sub-assemblies within the energy volume housing 205 (e.g., within the space defined by the top 257 and sidewalls 259 of the cover 277). For example, the energy volume housing 205 may include a removable tray panel to expose an opening in the bottom of the cover 277.

[0094] exist Figure 2A In the example, the cover 277 is provided with ribs 275 (e.g., for additional strength). In Figure 2A In the example, battery pack 110 includes one or more mounting features 273 (e.g., for mounting battery pack 110 to one or more body structures of a vehicle (such as vehicle 100). Figure 2AAs shown and discussed in further detail below, the energy volume housing 205 may include one or more sidewall structures 271. These sidewall structures 271 may be attached to the sidewall 259 of the cover 277 and / or extend considerably, and may provide shock absorption and / or redistribution functionality to distribute energy from a side impact to the battery pack 110 (e.g., from a side impact to the vehicle 100), away from and / or surrounding one or more battery modules 115, battery cells 120, and / or other battery sub-assemblies within the energy volume housing 205.

[0095] Figure 2B It is depicted that it can be set in the battery pack 110 (e.g., in Figure 2A Various examples of battery modules 115 (within the energy volume casing 205). Figure 2B In the example shown, battery module 115A includes a battery module housing 223 having a rectangular cubic shape with a length approximately similar to its width. In this example, battery module 115A includes a plurality of battery cells 120 implemented as cylindrical battery cells. In this example, battery module 115A includes rows and columns of cylindrical battery cells coupled together via an interconnection structure 200 (e.g., a current connector assembly or CCA). For example, the interconnection structure 200 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 include a charge collector or bus 202. For example, bus 202 may be electrically coupled to interconnection structure 200 to collect the charge generated by battery cells 120, thereby providing a high voltage output from battery module 115A.

[0096] Figure 2B A battery module 115B with an elongated shape is also shown, wherein the length of the battery module housing 223 (e.g., extending along a direction from the front end to the rear end of the battery pack 110 when the battery module 115B is mounted in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., in a lateral direction along a direction from the front end to the rear end of the battery pack 110 when the battery module 115B is mounted in the battery pack 110). For example, one or more battery modules 115B may span the entire front-to-back length of the battery pack within the energy volume housing 205. As shown, the battery module 115B may also include a bus 202 electrically coupled to the interconnect structure 200. For example, the bus 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115B.

[0097] In specific embodiments of battery modules 115A and 115B, 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. For example, Figure 2B A battery module 115C with a battery module housing 223 is also shown. This housing has a rectangular-cubic shape with a length approximately equal to its width and includes a plurality of battery cells 120 implemented as prismatic battery cells. In this example, the battery module 115C includes rows and columns of prismatic battery cells coupled together via an interconnection structure 200 (e.g., a current collector assembly or CCA). For example, the interconnection structure 200 may couple the positive terminals of the battery cells 120 together and / or couple the negative terminals of the battery cells 120 together. As shown, the battery module 115C may include a charge collector or bus 202. For example, the bus 202 may be electrically coupled to the interconnection structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115C.

[0098] Figure 2B A battery module 115D comprising prismatic battery cells and having an elongated shape is also shown, wherein the length of the battery module housing 223 (e.g., extending along a direction from the front end to the rear end of the battery pack 110 when the battery module 115D is mounted in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., in a lateral direction along a direction from the front end to the rear end of the battery pack 110 when the battery module 115D is mounted in the battery pack 110). For example, one or more battery modules 115D having prismatic battery cells may span the entire front-to-back length of the battery pack within the energy volume housing 205. As shown, the battery module 115D may also include a bus 202 electrically coupled to the interconnect structure 200. For example, the bus 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115D.

[0099] For example, Figure 2BA battery module 115E with a battery module housing 223 is also shown. This housing has a rectangular-cubic shape with a length approximately equal to its width and includes a plurality of battery cells 120 implemented as pouch-like battery cells. In this example, battery module 115E includes rows and columns of pouch-like battery cells coupled together via an interconnection structure 200 (e.g., a current collector assembly or CCA). For example, the interconnection structure 200 may couple the positive terminals of battery cells 120 together and the negative terminals of battery cells 120 together. As shown, battery module 115E may include a charge collector or bus 202. For example, bus 202 may be electrically coupled to the interconnection structure 200 to collect the charge generated by the battery cells 120, thereby providing a high-voltage output from battery module 115E.

[0100] Figure 2B A battery module 115F, comprising pouch-shaped battery cells and having an elongated shape, is also shown, wherein the length of the battery module housing 223 (e.g., extending along a direction from the front end to the rear end of the battery pack 110 when the battery module 115E is mounted in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., in a lateral direction along a direction from the front end to the rear end of the battery pack 110 when the battery module 115E is mounted in the battery pack 110). For example, one or more battery modules 115E having pouch-shaped battery cells may span the entire front-to-back length of the battery pack within the energy volume housing 205. As shown, the battery module 115E may also include a bus 202 electrically coupled to the interconnect structure 200. For example, the bus 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115E.

[0101] In various embodiments, the battery pack 110 may include any or more of battery modules 115A, 115B, 115C, 115D, 115E, and 115F. In one or more other embodiments, the battery pack 110 may not include battery modules 115 (e.g., in a battery cell-battery pack embodiment). In one or more embodiments, the battery pack 110 may include three elongated battery modules (e.g., three battery modules 115B, 115D, and / or 115F).

[0102] In one or more specific implementations, Figure 2BIn any of the specific embodiments, multiple battery modules 115 may be coupled (e.g., in series) to a current collector of the battery pack 110. In one or more embodiments, the current collector may be coupled to one or more external connectors (e.g., electrical contacts 203) on the battery pack 110 via a high-voltage wiring harness. In one or more embodiments, the battery pack 110 may not be provided with any battery modules 115. For example, the battery pack 110 may have a cell-to-pack configuration, wherein battery cells 120 are arranged directly as part of the battery pack 110 without being assembled into modules 115 (e.g., excluding separate battery module housings 223). For example, the battery pack 110 (e.g., energy volume housing 205) may include or define multiple structures for directly positioning battery cells 120 within the energy volume housing 205.

[0103] Figure 2C A 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 some 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 some 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.

[0104] In some 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 can 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 include a lithium salt in an organic solvent.

[0105] 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 some 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] Figure 2D A 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 2DThe 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, busbars, 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.

[0110] 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 some 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.

[0111] Figure 2FAn 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 specific implementations, the cell housing 224 can 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 can be as low as or less than 0.1 mm, 0.05 mm, 0.02 mm, or 0.01 mm to provide a flexible or stretchable housing for the pouch-shaped battery cell. In some 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.

[0112] In some 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 some 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.

[0113] Figure 3 A perspective view is shown of an example of a battery cell 120 according to one or more specific embodiments, the battery cell being implemented as a cylindrical cell having a cylindrical cell housing 524. Figure 5In the example, battery cell 120 includes a cover 500, which includes a central portion 502 and a peripheral edge 504. In some embodiments, the central portion 502 may be implemented as a terminal, such as the positive terminal of battery cell 120. In some embodiments, the peripheral edge 504 may be implemented as a terminal, such as the negative terminal of battery cell 120. In some embodiments, battery cell 120 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 120 (e.g., closed by cylindrical cell housing 524 and cover 500) from the external environment of battery cell 120.

[0114] Figure 4 An exploded perspective view of battery module 115 is shown. Battery module 115 includes a cover 460, one or more encapsulants 450, a current collector assembly 400, a series bus 600, one or more frames 510, 512 and / or 514, one or more separator layers 590, one or more groups 122 of battery cells 120, and a base 302.

[0115] A cover 460 may be disposed on the top of the battery module 115, and a base 302 may be disposed on the bottom of the battery module 115. The base 302 may be provided as a single piece or in multiple pieces. Battery cells 120 may be inserted in groups 122 into a crate structure formed by the base 302. One or more groups 122 of battery cells 120 may be positioned on opposite sides of a cooling element (not shown) and / or within the sidewall of the base 302.

[0116] In some embodiments, each of frames 510, 512, and / or 514 may take the form of a monolithic single body (e.g., a molded body formed of plastic and / or other materials) and may include a top portion and / or sidewalls. Each of frames 510, 512, and / or 514 may extend across at least a portion of each group 122 of battery cell 120. Frames 510, 512, and / or 514 may be engaged together when secured to battery cell 120. In the case of providing multiple frames 510, 512, and / or 514, two of the frames may form the ends of a joint structure, and one or more additional frames may form the middle portion of the joint structure. Thus, any configuration, number, and / or length of the groups 122 of battery cell 120 can be achieved by selecting the corresponding frame groups. Each group 122 may secure its battery cell 120 together along its length. In addition, multiple frames 510, 512 and / or 514 may be fixed to one or more groups 122 to be fixed relative to each other along the length of the group 122 of the battery cell 120.

[0117] like Figure 4As shown, a CCA 400 is provided. As discussed in further detail below, when assembling the battery module 115, the CCA 400 can take the form of a means of connecting the corresponding terminals of the battery cells 120 of the battery module 115 to a bus 320. Several buses can be integrated. For example, bus 320 (e.g., a positive bus) can be electrically coupled to a corresponding first terminal (e.g., a positive terminal) of the battery cells of the battery module 115, and bus 320 (e.g., a negative bus) can be electrically coupled to a corresponding second terminal (e.g., a negative terminal) of the battery cells of the battery module 115. Figure 4 As further shown, a series busbar 600 may also be provided (e.g., on the ends of frames 510, 512, and / or 514 opposite to the ends of the respective unit carriers where busbars 320 are mounted). As used herein, the series busbar 600 may correspond to... Figure 2B One or more of the busbars 202 shown.

[0118] like Figure 4 As further shown, one or more encapsulants 450 may each be disposed between the cover 460 and a corresponding battery cell in the battery cell 120. The encapsulant 450 may surround the area where the CCA 400 is connected to the terminal of the corresponding battery cell 120. The encapsulant 450 may further extend to cover and / or contact portions of the frames 510, 512 and / or 514.

[0119] A series bus 600 may be provided to connect groups 122 of battery cells 120 to each other. For example, a series bus 600 may be provided to connect a first group 122 of battery cells 120 on a first side of cooling element 306 to a second group 122 of battery cells 120 on a second side of cooling element 306. The series bus 600 may be disposed on top of one or more of frames 510, 512, and / or 514. In some embodiments, the series bus 600 is disposed in the same plane occupied by current collector assembly 400 and / or encapsulant 450. This arrangement allows the series bus 600 to be surrounded by the same frame and cover surrounding other components such as current collector assembly 400 and / or encapsulant 450. The series bus 600 may also be provided with one or more alignment features for alignment with one or more other structures such as frames 510, 512, and / or 514. Thus, the assembly may be provided with a series bus 600 aligned with other components of battery module 115.

[0120] In some implementations, a voltage and temperature equalization (“BVT”) module 314 is communicatively coupled to a thermistor assembly 316. The BVT module 314 may take the form of a modular assembly of various electrical components to monitor and / or control components of the battery module 115. For example, the BVT module 314 may include a circuit board attached to a housing of the BVT module 314. As a non-limiting example, the 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 the battery module 115 and / or its battery cells 120. Voltage sensors or equalizers may sense or control the voltage flowing through the battery module 115 and / or its battery cells 120. Communication devices may receive, transmit, or analyze data associated with the battery module 115 and / or its battery cells 120.

[0121] In some embodiments, the BVT module 314 may include processing circuitry. This processing circuitry may include monitoring and / or control circuitry, such as temperature and voltage balancing (BVT) circuitry. For example, the BVT circuitry may include an electronic control unit (ECU) that obtains data from one or more sensors within the battery pack or energy volume (e.g., voltage data, such as battery cell voltage data, and / or temperature data, such as one or more temperatures at one or more locations within the battery pack or energy volume). The one or more sensors may be or include voltage sensors, current sensors, temperature sensors, pressure sensors, and / or gas sensors. The BVT may process the sensor data to monitor battery cell voltages, monitor one or more temperatures, and / or perform cell balancing operations on the battery cells. In some embodiments, the BVT module 314 may provide the sensor data and / or processed data derived from the sensor data to an additional processing circuitry system (e.g., a battery management system (“BMS”)) via a wired or wireless connection.

[0122] Figure 5 A cross-sectional side view of a portion of the battery module is shown. Figure 5As shown, the cover 460 may extend across the encapsulant 450 surrounding the top portion of the battery cell 120. The frame 510 may rest on the peripheral edge 504 of the battery cell 120 while exposing the central portion 502. A CCA 400 (e.g., having a first interconnect portion 422 and a second interconnect portion 424) may extend beyond the frame 510 and into the battery cell 120. The encapsulant 450 may surround a contact area between the first interconnect portion 422 and the central portion 502 of the battery cell 120 (e.g., a terminal). The encapsulant 450 may surround a contact area between the second interconnect portion 424 and the peripheral edge 504 of the battery cell 120 (e.g., a terminal). The encapsulant 450 may extend into the frame 510. The cover 460 may have a shape adapted to the encapsulant 450. For example, the cover 460 may have a concave shape facing the battery cell 120 (e.g., and / or the encapsulant 450). For example, the cover 460 may have a convex shape opposite to the battery cell 120. The cover 460 may rest on and / or engage with the CCA 400 and / or the frame 510. The cover 460 may be substantially rigid. The cover 460 may be made of a material such as metal (e.g., steel).

[0123] In some embodiments, the cover 460 is integrally (e.g., monolithically) formed with one or more frames (e.g., frames 510, 512, and / or 514). For example, the cover and / or frames may be extruded around the CCA 400 on opposite sides of the CCA 400. The CCA 400 may provide electrical conduction within this integrated structure.

[0124] The cover 460 can receive forces and / or other loads from above (such as from the upper layer 464 and / or through the compressible layer 462). For example, the compressible layer 462 may comprise a compressible material, such as foam and / or an elastic material. Forces applied to the upper layer 464 can be attenuated by the compressible layer 462. Forces applied to the cover 460 can be directed around and away from the encapsulant 450, the first interconnect portion 422, the second interconnect portion 424, and / or the central portion 502 of the battery cell 120. Instead, forces can be directed to portions of the peripheral edge 504 of the battery cell 120 (e.g., via the CCA 400 and / or the frame 510). Thus, although forces are applied to the cover 460, the connections between the first interconnect portion 422 and the central portion 502 of the battery cell 120 (e.g., terminals) and between the second interconnect portion 424 and the peripheral edge 504 of the battery cell 120 (e.g., terminals) are protected. In some embodiments, the encapsulant 450 has a modulus of elasticity less than that of the cap 460 and the frame 510. When forces are transmitted to the encapsulant 450, such forces can attenuate before reaching the connection between the first interconnect portion 422 and the central portion 502 (e.g., a terminal) of the battery cell 120, and between the second interconnect portion 424 and the peripheral edge 504 (e.g., a terminal) of the battery cell 120. By utilizing these and / or other features to protect the battery cell 120, the battery module 115 and / or the battery pack containing one or more battery modules 115 can be positioned at or near the floor of the vehicle cabin. For example, since the cap 460 and / or the encapsulant 450 are considered to provide sufficient protection for the battery cell 120, the thickness of other intermediate structures between the battery pack and the floor of the vehicle cabin can be minimized. Also, the amount and / or quantity of additional damping material can be reduced. Therefore, the overall height of the structure beneath the vehicle cabin floor can be minimized, resulting in a final assembled product with greater space efficiency.

[0125] See now Figures 6 to 8Positioning features can be provided to facilitate the alignment of components of the battery module during assembly. Each positioning feature may include one or more parts and / or an arrangement of parts forming a reference. As used herein, a reference refers to one or more parts and / or an arrangement of parts that restricts the relative movement of two or more components relative to each other in one or more degrees of freedom. In some embodiments, a degree of freedom is defined as a direction along one or more axes of a coordinate system (e.g., including two opposite directions along a single axis). For example, a two-axis reference restricts the relative movement of two or more components relative to each other in two degrees of freedom, such as two opposite directions along a common axis. As another example, a four-axis reference restricts the relative movement of two or more components relative to each other in four degrees of freedom, such as two opposite directions along each of two different (e.g., orthogonal) axes. It should be understood that the positioning features of a given component form a reference for another component based on the interaction with another feature of another component. In cases where a single positioning feature interacts with multiple other components, one or more degrees of freedom may be provided for each other component relative to the positioning feature in a common direction and / or along a common axis.

[0126] Figure 6 A top view of multiple frames on the battery cells of the battery module is shown. Each of the frames 510, 512, and / or 514 may include one or more positioning features to engage the battery cell 120. In some embodiments, such as Figure 6 As shown, the first connector 520 can form a four-way reference, and the second connector 530 can form a two-way reference.

[0127] Figure 7 A bottom view of the first part of the frame on the battery cell of the battery module is shown. (As shown) Figure 7 As shown, the frame 510 may include a plurality of first (e.g., three or more) connectors 520 extending between one or more battery cells 120. Each of the first connectors 520 may be formed as a pin or post extending parallel to the height of the battery cell 120. The first connectors 520 may be distributed around any of the battery cells 120. Thus, the first connectors 520 may form a four-way reference to limit movement of the frame 510 relative to the battery cells 120 on two different (e.g., orthogonal) axes.

[0128] Figure 8 A bottom view of the second part of the frame on the battery cell of the battery module is shown. (As shown) Figure 8As shown, the frame 510 may include a second connector 530 extending between one or more battery cells 120. The second connector 530 may be formed as a rib extending parallel to the height of the battery cells 120 and its length extending transversely to the height of the battery cells 120. The second connector 530 may be positioned between any two or more of the battery cells 120. Therefore, the second connector 530 may form a two-way reference to limit movement of the frame 510 relative to the battery cells 120 along one axis. The combination of the first connector 520 and the second connector 530 may further limit rotation of the frame 510 relative to the battery cells 120.

[0129] Figure 9 A top view of the battery module frame and the current collector assembly on the battery cell is shown. Each of the frames 510, 512, and / or 514 may include one or more positioning features to engage the CCA 400. For example, each of the third connectors 540 may form a two-way reference. Figure 9 As further shown, each of frames 510, 512, and / or 514 may include one or more third connectors 540 extending into an opening 440 of the CCA 400. Each third connector 540 may be formed as a pin or post extending in a direction opposite to that of the first and second connectors. Each third connector 540 may extend into a corresponding opening 440 of the CCA 400. In some embodiments, the shape, size, and / or orientation of the opening 440 allows movement of the CCA 400 along one axis and restricts movement of the CCA 400 along another (e.g., orthogonal) axis. Where the openings 440 corresponding to (e.g., overlapping) each of frames 510, 512, and / or 514 differ (e.g., in shape, size, and / or orientation), the permitted and restricted directions of movement may differ. Thus, although each of the third connectors 540 and its corresponding opening 440 can form a two-axis reference to limit the movement of the CCA 400 relative to the frame on one axis, the combination of multiple third connectors 540 and their corresponding openings 440 can form a four-axis reference to limit the movement of the CCA 400 relative to the frames 510, 512 and / or 514 on two axes.

[0130] Now for reference Figures 10 to 12 The frame can provide openings for access to one or more battery cells covered by the frame. Figure 10 A top view of a portion of the frame on the battery cell of the battery module is shown. Figure 10As shown, frame 510 may define an opening 550 aligned with a portion of battery cell 120. Opening 550 may expose a central portion 502 of battery cell 120, which may also expose terminals located thereon. Frame 510 may include structures aligned to partially overlap with a peripheral edge 504 of battery cell 120. Additionally, opening 550 may include a cutout 552 that exposes a portion of peripheral edge 504, which may also expose terminals located thereon. Thus, both the central portion 502 and a portion of peripheral edge 504 of battery cell 120 are exposed to provide connection at the terminals thereon.

[0131] Figure 11 It shows Figure 10 A top view of a portion of the current collector assembly on the frame and battery cells. The CCA 400 is connected (e.g., mechanically and electrically) to a plurality of battery cells 120 of the battery module. The CCA 400 defines an opening 440 that partially overlaps with the battery cells 120. A first interconnect portion 422 and a second interconnect portion 424 extend into the opening 440 of the CCA 400 and the opening of the frame to connect with the battery cells 120. The first interconnect portion 422 of the CCA 400 is connected to the central portion 502 of the battery cells 120. The second interconnect portion 424 of the CCA 400 is connected to the peripheral edge 504 of the battery cells 120. The first interconnect portion 422 and the second interconnect portion 424 may extend into the opening 440 from different directions. While the first interconnect portion 422 may extend into the opening 550 of the frame 510, the second interconnect portion 424 may extend into a cutout 552 exposing a portion of the peripheral edge 504 of the battery cells 120.

[0132] Figure 12 A top view of the battery module frame and the encapsulation on the battery cells is shown. (As shown) Figure 12 As shown, each encapsulant in the encapsulant 450 may be disposed on the upper side of the corresponding battery cell 120. For example, each encapsulant 450 may cover at least a portion of the central portion 502 and the peripheral edge 504 of the corresponding battery cell 120. Thus, the encapsulant 450 may extend into the opening 550, including extending into at least a portion of the cutout 552. The encapsulant 450 may extend into and / or overlap with a portion of the frame 510 and / or CCA 400, including its interconnection portion (not shown) to the battery cell 120.

[0133] Figures 13A to 13GVarious examples of cover 460 are shown. In one or more embodiments, cover 460 may be a composite protective cover having a compression-molded dome 466 and a channel 468, which helps dissipate loads in the Z direction (e.g., orthogonal to the surface of cover 460) and prevent deformation of the underlying battery cells, thereby preventing thermal runaway. The compression-molded dome 466 and channel 468 may contain encapsulating adhesive to protect the welds between the battery cells and the current collector assembly.

[0134] Figure 13A A perspective view of a cover according to one or more specific embodiments of this disclosure is shown. Figure 13A As shown, the cover 460 may include one or more domes 466, each dome forming a concave shape on a first side of the cover 460 and a convex shape on a second side of the cover 460. Figure 13A As further shown, the cover 460 may include one or more channels 468. The channels 468 may extend between and / or connect to two or more domes 466, such that the individual spaces surrounded by the connected dome portions are connected to form a continuous space.

[0135] Figure 13B A perspective view of a cover according to one or more specific embodiments of this disclosure is shown. Figure 13B As shown, the cover 460 may include one or more domes 466, wherein the domes 466 may have shapes that are similar (e.g., identical) and / or different from each other. In cases where the shapes and / or dimensions of the individual domes 466 vary, one or more domes 466 having a common first shape and / or size may be arranged in a common first row and / or column, and one or more domes 466 having a common second shape and / or size different from the first shape and / or size may be arranged in a common second row and / or column. Figure 13B As further shown, cover 460 may optionally omit one or more channels.

[0136] Figure 13C A perspective view of a cover according to one or more specific embodiments of this disclosure is shown. Figure 13C As shown, the cover 460 may include one or more channels 468. Channels 468 may extend parallel to and / or parallel to opposite ends of the cover 460. Figure 13C As further shown, cover 460 may optionally omit one or more domes.

[0137] Figure 13D and Figure 13EA top view of a cover according to one or more specific embodiments of the present disclosure is shown. The cover 460 may include multiple portions, such as a first cover portion 460A and a second cover portion 460B. Each of the first cover portion 460A and the second cover portion 460B may include one or more domes 466 and / or one or more channels 468. The first cover portion 460A and the second cover portion 460B may have complementary shapes at their ends for engagement together. For example, as... Figure 13E As shown, the cover 460 may define an opening 467 through which one or more other parts of the assembly may extend and / or be accessed. One or more openings 467 may be closed to completely define one of the first cover portion 460A and the second cover portion 460B. One or more openings 467 may be open to partially define one of the first cover portion 460A and the second cover portion 460B and / or the space between the first cover portion 460A and the second cover portion 460B.

[0138] Figure 13F A perspective view of a cap according to one or more specific embodiments of the present disclosure is shown. In some embodiments, the cap 460 may be integrated with one or more potting dams 790. For example, potting dams 790 may be located at one or both of the opposite ends of the cap 460. Alternatively, a plurality of potting dams 790 may surround one or more domes 466 and / or one or more channels 468. The potting dams 790 may be formed from materials such as foam (e.g., die-cut). Each potting dam 790 may be attached to the cap 460, for example, using pressure-sensitive adhesive (PSA) tape and / or another adhesive and / or fastening mechanism.

[0139] Figure 13G A bottom view of a cover according to one or more embodiments of the present disclosure is shown. The cover 460 may include, for example, an adhesive 465 for securing to a lower structure of the assembly on its bottom side. For example, the cover 460 may be bonded to the underlying layer using pressure-sensitive adhesive (PSA) tape and / or another adhesive and / or securing mechanism. Alternatively, the adhesive 465 may be applied to the cover 460 via roll coating. The adhesive 465 may be disposed between, beside, and / or across one or more domes 466 and / or one or more channels 468. In some embodiments, the adhesive 465 may be disposed at multiple locations and / or extend in different directions to provide retention against forces that may be applied in various directions. In some embodiments, the cover 460 may be bonded to the underlying layer using adhesives, thermal riveting, push-clamping, welding, riveting, and / or combinations thereof.

[0140] Figure 13HA perspective view of a cap according to one or more specific embodiments of the present disclosure is shown. In some embodiments, the cap 460 may be integrated with one or more potting dams 790. In some embodiments, the cap 460 defines one or more gap holes 792 at each of its opposite ends. Each gap hole 792 may receive a boss or stud (e.g., plastic) that is thermally riveted to secure the cap 460 in place by being thermally riveted and / or melted into a shape (e.g., a dome).

[0141] Figure 14A An exploded perspective view of the cover above the current collector assembly of the battery module is shown. Figure 14A As shown, cap 460 may be positioned above frames 510, 512 and / or 514, CCA 400 and / or encapsulant.

[0142] Figure 14B A top view of the cover on the frame of the battery module is shown. Each of the frames 510, 512, and / or 514 may include one or more positioning features to engage the cover 460. For example, each of the fourth connectors 542 may form a two-way reference. Figure 14B As further shown, each of frames 510, 512, and / or 514 may include one or more fourth engagements 542 extending into an opening 472 of the cover 460. Each of the fourth engagements 542 may be formed as a pin or post extending in a direction opposite to that of the first and second engagements. Each of the fourth engagements 542 may extend into a corresponding opening 454 of the cover 460. In some embodiments, the shape, size, and / or orientation of the opening 472 allows the cover 460 to move along one axis and restricts the cover 460 to move along another (e.g., orthogonal) axis. Where the opening 472 corresponding to (e.g., overlapping) each of frames 510, 512, and / or 514 differs (e.g., in shape, size, and / or orientation), the permitted and restricted directions of movement may differ. Thus, although each of the fourth connectors 542 and its corresponding opening 454 can form a two-axis reference to limit the movement of the cover 460 relative to the frame on one axis, the combination of multiple fourth connectors 542 and their corresponding openings 454 can form a four-axis reference to limit the movement of the cover 460 relative to the frames 510, 512 and / or 514 on two axes.

[0143] Now for reference Figures 15A to 16D A series bus can be configured to connect different groups (e.g., rows) of battery cells to each other. This series bus provides robust conductivity between different groups of battery cells, while also providing one or more fuses to disconnect the electrical connection between them under certain conditions.

[0144] Figure 15AA perspective view of the series bus 600 of the battery module is shown. (As shown) Figure 15A As shown, the series bus 600 includes a first terminal 610 and a second terminal 612. In some embodiments, the first terminal 610 and the second terminal 612 may include one or more alignment features 608 for receiving one or more connectors (e.g., posts, pins, extensions, etc.) of a frame (not shown). For example, the alignment feature 608 may include one or more openings. The openings may form a two-way and / or four-way reference with the connectors of the frame. For example, one or more of the alignment features 608 may receive the connectors of the frame and allow them a limited range of movement within the respective openings of the alignment feature 608. The series bus 600 may be thermally riveted or otherwise secured to the frame at or near the location of the alignment feature 608.

[0145] In some embodiments, the first terminal 610 may be configured (e.g., via CCA) to be connected (e.g., mechanically and electrically) to a first group of battery cells, and the second terminal 612 may be configured (e.g., via CCA) to be connected (e.g., mechanically and electrically) to a second group of battery cells. The series bus 600 may also include a fuse 620, which may include multiple fuse elements 622, 624, and / or 626. The fuse 620 may be connected (e.g., mechanically and electrically) in parallel to the first terminal 610 and the second terminal 612. Although three fuse elements are shown, it should be understood that any number of fuse elements may be provided. Fuse elements 622, 624, and / or 626 provide the ability to disconnect under excessive current, thereby disconnecting the first group of battery cells from the second group of battery cells under certain conditions.

[0146] In some embodiments, each of the plurality of fuse elements 622, 624, and / or 626 has a different cross-sectional size. As used herein, the cross-sectional size can be width, thickness, height, diameter, and / or other dimensions defined in the cross-section of fuse elements 622, 624, and / or 626. One of fuse elements 622, 624, and / or 626 may have a minimum cross-sectional size. Therefore, the fuse element 622, 624, and / or 626 with the minimum cross-sectional size may have a minimum threshold current at which it will break. When breaking, the current through the remaining fuse elements 622, 624, and / or 626 may increase. While these remaining fuse elements may have a higher current threshold (at which they will break), this increase may approach that threshold. For example, a first fuse element 622 on the first side 602 of the series bus 600 may have a first cross-sectional size. The second fuse element 624 between the first fuse element 622 and the third fuse element 626 may have a second cross-sectional size (e.g., different from and / or larger than the first cross-sectional size). The third fuse element 626 on the second side 604 of the series bus 600 opposite the first side 602 may have a third cross-sectional size (e.g., different from and / or larger than the first and / or second cross-sectional sizes). The first side 602 may face the CCA and / or other components of the battery module. The second side 604 may face away from the CCA and / or other components of the battery module. Therefore, in the event that the fuse 620 receives excessive current, the first fuse element 622, which is closest to other components of the battery module, may break first when the current at its location is relatively low. One or more other fuse elements (including the third fuse element 626, which is furthest from other components of the battery module) may break later when the current at its location is relatively high.

[0147] In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., fuse elements 622, 624, and / or 626) are made of a conductive material (e.g., aluminum, copper, combinations thereof, etc.). In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., fuse elements 622, 624, and / or 626) form a monolithic structure.

[0148] Figure 15B It shows a casing Figure 15A A perspective view of the series buses. (See attached image.) Figure 15BAs shown, the series busbar 600 may include a fuse housing and / or a container 690 for housing and / or surrounding the fuse 620, including fuse elements 622, 624, and / or 626. The container 690 may be made of a non-conductive material (e.g., plastic). In some embodiments, the container 690 is provided as multiple (e.g., two) portions, such as a first container portion 691 and / or a second container portion 695. The first container portion 691 and the second container portion 695 are assembled together on opposite sides of the fuse 620. The first container portion 691 and the second container portion 695 may be fixed together, for example, by ultrasonic welding and / or similar methods. In some embodiments, the container 690 encapsulates a space therein and provides an encapsulating agent in one or more of the spaces. For example, the container 690 may be filled with one or more materials used as an encapsulating agent. Alternatively, the encapsulating agent may include a quantity of an electrically insulating material (e.g., silica sand, other electrically insulating particles, etc.). Encapsulant may fill the space between the various portions of container 690 and / or fuse 620. In some embodiments, container 690 is filled with encapsulant (e.g., silica sand), and a sealing plug (e.g., by press fit) is subsequently provided to retain the encapsulant therein.

[0149] Figure 16A A perspective view of a portion of another series bus 600 of the battery module is shown. Figure 16A As shown, the series bus 600 includes a first terminal 610 and a second terminal 612, which may have the following characteristics relative to... Figure 15A and Figure 15B The series bus 600 describes one or more features. The series bus 600 may also include a fuse 620, which may include one or more fuse plates 632. The fuse 620 may be connected in parallel (e.g., mechanically and electrically) to a first terminal 610 and a second terminal 612. Although two fuse plates 632 are shown, it should be understood that any number of fuse plates may be provided. Each fuse plate 632 defines one or more fuse elements 636, which are arranged in one or more columns (e.g., ...). Figure 16A The two columns shown are separated from each other by one or more openings 638, each opening being arranged between a corresponding pair of fuse elements 636. The openings 638 may be circular (e.g., annular) or of another shape. Therefore, each fuse element 636 may have a variable cross-sectional dimension along its respective length. The fuse elements 636 provide the ability to disconnect under excessive current, thereby disconnecting the first group of battery cells from the second group of battery cells under certain conditions.

[0150] In some embodiments, one or more (e.g., two or more) fuse plates 632 are provided between the first terminal 610 and the second terminal 612. In some embodiments, each fuse plate 632 provides one or more (e.g., two or more) rows of fuse elements 636 and / or openings 638. In some embodiments, the fuse elements 636 and / or openings 638 have variable (e.g., curved, circular, and / or annular) cross-sectional shapes and / or uniform (non-variable) cross-sectional shapes along their respective lengths.

[0151] In some embodiments, each of the plurality of fuse elements 636 has a different cross-sectional dimension than one or more of the other fuse elements 636. As used herein, the cross-sectional dimension can be width, thickness, height, diameter, and / or other dimensions defined in the cross-section of the fuse element 636. One of the fuse elements 636 may have the smallest cross-sectional dimension relative to one or more of the other fuse elements 636. Therefore, the fuse element 636 with the smallest cross-sectional dimension may have the lowest threshold of current at which it will break. When breaking, the current through the remaining fuse elements 636 may increase. While these remaining fuse elements may have a higher current threshold (at which they will break), this increase may approach that threshold. For example, the first fuse element 636 on the first side 602 may be smaller than the fuse element 636 on the second side 604. Therefore, in the event that the fuse 620 receives excessive current, the smaller fuse element 636 closest to other components of the battery module may break first when the current at its location is relatively low. One or more other fuse elements 636 furthest from other components of the battery module may disconnect later when the current at their location is relatively high. In some embodiments, fuse elements 636 may have a common cross-sectional dimension (e.g., a minimum cross-sectional dimension).

[0152] In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., fuse plate 632) are made of a conductive material (e.g., aluminum, copper, combinations thereof, etc.). In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., fuse plate 632) are components of a single part. This provides the ability to assemble multiple fuse plates 632 in parallel between the first terminal 610 and the second terminal 612.

[0153] Figure 16BA perspective view of a first container portion 691 of a container for a busbar according to one or more embodiments of the present disclosure is shown. In some embodiments, the first container portion 691 includes a first body 692 and one or more connectors 693 (e.g., posts, pins, extensions, etc.) extending from the first body 692. For example, each connector 693 may extend, for example, in a common direction. In some embodiments, the connectors 693 may have the same size, shape, and / or other features. In some embodiments, the first container portion 691 may provide symmetry across one or more axes. The first container portion 691 may be provided with and / or provided with an adhesive 694 on one or more of its surfaces (such as the surfaces from which the connectors 693 extend).

[0154] Figure 16C A perspective view of a second container portion 695 of a container for a busbar according to one or more embodiments of the present disclosure is shown. In some embodiments, the second container portion 695 includes a second body 696 and one or more openings 697 (e.g., cavities, recesses, holes, etc.) extending within the second body 696. For example, each of the openings 697 may extend, for example, in a common direction. In some embodiments, one or more of the openings 697 may have the same size, shape, and / or other features. In some embodiments, one or more of the openings 697 may have different sizes, shapes, and / or other features. The openings 697 may form a two-way and / or four-way reference with the connector 693 of the first container portion 691. For example, one or more of the openings 697 may receive the connector 693 of the first container portion 691 and allow it a limited range of movement within a corresponding opening 697 of the second container portion 695. In some embodiments, the second container portion 695 may provide symmetry across one or more axes. The second container portion 695 may be provided with and / or provided with adhesive 698 on one or more of its surfaces (such as the surface to which the opening 697 extends).

[0155] Figure 16D A perspective view of a portion of a busbar and a first portion of a container according to one or more embodiments of this disclosure is shown. In some embodiments, such as Figure 16DAs shown, the series bus 600 (e.g., near or at the fuse 620) may include one or more alignment features 634 for receiving the connector 693 (e.g., post, pin, extension, etc.) of the first container portion 691. For example, alignment feature 6345 may be formed at or near one or both of the first terminal 610 and the second terminal 612. In some embodiments, alignment feature 634 may include one or more openings. These openings may form a two-way and / or four-way reference with the connector 693 of the first container portion 691. For example, one or more of the alignment features 634 may receive the connector 693 of the first container portion 691 and allow it a limited range of movement within the corresponding opening of the alignment feature 634.

[0156] Now for reference Figures 17 to 20 The battery module 115 may be provided with features that facilitate the management of potting and support its components. For example, one or more potting dams may be provided to restrict the entry of potting material.

[0157] Figure 17 A perspective view of the potting barrier of the battery module is shown. Figure 17 As shown, the potting dam 700 may include a structure whose shape is complementary to other components of the battery module and provides a seal to prevent the passage of potting material. In some embodiments, the potting dam 700 includes a lateral structure 710 and one or more longitudinal structures 720. The one or more longitudinal structures 720 may extend laterally to the lateral structure 710. It should be understood that the potting dam 700 may have one or more of a variety of shapes and / or sizes to provide a seal at the edges and / or corners of the battery module. The potting dam 700 may be a flexible, compressible, and / or compliant material, such as a polymer (e.g., neoprene), an elastic material, and / or foam. The potting dam 700 may be substantially impermeable to potting material.

[0158] Figure 18 A perspective view of a portion of a battery module with a potting dam is shown. Figure 18 As shown, the potting dam 700 may extend at the peripheral edge of one or more components of the battery module 115. For example, a transverse structure 710 may extend along an end of the cover 460. One or more longitudinal structures 720 may extend between the cover 460 and the base 302, for example at its terminals. It should be understood that the potting dam 700 may include one or more other portions to extend along other components of the battery module 115 and / or other components adjacent to the battery module.

[0159] Figure 19 A perspective view of a portion of a battery module with a potting dam is shown. Figure 19 As shown, the battery module 115 can be configured to receive potting material. For example, the battery module 115 can be relative to... Figure 18 The orientation shown is an inverted orientation. In this configuration, the lateral structure 710 of the potting dam 700 extends horizontally along the bottommost part of the terminal ends of the battery module 115. Additionally, in this configuration, the longitudinal structure 720 of the potting dam 700 extends vertically along the edges and corners of the battery module 115. Furthermore, in this configuration, the battery module 115 is prepared to receive potting material, for example, as a fluid to be solidified. Therefore, the potting dam 700 helps to keep the potting material within the boundaries defined by the periphery of the battery module 115.

[0160] Figure 20 A perspective view of a portion of a battery module with multiple infilled retaining dams is shown. Figure 20 As shown, the bracket 800 can support multiple battery modules (not shown) between opposing pairs of potting dams 700. For example, the bracket 800 may include multiple compartments 810, each compartment for receiving a corresponding battery module from the multiple battery modules. The battery modules may be disposed between opposing pairs of potting dams 700, and potting material may be supplied to the battery modules and / or the multiple compartments 810 of the bracket 800. Thus, the potting dams 700 can retain the potting material within the compartments 810.

[0161] Now for reference Figure 21 and Figure 22 The battery module 115 may provide features that facilitate potting and support its components. For example, openings in the base and / or frame facilitate the entry of potting material into the entire assembly and venting during thermal events.

[0162] Figure 21 A perspective view of a portion of a battery module 115 having a base 302 and a frame containing a battery cell 120, according to one or more specific embodiments of the present disclosure, is shown. Figure 22 A bottom view of a portion of a battery module 115 having a base 302 supporting a battery cell 120, according to one or more embodiments of the present disclosure, is shown.

[0163] like Figure 21As shown, the battery module 115 may include a base 302 and a frame 510 (and / or frames 512 and / or 514, not shown). The base 302 may include a substrate 304 defining a plurality of substrate openings 372. Each of the plurality of substrate openings 372 may extend through the substrate 304 to provide access to a first side of a corresponding one of the plurality of battery cells 120. The base 302 may also include base walls 360 extending from the inside of the substrate 304 at opposite edges of the substrate 304. Each base wall 360 may define a plurality of base wall openings 370, each base wall opening extending through a corresponding base wall 360. In some embodiments, each base wall opening 370 is arranged opposite to a corresponding substrate opening in the substrate opening 372. In some embodiments, the base wall 360 also defines a plurality of base recesses 362 facing away from each other and base flanges 364 configured to face away from the frame. Multiple base recesses 362 facilitate engagement via a carrying tool or other items acting on the base 302 (e.g., for moving and / or rotating the battery module 115).

[0164] Frame 510 may include a frame plate defining a plurality of frame openings 550. Each of the plurality of frame openings 550 may extend through the frame plate to provide access to a second side of a corresponding one of the plurality of battery cells 120. Frame 510 may also include frame walls 560 extending from the inside of the frame plate at opposite edges of the frame plate. Each of the frame walls 560 may define a plurality of frame wall openings 570, each frame wall opening extending through a corresponding frame wall in the frame walls 560. The substrate opening 372, the base wall opening 370, and the frame wall openings 570 provide flow paths for potting material to travel along the sides of the plurality of battery cells 120 to the exterior of the battery sub-assembly. In some embodiments, each frame wall opening 570 is arranged opposite to a corresponding frame plate opening in the frame plate opening (not shown). In some embodiments, the base wall 360 also defines a plurality of frame recesses 562 facing away from each other and frame flanges 564 configured to face away from the base 302. Multiple frame recesses 562 facilitate engagement by means of a carrying tool or other items acting on the frame 510 (e.g., for moving components).

[0165] Now for reference Figures 22 to 24 In some implementations, the components include support structures that separate the rows of battery cells from each other and provide resistance against bending. Figure 23 A cross-sectional view of a portion of a battery module 115 having a base 302 supporting a battery cell 120, according to one or more embodiments of the present disclosure, is shown. Figure 24A perspective view of a portion of a battery module 115 having a base 302 supporting a battery cell 120, according to one or more embodiments of the present disclosure, is shown.

[0166] like Figures 22 to 24 As shown, the base 302 for the battery module 115 may include a plate 304 defining a plurality of openings 372, each of the plurality of openings 372 extending through the plate 304. The base 302 may include protrusions 380 on the plate 304, each protrusion extending radially inward into a corresponding opening of the plurality of openings 372 for supporting a corresponding battery cell of the plurality of battery cells 120. The maximum cross-sectional dimension across each of the plurality of openings 372 is greater than the maximum cross-sectional dimension of the corresponding battery cell of the battery cell 120. The minimum cross-sectional dimension across each of the plurality of openings 372 defined by at least one of the protrusions 380 is less than the maximum cross-sectional dimension of the corresponding battery cell of the battery cell 120.

[0167] like Figure 23 As shown, the base 302 may further include inner beams 352, each extending from the inside of the plate 304 and between corresponding pairs of rows in the plurality of rows of battery cells 120. The base 302 may also include outer beams 354, each extending from the outside of the plate 304 between corresponding pairs of rows in the plurality of rows of openings. In some embodiments, the number of outer beams 354 is greater than the number of inner beams 352. In some embodiments, each inner beam of the inner beams 352 is aligned with a corresponding outer beam of the outer beams 354. In some embodiments, the outer beams 354 include at least two outer beams 354 extending between a given pair of rows in the plurality of rows of openings. In some embodiments, the outer beams 354 have a first height that is less than a second height of the inner beams 352.

[0168] like Figure 24 As shown, different types of openings can be provided. For example, a frame panel opening 372 can be provided, and the panel 304 can also be defined extending between at least two outer beams 354 and providing an additional fluid-communication opening 358 between the inner and outer sides of the panel 304. Figure 24 As further shown, different types of openings can be provided. For example, the outer beam can be a first outer beam 354, and the base 302 may also include a second outer beam 356 that extends across one or more rows of multiple openings to connect multiple first outer beams in the first outer beam 354.

[0169] Now for reference Figure 25 The base may provide one or more features for securing the battery cell to it. Figure 25A perspective view of a portion of a battery module 115 having a base 302 supporting a battery cell 120, according to one or more embodiments of the present disclosure, is shown. Figure 25 As shown, the base 302 of the battery module 115 may include an adhesive tape 390 (e.g., made of or comprising a pressure-sensitive adhesive) to couple battery cells 120 to the base 302 along opposite edges of adjacent rows. The tape 390 may be arranged to contact only certain sides of the battery cells 120 in different rows. For example, when the battery cells 120 are provided to the base 302, the adhesive tape 390 may be positioned to contact a first side of the battery cells 120 arranged in the first and second rows. Thus, the tape 390 may extend along the inside of the base 302 such that the adhesive tape 390 couples to opposite portions of the battery cells 120 in the first and second rows. Thereafter, one or more frames may be provided as adjacent second sides of the battery cells 120, the second sides of which are opposite the first sides of the battery cells 120. A current collector assembly 400 may be disposed on the second side of the battery cells 120. One or more potting dams may each extend along a respective end of the frame to the base 302. Then potting material can be provided between the frame and the base 302.

[0170] Figure 26 A perspective view of a portion of a battery module 115 having a voltage and temperature equalization (“BVT”) module according to one or more embodiments of the present disclosure is shown. In some embodiments, a BVT module 314 is disposed at an end of the battery module 115. The BVT module 314 is communicatively coupled to one or more temperature sensors, such as thermistor assemblies 316 and / or 317. The BVT module 314 may take the form of a modular assembly of various electrical components to monitor and / or control components of the battery module 115. For example, the BVT module 314 may include a circuit board 338 attached to a housing 330 of the BVT module 314. As a non-limiting example, the BVT module 314 may include various connectors for coupling to, for example, a thermistor, a voltage sensor assembly 328, and / or communication devices. The voltage sensor assembly 328 may include a wiring harness 326 for connection to the BVT module 314. The voltage sensor or equalizer may sense or control the voltage flowing through the battery module 115 and / or one or more of its battery cells 120. The communication device can receive, transmit, or analyze data associated with the battery module 115 and / or its battery cells 120. In some embodiments, the BVT module 314 may include one or more connectors 324 and / or one or more test pads 322 for testing and / or connecting to other devices. Figure 26As further shown, the battery module 115 may include one or more buses 320 for connection to one or more other devices and / or components. The one or more buses 320 may include and / or define terminals for supplying power to another device and / or component. Each bus 320 may be provided with a seal 318 or other barrier surrounding a portion thereof.

[0171] Now for reference Figures 27 to 33 It can be equipped with a current collector assembly (CCA) to connect one or more battery cells. Figure 27 A top view is shown of a portion of a battery module 115 having a current collector assembly 400 connected to a battery cell 120, according to one or more specific embodiments of the present disclosure. Figure 27 As shown, the CCA 400 has a welded tab geometry that provides the degree of overlap with the corresponding terminals of the battery cell 120.

[0172] like Figure 27 As shown, a battery module 115 is assembled by providing a current collector assembly 400 to one or more battery cells 120. Each of the one or more battery cells 120 includes a central portion 502 defining a first terminal and a peripheral edge 504 defining a second terminal. In some embodiments, the battery module 115 may include one or more battery cells 120, each including a central portion 502 defining a first terminal and a peripheral edge 504 defining a second terminal. The current collector assembly 400 may include one or more first interconnect portions 422 and one or more second interconnect portions 424. The one or more first interconnect portions 422 may each be soldered to a corresponding central portion 502 of a corresponding battery cell in the one or more battery cells 120. The one or more second interconnect portions 424 may each be soldered to a corresponding peripheral edge 504 of a corresponding battery cell in the one or more battery cells 120.

[0173] In some embodiments, each of the one or more first interconnect portions 422 of the current collector assembly 400 is soldered to a corresponding center portion 502 of a corresponding battery cell in one or more battery cells using one or more first solder areas 432. In some embodiments, each of the one or more second interconnect portions 424 of the current collector assembly 400 is soldered to a corresponding peripheral edge 504 of a corresponding battery cell in one or more battery cells 120 using one or more second solder areas 434.

[0174] In some embodiments, each of the one or more second interconnect portions 424 terminates at a corresponding concave edge 430 that extends along the concave shape of a corresponding peripheral edge 504 of a corresponding battery cell in one or more battery cells 120. In some embodiments, the corresponding concave edge 430 of each of the one or more second interconnect portions 424 is positioned such that multiple portions along the corresponding concave edge 430 are at a common distance from a corresponding central portion 502 of a corresponding battery cell in one or more battery cells 120. Thus, the distance between the concave edge 430 and the central portion 502 can be maintained at a substantially constant distance across its respective portions. This distance can be selected to minimize and / or avoid dielectric breakdown between the concave edge 430 and the central portion 502.

[0175] Figure 28 A top view of a portion of a current collector assembly 400 according to one or more embodiments of this disclosure is shown. Figure 28 As shown, the current collector assembly 400 may include a first conductor 442 and a second conductor 444. The first conductor 442 may have one or more portions terminating at locations adjacent to each of the one or more first interconnect portions 422. For example, the second conductor 444 may define an end (e.g., a termination) terminating at a location where the respective interconnect portion extends from it into an opening 440 of the CCA 400. The second conductor 444 may overlap with the first conductor 442 and define at least a portion of each of the one or more first interconnect portions 422.

[0176] In some embodiments, the first conductor 442 is soldered to the second conductor 444 at one or more CCA solder areas 480. In some embodiments, one or more CCA solder areas 480 extend along one or more portions of the first conductor 442 in one or more rows. In some embodiments, each of the one or more first interconnect portions 422 extends from a corresponding portion of the one or more portions of the first conductor 442.

[0177] Figure 29 A top view of a portion of a current collector assembly 400 according to one or more embodiments of the present disclosure is shown, with enlarged views of interconnect portions 422 and 424. In some embodiments, each interconnect portion 422 and / or 424 extends into an opening 440 of the CCA 400. For example, a pair of interconnect portions 422 and 424 may extend into a common opening 440.

[0178] Figure 30A top view of a portion of a current collector assembly 400 according to one or more specific embodiments of the present disclosure is shown. In some embodiments, each of one or more first interconnect portions 422 (e.g., defined as a portion of a first conductor 442) extends from a corresponding portion of a second conductor 444 including one or more CCA solder areas 480. For example, as Figure 30 As shown, the first interconnect portion 422 can be defined as a portion of the first conductor 442 extending into the opening 440 of the CCA 400. The first interconnect portion 422 may extend from a portion of the second conductor 444, where a plurality (e.g., three) CCA solder areas 480 are provided to couple the first conductor 442 to the second conductor 444. This provides reinforced fixation of the first conductor 442 to the second conductor 444 at locations where additional force can be applied (e.g., via the first interconnect portion 422).

[0179] Now for reference Figures 31 to 33 CCA welding can be provided in one or more of a variety of shapes to provide a strong coupling between conductor layers.

[0180] Figure 31 A top view of a portion of a current collector assembly 400 according to one or more specific embodiments of the present disclosure is shown. In some embodiments, such as Figure 31 As shown, each of the one or more CCA welding zones 480 defines a helical shape. This shape provides redundant fixation within the zone (e.g., via multiple turns of the helix) while avoiding excessive energy application during the welding process. For example, the helix may be configured with gradual turns (e.g., no corners) without intersecting its own path. Therefore, energy application can be consistent along the entire length to provide a consistent weld depth.

[0181] Figure 32 A top view of a portion of a current collector assembly 400 according to one or more specific embodiments of the present disclosure is shown. In some embodiments, such as Figure 32 As shown, each of the one or more CCA welding regions 480 defines a continuous series of multiple loops (and / or as part thereof) extending along the length of the first conductor 442. This shape provides redundant fixation within the region (e.g., via multiple loops) while avoiding excessive energy application during welding. For example, the loops may be configured with gradual turns (e.g., without corners). These loops may intersect their own paths but may be spaced apart so that previously welded areas can cool sufficiently before intersecting. Thus, energy application can be consistent throughout the length to provide a consistent weld depth. The continuous aspect of the multiple loops provides continuous fixation across their length.

[0182] Figure 33 A top view of a portion of a current collector assembly 400 according to one or more specific embodiments of the present disclosure is shown. In some embodiments, such as Figure 33 As shown, each of the one or more CCA welding regions 480 defines an undulating shape (and / or as part of it) extending along the length of the first conductor 442. This shape can provide redundant fixation (e.g., via multiple waves) within the region while avoiding excessive energy application during the welding process. For example, a loop may be configured with gradual turns (e.g., without corners) without crossing its own path. Thus, energy application can be consistent over the entire length to provide a consistent weld depth. The continuous aspects of the undulating shape (e.g., having multiple waves) provide continuous fixation across its length.

[0183] Now for reference Figure 34 and Figure 35 The layers of the current collector assembly can be welded together to provide fixation and conductivity there. Figure 34 A cross-sectional view of a portion of a current collector assembly 400 and a voltage sensor assembly 328 according to one or more specific embodiments of this disclosure is shown. Figure 34 As shown, the CCA 400 may include multiple layers, including one or more conductors (e.g., first conductor 442 and / or second conductor 444) and one or more cover layers (e.g., top cover layer 482 and / or bottom cover layer 488). The first conductor 442 and / or second conductor 444 may include conductive materials (e.g., aluminum, copper, nickel, and / or combinations thereof). The top cover layer 482 and / or bottom cover layer 488 may include electrically insulating materials (e.g., PET, another polymer, and / or combinations thereof). The top cover layer 482 and bottom cover layer 488 may surround the first conductor 442 and / or second conductor 444 at various regions of the CCA 400 to provide electrical isolation.

[0184] By providing a first conductor 442 and a second conductor 444 in separate layers, an efficient welding process is facilitated. In some embodiments, the first conductor 442 may be thinner than the second conductor 444 (e.g., having a lower thickness). Such relative dimensions allow the relatively thinner layer (e.g., the first conductor 442) to be fused, melted, and / or welded to a relatively thicker layer (e.g., the second conductor 444). The combined thickness of the first conductor 442 and the second conductor 444 provides sufficient electrical conductivity. The second conductor 444 provides continuity to interconnect portions 422 and / or 424, such that portions of the second conductor 444 form interconnect portions 422 and / or 424. As described herein, interconnect portions 422 and / or 424 are subsequently welded to the battery cell. Thus, the second conductor 444 provides material to be fused, melted, and / or welded to corresponding portions of the battery cell (e.g., the central portion and / or peripheral edges).

[0185] like Figure 34 As further shown, the voltage sensor assembly 328 may include multiple layers, including one or more conductors (e.g., VS conductor 334) and one or more cover layers (e.g., top VS cover layer 332 and / or bottom VS cover layer 336). It should be understood that the voltage sensor assembly 328 may extend only a portion across the CCA 400. The VS conductor 334 may include a conductive material (e.g., aluminum, copper, nickel, and / or combinations thereof). The top VS cover layer 332 and / or bottom VS cover layer 336 may include an electrically insulating material (e.g., PET, another polymer, and / or combinations thereof). The top VS cover layer 332 and / or bottom VS cover layer 336 may surround the VS conductor 334 at various regions of the voltage sensor assembly 328 to provide its electrical isolation.

[0186] like Figure 34 As further shown, an adhesive layer 452 is provided for adhering the CCA 400 to a frame (not shown). Adhesive 452 may include a pressure-sensitive adhesive. The CCA 400 (e.g., at the bottom cover layer 488) can firmly adhere to the frame when pressure or force (e.g., pressing) is applied. As further described herein, this adhesion can be achieved after the CCA 400 is aligned relative to the frame. Thus, adhesive 452 secures the CCA 400 to the frame, and welding at the interconnect portions secures the CCA 400 to the battery cell.

[0187] Figure 35 A cross-sectional view of a portion of a CCA 400 according to one or more specific embodiments of this disclosure is shown. Figure 35As shown, the second conductor 444 may have a thickness Tr. For example, in one or more embodiments, the thickness Tr may be between 0.2 mm and 0.8 mm (e.g., 0.5 mm). Similarly, in one or more embodiments, the thickness of the first conductor 442 may be between 0.1 mm and 0.7 mm (e.g., 0.3 mm). As shown, the depth of the CCA solder joint 480 to the second conductor 444 may be within the thickness Tr of the second conductor 444. For example, in the process of soldering the first conductor 442 to the second conductor 444, in some cases, the CCA solder joint 480 may be allowed to penetrate to and / or completely through the second conductor 444 (e.g., extending to or not extending to another substrate, such as the bottom cover layer 488). Figure 35 In the example, the CCA weld 480 connecting the first conductor 442 to the second conductor 444 includes a plurality of weld portions 480A, 480B, and 480C, which may represent portions of a continuous weld. For example, the plurality of weld portions 480A, 480B, and 480C may represent a plurality of turns in a spiral shape, a plurality of loops in a continuous shape, and / or a plurality of waves in an undulating shape.

[0188] Now for reference Figure 36 and Figure 37 Alignment tools and procedures can be provided to align multiple components of the battery assembly. In some embodiments, alignment features can interact with alignment tools that are not necessarily part of the resulting battery module. Each layer of the sub-assembly also includes positioning reference features for alignment.

[0189] Figure 36 A perspective view of a portion of a battery module 115 according to one or more embodiments of the present disclosure is shown, the battery module including a current collector assembly 400 and a frame 510 stacked on top of each other and located above a battery cell 120. In some embodiments, such as Figure 36 As shown, battery module 115 includes a current collector assembly 400 and / or a frame 510 (and / or frames 512 and / or 514, not shown). The current collector assembly 400 may be positioned below a cover (not shown) and includes interconnecting portions 422 and / or 424 for electrical connection to terminals and / or one or more battery cells 120. The current collector assembly 400 may define a CCA opening 402 extending through the current collector assembly 400 and forming a shape having a second dimension smaller than (e.g., the cover's) a first dimension. The frame 510 may define a frame opening 516 extending through the frame and forming a third dimension smaller than the second dimension. The current collector assembly 400 may be connected to one or more battery cells 120 through additional frame openings in the frame 510.

[0190] Figure 37A cross-sectional view is shown of a portion of a battery module 115 having a cover 460 aligned with a conical tool, a current collector assembly 300, and a frame 510, according to one or more embodiments of this disclosure. Figure 37 As shown, the cover opening, CCA opening, and frame opening can be concentrically aligned. The cover 460 can overlap with the current collector assembly 400, which can overlap with the frame 510. In some embodiments, the cover 460 can define a cover opening 472 that extends through the cover 460 and forms a shape having a first dimension. For example, the CCA opening 402 of the current collector assembly 400 can be concentrically aligned with the frame opening 516 of the frame 510 between the current collector assembly 400 and one or more battery cells. Similarly, the cover opening 472 of the cover 460 can be concentrically aligned with the CCA opening of the current collector assembly 400. This alignment can be performed sequentially or simultaneously. For example, an alignment tool 490 can be provided. The alignment tool 490 can have a tapered or other shape that engages with each of the cover opening 472 of the cover 460, the CCA opening 402 of the current collector assembly 400, and the frame opening 516 of the frame 510. Based on the respective shapes and / or dimensions of the cover opening 472, CCA opening 402, and frame opening 516, the alignment tool 490 can facilitate concentricity among the corresponding structures. For example, the cover opening 472, CCA opening 402, and frame opening 516 can be the same or similar shapes with different dimensions (e.g., gradually increasing or decreasing in the stacking direction). In this way, the alignment tool 490 can facilitate alignment between the cover 460, the current collector assembly 400, and the frame 510.

[0191] Figure 38 A flowchart illustrating an example of a process 900 executable for forming a battery module according to one or more specific embodiments of the present disclosure is shown. For purposes of explanation, this document primarily refers to... Figures 4 to 37 The components shown are used to describe process 900. However, process 900 is not limited to... Figures 4 to 37 The components shown, one or more blocks (or operations) of process 900, can be performed by one or more other components of other suitable means, devices, or systems. Further, for illustrative purposes, some blocks of process 900 are described herein as occurring sequentially or linearly. However, multiple blocks of process 900 may occur in parallel. Moreover, the blocks of process 900 do not need to be performed in the order shown, and / or one or more blocks of process 900 need not be performed and / or may be replaced by other operations.

[0192] At frame 902, a base is provided. The base may be constructed and arranged to support one or more battery cells, including one or more such battery cells.

[0193] At frame 904, one or more battery cells and / or groups of battery cells are provided. For example, battery cells and / or groups of battery cells may be provided to a base. Groups of battery cells may be arranged to contact cooling elements (e.g., inter-cell cooling pipes). For example, battery cells may be separated by cooling elements. The arrangement of cells in contact with cooling elements (e.g., inter-cell cooling pipes) may be referred to as a vine or vine assembly.

[0194] At box 906, one or more frames are provided. For example, the one or more frames may be configured to extend above one or more battery cells and / or such as battery cells.

[0195] At frame 908, a current collector assembly is connected to each of the one or more battery cells. For example, the current collector assembly may be positioned on top of one or more frames, and portions of the current collector assembly may extend through the frames to connect to the terminals of the battery cells.

[0196] At frame 910, one or more encapsulants may be provided. For example, each encapsulant may cover a portion of the frame, a portion of the battery cell (e.g., terminals), and a portion of the current collector assembly (e.g., interconnection portion).

[0197] At frame 912, a busbar is connected to one or more battery cells in a battery cell and / or battery cell group. For example, the busbar may be located on top of a portion of one or more frames. Alternatively, the busbar may connect a first group of battery cells on a first side of a cooling element to a second side of battery cells on a second side of a cooling element.

[0198] At frame 914, a cover is provided. For example, the cover may be provided on top of at least a portion of one or more frames, current collector assemblies, and / or encapsulants.

[0199] At frame 916, one or more potting dams are provided. For example, potting dams may be provided at each end of a portion of the battery module.

[0200] At frame 918, a potting material is provided. For example, the potting material may be configured to penetrate into and / or between one or more components of the battery module. The one or more potting dams may retain the potting material within the area of ​​the battery module.

[0201] According to one or more embodiments of this disclosure, a method for assembling a battery module is provided. According to one or more embodiments of this disclosure, an apparatus for assembling a battery module therein is provided. Figure 39 A flowchart illustrating an example of a process executable for assembling a battery module according to one or more specific embodiments of this disclosure is shown. For purposes of explanation, this document primarily refers to... Figures 4 to 37The components shown are used to describe the process. However, process 1000 is not limited to... Figures 4 to 37 The components shown, one or more blocks (or operations) of the process, can be performed by one or more other components of other suitable means, devices, or systems. Further, for illustrative purposes, some blocks of the process are described herein as occurring sequentially or linearly. However, multiple blocks of the process may occur in parallel. Moreover, the blocks of the process do not need to be performed in the order shown, and / or one or more blocks of the process do not need to be performed and / or may be replaced by other operations.

[0202] In the first stage 1010 (e.g., the battery cell assembly stage), and at frame 1012, a group of battery cells can be arranged in a predetermined layout and / or pattern (e.g., “vine”), including one or more rows and / or columns, for example, to contact thermal management elements or components, such as cooling elements or components. At frame 1014, battery cells (e.g., at cooling pipes located between battery cells) can be loaded into a clamp (and / or adjacent to a cooling element). At frame 1014, the clamp can be rotated (e.g., in a first direction) to align the battery cells, for example, with one or more references and / or with gravity (where the battery cells abut a first side against a cooling element). At frames 1016 and 1018, the first side of the battery cell arrangement (e.g., the starboard side) can be adhesive-guided (e.g., using adhesives or other materials to attach the battery cells to the cooling pipes) and allowed to cure. At frame 1020, the clamp can be rotated (e.g., in a second direction) to align the battery cells, for example, with one or more references and / or with gravity (where the battery cells abut a second side against a cooling element). At frames 1022 and 1024, the second side (e.g., the port side) of the battery cell arrangement may be coated with adhesive (e.g., a bonding agent or other material) and allowed to cure.

[0203] In the second stage 1030 (e.g., the battery cell assembly inspection stage), a group of battery cells may be inspected. At frames 1032, 1034, and 1036, such inspection may include rotation of the fixture (and / or battery cell arrangement), measurement (e.g., using one or more metrics), and / or high-potential testing to assess the dielectric strength of the battery cell insulation.

[0204] In the third stage 1040 (e.g., the battery cell pack unloading stage), at frames 1042, 1044 and 1046, the arrangement of the battery cells can be provided to a tray that has been prepared with barriers and arranged relative to the arrangement of the battery cells.

[0205] In the fourth stage 1050 (e.g., the frame assembly stage), as described herein, the battery cell group may be provided to the base, and at box 1052, a first or more frames (e.g., a rear frame and / or a front frame) and a voltage and temperature equalization (BVT) module may be provided. At box 1054, another frame (e.g., a center frame) and one or more buses may be provided.

[0206] In the fifth stage 1060 (e.g., the heat-riveting and CCA mounting stage), and at frame 1062, one or more frames can be pressed down. This action facilitates adhesion, for example, by pressure-sensitive adhesive. At frame 1062, one or more busbars can be heat-riveted to provide electrical and mechanical connections to the battery cells. At frame 1064, the current collector assembly can be mounted and pressed onto one or more frames and aligned with the battery cells.

[0207] In stage 6, 1070 (e.g., the interconnection and testing stage), and at box 1072, the interconnection portions of the current collector assembly may be connected to the battery cell, for example, by welding electrical connections and mechanical connections. At box 1074, the welds may be optically scanned or otherwise evaluated (e.g., non-contact) to determine the quality of the connection. At box 1076, the welds may be mechanically evaluated (e.g., contact) to determine the quality of the connection. From box 1076, if one or more welds are unsatisfactory, the connection may be repeated or corrected (e.g., by welding).

[0208] In stage 7 1080 (e.g., end of production line (“EOL”), encapsulation and cap installation stage), one or more components may be connected to, for example, a BVT module. At box 1082, components thus installed may include thermistors, voltage sensors, and / or communication devices. At box 1084, one or more seals may be installed, and inspections may be performed. At box 1086, one or more tests may be performed on the battery module. At box 1088, as described herein, one or more encapsulants may be dispensed onto one or more corresponding interconnects and / or battery cells. At box 1088, a cap may be provided over the encapsulant and pressed onto the encapsulant.

[0209] In a subsequent stage, the battery module can be rotated and / or flipped to prepare it for placement in a tray and encapsulation therein.

[0210] Figure 40 A perspective view of a facility for assembling battery modules according to one or more specific embodiments of this disclosure is shown. The facility may provide workstations for performing the operations described herein. For example, as Figure 40 As shown on the right, one or more workstations may be provided to assemble battery modules as described herein. For example, as... Figure 40As shown on the left, one or more workstations may be provided to assemble each battery module into a battery pack as described herein.

[0211] In some implementations, at the first station 1110 (e.g., a battery cell processing station) and / or the second station 1120 (e.g., a group of battery cells assembly station), the following can be performed relative to Figure 39 The assembly includes one or more stages, such as Figure 39 The process 1000 shown includes a first stage 1010 (e.g., battery cell assembly stage), a second stage 1030 (e.g., battery cell group inspection stage) and / or a third stage 1040 (e.g., battery cell group unloading stage).

[0212] In some implementations, at the third station 1130 (e.g., the module assembly station), the following can be performed relative to... Figure 39 The assembly includes one or more stages, such as Figure 39 The process 1000 shown includes the fourth stage 1050 (e.g., frame assembly stage) and / or the fifth stage 1060 (e.g., thermal riveting and CCA installation stage).

[0213] In some implementations, at the fourth station 1140 (e.g., the laser welding station), the following can be performed relative to... Figure 39 The assembly includes one or more stages, such as Figure 39 The sixth stage 1070 of the process 1000 shown (e.g., the interconnection and testing stage).

[0214] In some implementations, at the fifth station 1150 (e.g., the high-voltage distribution box assembly station), the following can be performed relative to Figure 39 The assembly may include one or more stages, such as at least a portion of stage 7 1080 (e.g., end of production line (“EOL”), encapsulation and cap installation stage). For example, a high-voltage distribution box (“HVDB”) may be installed. A HVDB is a component in an electric vehicle that manages and distributes high-voltage power from the battery to various systems and components within the vehicle. It ensures safe and efficient power distribution and typically incorporates safety features such as fuses and relays to protect the vehicle's electrical systems. As another example, an energy management module (“EMM”) may be installed. An EMM is a system or device that optimizes the use and distribution of energy within an electric vehicle. It monitors energy consumption, manages power distribution, and ensures efficient operation by controlling various components, thereby reducing energy waste and improving overall performance.

[0215] In some implementations, at the sixth station 1160 (e.g., the end-of-line testing station of the packaging production line), the following can be performed relative to... Figure 39 The assembly includes one or more stages, such as Figure 39 This refers to at least a portion of the seventh stage 1080 of process 1000 shown (e.g., end-of-line (“EOL”), encapsulation and cap installation stage). End-of-line (“EOL”) testing is a quality control process that can be performed at the final stage of manufacturing to ensure that the product correctly meets all specified requirements and functions before being shipped to the customer. In the context of automotive manufacturing, EOL testing may involve checking various aspects of a vehicle's performance, safety features, and system functionality to verify that it operates as intended. This process helps identify any defects or problems that need to be addressed before product delivery.

[0216] In some implementations, at the seventh station 1170 (e.g., the packaging filling and sealing station), the following can be performed relative to Figure 39 The assembly process includes one or more stages. In some embodiments, at the eighth station 1180 (e.g., the module loading station), the battery module may be loaded onto the vehicle.

[0217] Figure 41 A top view of a facility for assembling battery modules according to one or more specific embodiments of the present disclosure is shown. The facility may provide workstations for performing the operations described herein. For example, one or more workstations may be provided for assembling battery modules as described herein. Figure 41 The facilities shown may include Figure 40 At least some of the workstations shown.

[0218] In some implementations, at the first station 1110 (e.g., the cell processing station), the following can be performed relative to Figure 39 The assembly of one or more stages, such as with Figure 39 One or more operations corresponding to block 1012 of process 1000 shown. For example, at position 1202, one or more battery cells may be loaded, tested, and / or forward-transported.

[0219] In some implementations, at the second station 1120 (e.g., a group of battery cell assembly station), the following can be performed relative to Figure 39 The assembly of one or more stages, such as with Figure 39The process 1000 shown corresponds to one or more operations in frames 1014, 1016, 1018, 1020, 1022, 1024, 1032, 1034, 1036, 1052, and / or 1054. For example, at position 1204, battery cells and / or cooling components or elements may be loaded. As another example, at position 1206, the electrical insulation of the cooling element and / or the group of battery cells may be tested (e.g., by HIPOT testing). As another example, at position 1208, the sub-assembly may be applied, rotated, and / or cured as described herein. As another example, at position 1210, the group of battery cells may be loaded and forward-conveyed. As another example, at position 1212, a base may be provided and the group of battery cells may be loaded thereon. As another example, at position 1214, one or more frames may be provided for the group of battery cells.

[0220] In some implementations, at the third station 1130 (e.g., the module assembly station), the following can be performed relative to... Figure 39 The assembly of one or more stages, and as such Figure 39 One or more operations corresponding to blocks 1062 and / or 1064 of process 1000 shown. For example, at position 1216, a current collector assembly may be provided to the one or more frames and press-fitted onto them.

[0221] In some implementations, at the fourth station 1140 (e.g., the laser welding station), the following can be performed relative to... Figure 39 The assembly of one or more stages, such as with Figure 39 The processes 1000 shown correspond to one or more operations at blocks 1072, 1074, 1076, 1082, 1084, 1086, and / or 1088. For example, at position 1216, a current collector assembly may be provided to the one or more frames and press-fitted onto them. As another example, at position 1218, one or more interconnecting portions may be connected (e.g., welded) to one or more battery cells. As another example, at position 1220, welds may be inspected and / or tested, a thermistor may be installed, and / or a voltage sensing harness may be connected to the BVT module. As another example, at position 1222, one or more encapsulants may be dispensed, as described herein. As another example, at position 1224, the battery module may be unloaded for a packaging procedure.

[0222] According to one or more embodiments of this disclosure, a method for packaging a battery module is provided. According to one or more embodiments of this disclosure, an apparatus for assembling a battery module therein is provided. Figure 42 A flowchart illustrating an example of a process executable for packaging a battery module according to one or more specific embodiments of this disclosure is shown. For purposes of explanation, this document primarily refers to... Figures 4 to 37The components shown are used to describe the process. However, process 1300 is not limited to... Figures 4 to 37 The components shown may be performed by one or more other components of the process, such as other suitable means, devices, or systems. Further, for illustrative purposes, some of the blocks in the process are described herein as occurring sequentially or linearly. However, multiple blocks of the process may occur in parallel. Moreover, the blocks of the process do not need to be performed in the order shown, and / or one or more blocks of the process need not be performed and / or may be replaced by other operations.

[0223] In the first stage 1310 (e.g., the battery module unloading stage), and at block 1312, a set of battery cells may be loaded from the previous stage and / or operation. For example, block 1312 may correspond to Figure 41 The operation at position 1224.

[0224] In the second stage 1320 (e.g., the packaging preparation stage), the battery modules may be prepared for packaging. At box 1322, the battery modules may be prepared, for example, by providing one or more battery modules to a tray. At box 1324, the battery modules may be further prepared, for example, by providing a potting dam and / or testing for any leaks. At box 1326, potting material may be dispensed, and the resulting profile of the potting material may be tested. This dispensing and testing may be performed in stages, such that testing can be conducted as partial dispensing occurs. At box 1328, the battery modules may be tested for any leaks.

[0225] In the third stage 1330 (e.g., the packaging configuration and unloading stage), the battery modules can be prepared for packaging. At box 1332, the battery modules can be flipped and / or otherwise oriented as needed. A high-voltage distribution box and / or energy management module can be prepared for installation, for example, as described herein with respect to... Figure 40 As described in the fifth station 1150. At box 1334, a high-voltage distribution box and / or energy management module can be installed onto the battery module. At box 1336, the battery module can be prepared for final-line testing. At box 1338, a final-line test can be performed, for example, as described herein with respect to… Figure 40 The sixth station 1160 is described above. Alternatively, one or more tests can be performed, including verifying the functionality of the battery module. The battery module can be returned from box 1338 to the second stage 1320, for example, back to box 1328, where the battery module is tested again for any leaks. The battery module can then be loaded into the vehicle from box 1328.

[0226] 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.

[0227] As used herein, the phrase “at least one of” following a series of items, together 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.

[0228] 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.

[0229] The predicates “configured to,” “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 some embodiments, a processor configured 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 configured to execute code can be interpreted as a processor programmed to execute code or operable to execute code.

[0230] Phrases such as "aspect," "the aspect," "on the other hand," "some aspects," "one or more aspects," "one implementation," "the implementation," "another implementation," "some implementations," "one or more implementations," "an implementation scheme," "the implementation scheme," "another implementation scheme," "some implementation schemes," "one or more implementation schemes," "a configuration," "the configuration," "another configuration," "some configurations," "one or more configurations," "the subject matter," "disclosure," "this disclosure," other variations thereof, and similar phrases 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.

[0231] 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.

[0232] All structural and functional equivalents of elements of the various aspects described throughout this disclosure that are known to or will later be 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…”.

[0233] 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.

[0234] According to the present invention, a battery sub-assembly is provided, the battery sub-assembly having: one or more battery cells, each battery cell including a central portion defining a first terminal and a peripheral edge defining a second terminal; and a current collector assembly including: one or more first interconnect portions, each first interconnect portion being welded to a corresponding central portion of a corresponding battery cell in the one or more battery cells; and one or more second interconnect portions, each second interconnect portion being welded to a corresponding peripheral edge of a corresponding battery cell in the one or more battery cells, wherein each of the one or more second interconnect portions terminates in a corresponding concave edge, the corresponding concave edge extending along a concave shape of the corresponding peripheral edge of the one or more battery cells.

[0235] According to one embodiment, the corresponding concave edge of each of the one or more second interconnect portions is positioned such that a plurality of portions along the corresponding concave edge are at a common distance from the corresponding central portion of the corresponding one of the one or more battery cells.

[0236] According to one embodiment, each of the one or more first interconnect portions is welded to a corresponding central portion of a corresponding battery cell in the one or more battery cells using a plurality of first welding areas; and each of the one or more second interconnect portions is welded to a corresponding peripheral edge of a corresponding battery cell in the one or more battery cells using a plurality of second welding areas.

[0237] According to one embodiment, the current collector assembly further includes: a first conductor terminating adjacent to each of the one or more first interconnect portions; and a second conductor overlapping the first conductor and defining at least a portion of each of the one or more first interconnect portions, wherein the first conductor is welded to the second conductor at one or more third welding areas.

[0238] According to one embodiment, each of the one or more third welding regions defines a spiral shape.

[0239] According to one embodiment, each of the one or more third welding regions defines a series of consecutive loops extending along the length of the first conductor.

[0240] According to one embodiment, the one or more third welding regions extend along one or more portions of the first conductor in one or more rows, wherein each of the one or more first interconnect portions extends from a corresponding portion of the one or more portions of the first conductor.

[0241] According to the present invention, a current collector assembly is provided having: one or more interconnect portions, each interconnect portion for welding to a corresponding portion of a respective battery cell among a plurality of battery cells; and a first conductor having an end adjacent to the termination of a respective interconnect portion among the one or more interconnect portions; and a second conductor overlapping the first conductor and defining at least a portion of each interconnect portion among the one or more interconnect portions, wherein the first conductor is welded to the second conductor at one or more welding areas.

[0242] According to one embodiment, each of the one or more welding areas defines a spiral shape.

[0243] According to one embodiment, each of the one or more welding regions defines a series of consecutive loops extending along the length of the first conductor.

[0244] According to one embodiment, each of the one or more welding regions defines an undulating shape extending along the length of the first conductor.

[0245] According to one embodiment, the one or more welding areas extend along one or more portions of the first conductor in one or more rows, wherein each of the one or more interconnect portions extends from a corresponding portion of the one or more portions of the first conductor.

[0246] According to one implementation, each of the one or more welding regions defines a concentric shape.

[0247] According to one embodiment, the one or more interconnect portions are one or more first interconnect portions, wherein the one or more welding areas are one or more first welding areas, and the current collector assembly further includes: one or more second interconnect portions, each second interconnect portion for welding to a corresponding portion of a corresponding battery cell among a plurality of battery cells, wherein each of the one or more first interconnect portions and each of the one or more second interconnect portions extends into a corresponding opening extending through the current collector assembly; and a third conductor having an end adjacent to the termination of a corresponding second interconnect portion among the one or more second interconnect portions; and a fourth conductor overlapping the third conductor and defining at least a portion of each of the one or more second interconnect portions, wherein the third conductor is welded to the fourth conductor at one or more second welding areas.

[0248] According to one embodiment, each of the one or more first interconnect portions is configured to be welded to a corresponding central portion of a corresponding battery cell in the plurality of battery cells; and each of the one or more second interconnect portions is welded to a corresponding peripheral edge of a corresponding battery cell in the plurality of battery cells.

[0249] According to the present invention, a method of assembling a battery assembly includes forming a current collector assembly by: welding a first conductor to a second conductor, the second conductor overlapping the first conductor and defining at least a portion of each of a plurality of first interconnect portions, the first conductor having an end adjacent to the termination of a corresponding first interconnect portion of the plurality of first interconnect portions; welding a third conductor to a fourth conductor, the fourth conductor overlapping the third conductor and defining at least a portion of each of a plurality of second interconnect portions, the third conductor having an end adjacent to the termination of a corresponding second interconnect portion of the plurality of second interconnect portions; welding each of the plurality of first interconnect portions to a corresponding central portion of a corresponding battery cell of a plurality of battery cells; and welding each of the plurality of second interconnect portions to a corresponding peripheral edge of a corresponding battery cell of the plurality of battery cells.

[0250] In one aspect of the invention, the method includes: providing a frame on the plurality of battery cells; and attaching a current collector assembly to the frame on a side of the frame opposite to the plurality of battery cells.

[0251] In one aspect of the invention, each of the plurality of first interconnect portions and each of the plurality of second interconnect portions extends into a corresponding opening extending through the current collector assembly.

[0252] In one aspect of the invention, each weld of the first conductor to the second conductor and each weld of the third conductor to the fourth conductor includes a weld area forming a defined helical shape.

[0253] In one aspect of the invention, each weld of the first conductor to the second conductor and each weld of the third conductor to the fourth conductor includes forming a weld area that defines a series of consecutive rings.

[0254] According to the present invention, a series busbar is provided, the series busbar having: a first terminal; a second terminal; and a plurality of fuse elements connected in parallel to the first terminal and the second terminal, wherein the plurality of fuse elements have different cross-sectional dimensions.

[0255] According to one embodiment, a first fuse element on a first side of the series busbar, configured to face the current collector assembly, has a first cross-sectional dimension; and a second fuse element on a second side of the series busbar, configured to face away from the current collector assembly, has a second cross-sectional dimension larger than the first cross-sectional dimension.

[0256] According to one implementation, the first terminal, the second terminal, and the plurality of fuse elements form an integral structure.

[0257] According to one embodiment, the invention is further characterized by a non-conductive container surrounding the plurality of fusible elements.

[0258] According to one embodiment, portions of the non-conductive container are each inserted between corresponding adjacent pairs of the plurality of fusible elements.

[0259] According to one embodiment, the plurality of fusible elements includes at least three fusible elements.

[0260] According to the present invention, a battery assembly is provided, the battery assembly having: a first group of battery cells; a second group of battery cells; a current collector assembly; and a series bus for being electrically connected to the first group of battery cells via the current collector assembly and electrically connected to the second group of battery cells via the current collector assembly, wherein the series bus occupies a plane occupied by the current collector assembly.

[0261] According to one embodiment, the invention is further characterized by: a frame for abutting the peripheral edges of the first and second battery cells, wherein the current collector assembly extends across the frame, wherein the interconnecting portion of the current collector assembly extends through an opening in the frame to reach the first and second battery cells; and a cover extending across the current collector assembly and the series busbar.

[0262] According to one embodiment, the series busbar includes: a first terminal; a second terminal; and a plurality of fuse elements connected in parallel to the first terminal and the second terminal, wherein the plurality of fuse elements have different cross-sectional dimensions.

[0263] According to one embodiment, a first fuse element of the plurality of fuse elements is located on a first side of the series bus facing the current collector assembly and has a first cross-sectional dimension; and a second fuse element of the plurality of fuse elements is located on a second side of the series bus facing away from the current collector assembly and opposite to the first side and has a second cross-sectional dimension larger than the first cross-sectional dimension.

[0264] According to one implementation, the first terminal, the second terminal, and the plurality of fuse elements form an integral structure.

[0265] According to one embodiment, the invention is further characterized by a non-conductive container surrounding the plurality of fusible elements.

[0266] According to one embodiment, portions of the non-conductive container are each inserted between corresponding adjacent pairs of the plurality of fusible elements.

[0267] According to one embodiment, the plurality of fusible elements includes at least three fusible elements.

[0268] According to the present invention, a method of assembling a battery assembly includes: providing a first set of battery cells and a second set of battery cells; connecting a current collector assembly to each of the first set of battery cells and the second set of battery cells; and connecting a series bus including a plurality of fuse elements to each of the first set of battery cells and the second set of battery cells via the current collector assembly.

[0269] In one aspect of the invention, the method includes providing a cover above the current collector assembly and the series bus.

[0270] In one aspect of the invention, the method includes providing one or more frames adjacent to the peripheral edge of each of a first group of battery cells and a second group of battery cells, wherein a current collector assembly is connected to each of the first group of battery cells and the second group of battery cells through an opening in the one or more frames.

[0271] In one aspect of the invention, the method includes: providing a base to support a first group of battery cells and a second group of battery cells; providing one or more potting dams, each potting dam extending along a corresponding end of the one or more frames to the base; and providing potting material between the cap and the base.

[0272] In one aspect of the invention, connecting a series bus to each of a first group of battery cells and a second group of battery cells includes: connecting a first terminal of the series bus to the first group of battery cells via a current collector assembly; and connecting a second terminal of the series bus to the second group of battery cells via a current collector assembly, wherein the plurality of fuse elements are connected in parallel to the first terminal and the second terminal, and wherein the plurality of fuse elements have different cross-sectional dimensions.

[0273] In one aspect of the invention, the method includes aligning series buses to occupy a plane occupied by a current collector assembly.

[0274] According to the present invention, a frame for a battery assembly is provided, the frame having: a structure for abutting the peripheral edge of each of a plurality of battery cells, the frame defining an opening, the frame being configured to support a current collector assembly extending across the frame and including interconnecting portions for extending through the opening to the plurality of battery cells; one or more first connectors configured to form a first reference with the plurality of battery cells; one or more second connectors configured to form a second reference with the plurality of battery cells; and one or more third connectors configured to form a third reference with the current collector assembly.

[0275] According to one embodiment, the one or more first connectors are configured to surround one or more of the plurality of battery cells; and the one or more second connectors are configured to extend between adjacent pairs of the plurality of battery cells.

[0276] According to one implementation plan, the first reference is a 4-axis reference; the second reference is a 2-axis reference.

[0277] According to one embodiment, the one or more third connectors are configured to extend into one or more CCA openings of the current collector assembly.

[0278] According to one implementation plan, the third reference is a four-dimensional reference.

[0279] According to one embodiment, the frame is further configured to support a cover extending across the current collector assembly, and the frame also includes one or more fourth couplings for forming a fourth reference with the cover.

[0280] According to one embodiment, the one or more fourth connectors are configured to extend into one or more cover openings of the cover.

[0281] According to one implementation plan, the fourth reference is a four-dimensional reference.

[0282] According to one embodiment, the frame is a first frame, wherein the battery cell is a first battery cell, and wherein the structure is a first structure, the second frame includes: a second structure for abutting the peripheral edge of each of the plurality of second battery cells; one or more fifth connectors configured to form a fifth reference with the plurality of second battery cells; one or more sixth connectors configured to form a sixth reference with the plurality of second battery cells; and one or more seventh connectors configured to form a seventh reference with a current collector assembly.

[0283] According to one embodiment, the first frame and the second frame are further configured to support a cover extending across the current collector assembly; the first frame also includes one or more fourth couplings for forming a fourth reference with the cover; and the second frame also includes one or more eighth couplings for forming an eighth reference with the cover.

[0284] According to the present invention, a method for assembling a battery assembly includes: providing a plurality of battery cells; aligning a frame with the plurality of battery cells using one or more first connectors and one or more second connectors of a frame, the one or more first connectors forming a first reference with the plurality of battery cells and the one or more second connectors forming a second reference with the plurality of battery cells; and aligning a current collector assembly with the frame using one or more third connectors of the frame, the one or more third connectors forming a third reference with the current collector assembly.

[0285] In one aspect of the invention, the first reference is a four-dimensional reference; the second reference is a two-dimensional reference.

[0286] In one aspect of the invention, the third reference is a four-directional reference.

[0287] In one aspect of the invention, the method includes aligning a cover with a frame, wherein one or more fourth couplings of the frame form a fourth reference with the cover.

[0288] In one aspect of the invention, the fourth reference is a four-directional reference.

[0289] In one aspect of the invention, the method includes aligning a frame with the plurality of battery cells by: abutting a structure of the frame against a peripheral edge of each of the plurality of battery cells; and connecting an interconnecting portion of a current collector assembly to each of the plurality of battery cells through a corresponding opening in the frame.

[0290] According to the present invention, a battery sub-assembly for a vehicle is provided, the battery sub-assembly comprising: a cover defining a cover opening extending through the cover and forming a shape having a first dimension; a current collector assembly located below the cover and including interconnecting portions for terminals electrically connected to one or more battery cells, the current collector assembly defining a CCA opening extending through the current collector assembly and forming a shape having a second dimension smaller than the first dimension; and a frame defining a frame opening extending through the frame and forming a third dimension smaller than the second dimension, wherein the cover opening, the CCA opening, and the frame opening are concentrically aligned.

[0291] According to one embodiment, the current collector assembly is connected to the one or more battery cells through an additional frame opening in the frame.

[0292] According to one embodiment, the invention is further characterized by: a base; a potting dam extending along the end of the frame to the base; and a potting material between the cover and the base.

[0293] According to one embodiment, the cover further defines an additional cover opening that extends through the cover and forms a shape having a first dimension; the current collector assembly further defines an additional CCA opening that extends through the current collector assembly and forms a shape having a second dimension; and the frame further defines an additional frame opening that extends through the frame and forms a shape having a third dimension, wherein the additional cover opening, the additional CCA opening, and the additional frame opening are concentrically aligned.

Claims

1. A battery sub-assembly, the battery sub-assembly comprising: Multiple battery cells, each battery cell forming a central portion and a peripheral edge; A frame, the frame being adjacent to the peripheral edge of each of the battery cells; A current collector assembly that extends across the frame and is connected to the central portion of each of the plurality of battery cells and the peripheral edge of each of the plurality of battery cells; and A cover that extends across the current collector assembly, wherein the cover is configured to direct forces applied thereto away from the central portion of each of the plurality of battery cells and toward the peripheral edge of each of the plurality of battery cells.

2. The battery sub-assembly according to claim 1, wherein the current collector assembly comprises: First interconnection portions, each of the first interconnection portions being connected to a corresponding central portion of a corresponding battery cell among the plurality of battery cells; and The second interconnect portion, each of the second interconnect portions, is connected to the corresponding peripheral edge of a corresponding one of the plurality of battery cells.

3. The battery subassembly of claim 2, wherein the frame defines an opening, each of the openings being for exposing: (i) the central portion of a corresponding battery cell of the plurality of battery cells for connection to a corresponding first interconnect portion of the first interconnect portion; and (ii) a portion of the peripheral edge of a corresponding battery cell of the plurality of battery cells for connection to a corresponding second interconnect portion of the second interconnect portion.

4. The battery subassembly of claim 1, wherein the cover forms an inner surface that defines a concave shape facing the central portion of a respective one of the plurality of battery cells.

5. The battery sub-assembly according to claim 1, wherein: The plurality of battery cells constitutes the first group of battery cells; The frame is a first frame that covers the first group of battery cells; and The battery sub-assembly also includes a second frame for covering the second group of battery cells.

6. A battery assembly, the battery assembly comprising: Multiple battery cells, each battery cell forming a central portion and a peripheral edge; A frame for adjacent to the peripheral edge of each of the plurality of battery cells; and Current collector assembly extending across the frame, the current collector assembly comprising: First interconnect portions, each of the first interconnect portions being connected to a corresponding central portion of a respective battery cell among the plurality of battery cells; and The second interconnect portion, each of the second interconnect portions, is connected to the corresponding peripheral edge of a corresponding battery cell among the plurality of battery cells; and A plurality of encapsulating agents, each encapsulating a corresponding central portion and a corresponding peripheral edge of a corresponding one of the plurality of battery cells, as well as a corresponding first interconnect portion of the first interconnect portion and a corresponding second interconnect portion of the second interconnect portion.

7. The battery assembly of claim 6, wherein the frame defines an opening, each of the openings being for exposing: (i) a central portion of a corresponding battery cell of the plurality of battery cells for connection to a corresponding first interconnect portion of the first interconnect portion; and (ii) a portion of the peripheral edge of a corresponding battery cell of the plurality of battery cells for connection to a corresponding second interconnect portion of the second interconnect portion.

8. The battery assembly of claim 7, wherein each of the plurality of encapsulants extends to the edge of the corresponding opening of the frame.

9. The battery assembly according to claim 6, wherein: The plurality of battery cells constitutes the first group of battery cells; The frame is a first frame that covers the first group of battery cells; and The battery assembly also includes a second frame for covering the second group of battery cells.

10. The battery assembly of claim 6, further comprising a cover configured to direct forces applied thereon away from the encapsulating agent between the cover and the central portion of each of the plurality of battery cells, and to the peripheral edge of each of the plurality of battery cells.

11. The battery assembly of claim 10, wherein the cover forms an inner surface defining a concave shape, each of the concave shapes being oriented toward a corresponding central portion of a respective encapsulant and a respective battery cell of a respective plurality of battery cells.

12. The battery assembly of claim 10, wherein the plurality of encapsulants have an elastic modulus smaller than that of the cap and the frame.

13. The battery assembly of claim 10, further comprising a foam layer on the side of the cover opposite to the frame.

14. The battery assembly of claim 10, further comprising: Base; A saturated retaining dam extends along the ends of the frame to the base; and Encapsulating material between the cover and the base.

15. A method for assembling a battery assembly, the method comprising: A first set of battery cells and a second set of battery cells are provided, wherein each of the first set of battery cells and the second set of battery cells defines a central portion including a first terminal and a peripheral edge including a second terminal; One or more frames are provided, the one or more frames being adjacent to the peripheral edge of each of the first group of battery cells and the second group of battery cells; Connect the current collector assembly to the first terminal and the second terminal of each battery cell in the first group of battery cells and the second group of battery cells; An encapsulant is provided above the respective central portions of the first group of battery cells and the second group of battery cells; as well as A cap is provided over the current collector assembly and each of the encapsulants.

16. The method of claim 15, wherein providing the cap over the current collector assembly and each of the encapsulants comprises: Align each of the plurality of concave shapes along the inner surface of the cap with a corresponding encapsulant.

17. The method of claim 15, further comprising providing a base to support the first group of battery cells and the second group of battery cells, wherein providing the first group of battery cells and the second group of battery cells includes applying an adhesive tape to the first group of battery cells and the second group of battery cells to the base.

18. The method according to claim 17, further comprising: Provide one or more grouting dams, each of the grouting dams extending along a respective end of the one or more frames to the base; as well as A potting material is provided between the cover and the base.

19. The method of claim 15, further comprising connecting a series bus to the first group of battery cells and the second group of battery cells, wherein the cover extends above the series bus.

20. The method of claim 15, further comprising providing a foam layer on the side of the cover opposite to the one or more frames.

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