Battery array bus bar frame design

Abstract

A battery array bus bar frame design for use within a traction battery pack is disclosed. An exemplary battery array may include a bus bar frame that includes features that facilitate the use of mechanical fastener-less connections inside the battery array. These features may include: legs that may be mounted to a top cover and / or a bottom cover of the array housing via an adhesive; and a holder providing an interface for connecting the cell spacers to the bus bar frame in order to mitigate movement of the bus bar frame and / or the cell spacers and increase the structural integrity of the battery array. Gaps between adjacent legs of the bus bar frame may further establish coolant flow channels for directing coolant around the battery cells for thermal management of the battery array.

Description

Technical Field

[0001] This disclosure generally relates to traction battery packs for electric vehicles, and more specifically to busbar frame designs that facilitate mechanical fastener-free connections with other battery array components. Background Technology

[0002] Electrified vehicles include a traction battery pack that powers the vehicle's motor and other electrical loads. The traction battery pack comprises multiple battery cells and various other internal battery components that support the propulsion of the electric vehicle. Summary of the Invention

[0003] A battery array for a traction battery pack according to an exemplary aspect of this disclosure particularly includes an array housing and a cell stack, the cell stack being housed within the array housing and comprising a plurality of battery cells disposed between a first busbar frame and a second busbar frame. Each of the first busbar frame and the second busbar frame includes a first leg configured to dock with the array housing.

[0004] In another non-limiting embodiment of the aforementioned battery array, the first leg docks with the top cover of the array housing.

[0005] In another non-limiting embodiment of any of the aforementioned battery arrays, an adhesive is disposed between the flat surface of the first leg and the top cover.

[0006] In another non-limiting embodiment of any of the aforementioned battery arrays, the first leg docks with the bottom cover of the array housing.

[0007] In another non-limiting embodiment of any of the aforementioned battery arrays, an adhesive is disposed between the flat surface of the first leg and the bottom cover.

[0008] In another non-limiting embodiment of any of the aforementioned battery arrays, the first leg docks with the top cover of the array housing, and the second leg of each of the first busbar frame and the second busbar frame docks with the bottom cover of the array housing.

[0009] In another non-limiting embodiment of any of the aforementioned battery arrays, a first adhesive is disposed between a first flat surface of the first leg and the top cover, and a second adhesive is disposed between a second flat surface of the second leg and the bottom cover.

[0010] In another non-limiting embodiment of any of the aforementioned battery arrays, each of the first busbar frame and the second busbar frame includes a second leg configured to dock with the array housing. A gap extends between the first leg and the second leg.

[0011] In another non-limiting embodiment of any of the aforementioned battery arrays, the gap establishes a coolant flow channel within the array housing.

[0012] In another non-limiting embodiment of any of the aforementioned battery arrays, each of the first busbar frame and the second busbar frame includes a retainer configured to dock with the cell spacers of the cell stack.

[0013] In another non-limiting embodiment of any of the aforementioned battery arrays, the retainer is U-shaped, and an adhesive is disposed between the retainer and the cell spacer.

[0014] In another non-limiting embodiment of any of the aforementioned battery arrays, the retainer includes a pair of flexible hook structures configured to engage slots formed in the cell spacers.

[0015] A battery array for a traction battery pack according to another exemplary aspect of this disclosure particularly includes an array housing and a cell stack, the cell stack being housed within the array housing and comprising a plurality of battery cells and a plurality of cell spacers arranged to extend laterally between a first busbar frame and a second busbar frame. Each of the first busbar frame and the second busbar frame includes: a first leg configured to abut with the array housing; and a first retainer configured to abut with a first cell spacer among the plurality of cell spacers.

[0016] In another non-limiting embodiment of the aforementioned battery array, the first retainer is U-shaped, and an adhesive is disposed between the first retainer and the first cell spacer.

[0017] In another non-limiting embodiment of any of the aforementioned battery arrays, the first retainer includes a pair of flexible hook structures configured to engage slots formed in the first cell spacer.

[0018] In another non-limiting embodiment of any of the aforementioned battery arrays, the first leg abuts against the top cover of the array housing, and an adhesive is disposed between the flat surface of the first leg and the top cover.

[0019] In another non-limiting embodiment of any of the aforementioned battery arrays, the first leg abuts against the bottom cover of the array housing, and an adhesive is disposed between the flat surface of the first leg and the bottom cover.

[0020] In another non-limiting embodiment of any of the aforementioned battery arrays, the first leg docks with the top cover of the array housing, and the second leg of each of the first busbar frame and the second busbar frame docks with the bottom cover of the array housing.

[0021] In another non-limiting embodiment of any of the aforementioned battery arrays, each of the first busbar frame and the second busbar frame includes a second leg configured to dock with the array housing. A gap extends between the first leg and the second leg.

[0022] In another non-limiting embodiment of any of the aforementioned battery arrays, the gap establishes a coolant flow channel within the array housing.

[0023] The embodiments, examples, and alternatives (including any of their various aspects or corresponding features) described in the foregoing paragraphs, claims, or the following description and drawings may be used independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

[0024] Various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The accompanying drawings, which briefly describe the specific embodiments, are as follows. Attached Figure Description

[0025] Figure 1 An electric vehicle is shown schematically.

[0026] Figure 2 This is a perspective view of an exemplary battery array of a traction battery pack.

[0027] Figure 3 yes Figure 2 An exploded view of the battery array.

[0028] Figure 4 yes Figure 3 An enlarged view of a selected portion of the cell stack of the battery array shown.

[0029] Figure 5 An exemplary busbar frame for a battery array is shown.

[0030] Figure 6 yes Figure 5 An enlarged view of a selected portion of the busbar frame shown.

[0031] Figure 7 Another exemplary flow bar frame is shown.

[0032] Figure 8 Another exemplary flow bar framework is shown.

[0033] Figure 9 The diagram schematically illustrates a manifold frame installed between the top array housing cover and the bottom array housing cover to establish a coolant flow channel.

[0034] Figure 10 Is it through Figure 9 Cross-sectional view of section 10-10.

[0035] Figure 11 The interface between the busbar frame and the cell spacer is shown.

[0036] Figure 12 A selected portion of another exemplary flow bar frame is shown.

[0037] Figure 13 It shows Figure 12 The interface between the busbar frame and the cell spacer.

[0038] Figure 14 yes Figure 13 A magnified view of a selected portion of the interface shown. Detailed Implementation

[0039] This disclosure details a busbar frame design for use within a traction battery pack. An exemplary battery array may include a busbar frame comprising features that facilitate mechanical fastener-free connections within the battery array. These features may include: legs that can be adhesively attached to a top and / or bottom cover of the array housing; and retainers that provide interfaces for connecting cell spacers to the busbar frame to mitigate movement of the busbar frame and / or cell spacers and increase the structural integrity of the battery array. The gaps between adjacent legs of the busbar frame may further establish coolant flow channels for guiding coolant around the battery cells for thermal management of the battery array. These and other features are discussed in more detail in the following paragraphs of this specific embodiment.

[0040] Figure 1An electrified vehicle 10 is schematically illustrated. The electrified vehicle 10 may include any type of electrified powertrain. In one embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and can be extended to other electrified vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, etc. Therefore, although not specifically shown in exemplary embodiments, the powertrain of the electrified vehicle 10 may be equipped with an internal combustion engine, which may be used alone or in combination with other power sources to propel the electrified vehicle 10.

[0041] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 may alternatively be a sports utility vehicle (SUV), van, pickup truck, or any other vehicle configuration. Although specific component relationships are shown in the accompanying drawings of this disclosure, the illustrations are not intended to limit the scope of this disclosure. The placement and orientation of the various components of the electrified vehicle 10 are schematically shown and may vary within the scope of this disclosure. Furthermore, the various drawings accompanying this disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to emphasize certain details of particular components or systems.

[0042] In the illustrated embodiment, the electrified vehicle 10 is a purely electric vehicle propelled solely by electricity (such as by one or more motors 12) without the assistance of an internal combustion engine. The motor 12 may operate as an electric motor, a generator, or both. The motor 12 receives electricity and may convert the electricity into torque for driving one or more wheels 14 of the electrified vehicle 10.

[0043] Voltage bus 16 can electrically connect motor 12 to traction battery pack 18. Traction battery pack 18 is an exemplary electric vehicle battery. Traction battery pack 18 can be a high-voltage traction battery pack assembly including multiple battery cells capable of outputting power to supply motor 12 and / or other electrical loads of electric vehicle 10. Other types of energy storage devices and / or output devices may alternatively or additionally be used to supply power to electric vehicle 10.

[0044] The traction battery pack 18 can be fixed to the bottom 20 of the electric vehicle 10. However, within the scope of this disclosure, the traction battery pack 18 can be located elsewhere on the electric vehicle 10.

[0045] The traction battery pack 18 may include one or more battery arrays 22 (e.g., battery modules, assemblies, or groups of rechargeable battery cells 24) capable of outputting power to supply the motor 12 and / or other electrical loads of the electrified vehicle 10. Each of the one or more battery arrays 22 of the traction battery pack 18 may each include a plurality of battery cells 24 that store energy for supplying power to the various electrical loads of the electrified vehicle 10. Within the scope of this disclosure, the traction battery pack 18 may employ any number of battery arrays 22 and battery cells 24. Therefore, this disclosure should not be limited to... Figure 1 The height is shown as a schematic configuration.

[0046] In one embodiment, the battery cell 24 of each battery array 22 is a lithium-ion pouch cell. However, battery cells having other geometries (cylindrical, prismatic, etc.), other chemical substances (nickel-metal hydride, lead-acid, etc.), or both may be used alternatively within the scope of this disclosure.

[0047] Battery array 22 and various other battery internal components (e.g., bus electrical hub, battery electrical control module, wiring, connectors, etc.) can be housed within internal region 26 of housing assembly 28. Housing assembly 28 may include, for example, a housing cover and a housing tray. The housing cover may be secured (e.g., bolted, welded, glued, etc.) to the housing tray to provide internal region 26. The size, shape, and overall configuration of housing assembly 28 are not intended to limit this disclosure.

[0048] Figures 2 to 4 Features associated with the battery array 22 of the traction battery pack are shown. For example, Figure 1 The traction battery pack 18 of the electrified vehicle 10 may include a battery pack having substantially similar characteristics to... Figures 2 to 4 The design of the battery array 22 shown is one or more battery arrays.

[0049] The battery array 22 may include one or more cell stacks 30 housed within an array housing 32. The array housing 32 may include a top cover 34 and a bottom cover 36. The top cover 34 may be vertically positioned above the bottom cover 36. Various terms such as “above,” “below,” “top,” and “bottom” are used in the various figures relative to the arrangement of components of the traction battery pack 18 and should not be considered limiting in any other way. These terms are for reference only when the traction battery pack 18 is installed... Figure 1 The general orientation of the electric vehicle 10. For the purposes of this disclosure, verticality is also referenced to the ground and how the traction battery pack 18 is oriented when mounted on the electric vehicle 10.

[0050] The top cover 34 can be secured (e.g., bolted, welded, adhered, etc.) to the bottom cover 36 to provide a sealed housing for receiving the cell stack 30. Within the scope of this disclosure, the size, shape, and configuration of the array housing 32 can vary.

[0051] The cell stack 30 may include a plurality of individual battery cells 24 arranged longitudinally between opposing end plates 38 and laterally between opposing busbar frames 40. The battery cells 24 may be arranged together between opposing end plates 38 along the cell stack axis A. The busbar frames 40 may be configured to position and hold a plurality of busbars 42 relative to the battery cells 24. The busbar frames 40 may position the busbars 42 in place to secure (e.g., weld) them to terminals 44 of the battery cells 24. For example, the busbar frames 40 may also be used to isolate the busbars 42 from other conductive components of the battery array 22, such as the housings of the battery cells 24.

[0052] Although a single cell stack 30 having a specific number of battery cells 24 and busbars 42 is shown in the accompanying drawings of this disclosure, the battery array 22 may include any number of cell stacks 30, each cell stack 30 having any number of individual battery cells 24 and busbars 42.

[0053] Cell expansion pad 46 (in) Figure 3 (Best shown in the diagram) can be arranged between some adjacent battery cells 24 within the cell stack 30. The cell expansion pad 46 may include a material suitable for accommodating the expansion of the battery cells (e.g., polyurethane foam, silicone foam, etc.).

[0054] One or more cell spacers 48 may be additionally arranged along the cell stack axis A of the cell stack 30. The cell spacers 48 may include metal fins, thermal barriers, foam layers, or any combination of these components. Therefore, in at least some embodiments, the cell spacers 48 can serve as thermal barriers to mitigate inter-cell heat transfer across the cell stack 30.

[0055] In one embodiment, a group of four individual battery cells 24 is separated by cell spacers 48 along the cell stack axis A of the cell stack 30. However, other configurations are contemplated within the scope of this disclosure, and those skilled in the art will appreciate that the cell stack 30 may include any number and arrangement of battery cells 24, cell expansion pads 46, and cell spacers 48.

[0056] The thermal energy level within the battery cells 24 of the battery array 22 can increase as the electrified vehicle 10 operates. A thermal management system can be used to manage the thermal energy level of the battery cells 24 of the battery array 22. The thermal management system can be configured to direct coolant C through the battery array 22 to manage the thermal energy within the battery array 22 by, for example, absorbing heat from the battery cells 24 of the battery pack 30 using coolant C.

[0057] In one embodiment, the thermal management system is an immersion thermal management system, wherein a portion of the cell stack 30 (here, at least a portion of the battery cells 24) may be immersed in a coolant C. Thermal energy can be transferred between the coolant C and the battery cells 24 as the coolant C flows over and / or around the battery cells 24 within the array housing 32. For example, the coolant C can help manage the thermal levels of the battery cells 24 and other components of the battery array 22, such as busbars 42.

[0058] The thermal management system can deliver coolant C to the interior region of the battery array 22 through inlet 50 of array housing 32. Coolant C can fill one or more open areas inside the battery array 22, such that the battery cells 24 are immersed in and in direct contact with the coolant C. Coolant C can absorb heat from the battery cells 24 to manage heat levels. Coolant C can exit the battery array 22 through outlet 52 of array housing 32. In one embodiment, both inlet 50 and outlet 52 are formed through the bottom cover 36 of array housing 32. However, other inlet 50 and / or outlet 52 locations are contemplated within the scope of this disclosure.

[0059] Coolant C exiting through outlet 52 can move to a heat exchange device (not shown), such as a heat exchanger, where heat can be transferred from coolant C to the atmosphere. As part of a closed-loop system, a pump (not shown) can be operated to selectively circulate coolant C between battery array 22 and the heat exchange device, and then back to battery array 22.

[0060] The coolant C circulating in the immersion thermal management system can be a dielectric fluid designed for immersion cooling of the battery cell 24 or another type of non-conductive fluid (e.g., oil). However, other non-conductive fluids may also be suitable, and the actual chemical composition and design characteristics (e.g., dielectric constant, maximum breakdown strength, boiling point, etc.) may vary depending on the environment in which the battery array 22 is employed.

[0061] In another embodiment, the thermal management system is a conventional cold plate system, wherein a coolant C (such as ethylene glycol) circulates through a cold plate (not shown) to thermally manage the heat generated by the battery cell 24. Therefore, the teachings of this disclosure are not limited to battery arrays having an immersion thermal management system. In a cold plate type thermal management system, the battery cell 24 is not immersed in the coolant C.

[0062] Continue to refer to Figures 2 to 4 In this case, Figures 5 to 6 Additional details associated with the busbar frames 40 of the cell stack 30 are shown. As further described below, in addition to positioning and holding the busbars 42 relative to the battery cells 24, each busbar frame 40 may also include features designed to facilitate mechanical fastenerless (i.e., without the use of screws, bolts, rivets, etc.) connections relative to the array housing 32 and the cell spacers 48, and each busbar frame 40 may also include features for establishing coolant flow channels for guiding the coolant C of the thermal management system above, below, and / or around the battery cells 24 for thermal management of the battery array 22.

[0063] Each busbar frame 40 may include a top wall 56, a bottom wall 58, opposing end walls 60 connecting the top wall 56 and the bottom wall 58, a first side 63, and a second side 65. In the assembled state of the battery array 22, the top wall 56 faces the top cover 34 of the array housing 32, the bottom wall 58 faces the bottom cover 36 of the array housing 32, the first side 63 of the busbar frame 40 faces and abuts against the battery cells 24 and cell spacers 48 of the cell stack 30, and the second side 65 faces and abuts against the busbars 42 of the cell stack 30. The busbars 42 can be mounted to the second side 65 of the busbar frame 40.

[0064] Multiple cell terminal openings 62 can be formed through the busbar frame 40. Therefore, the busbar frame 40 can have a trapezoidal frame design. The cell terminal opening 62 can be an elongated slot opening through both the first side 63 and the second side 65 to accommodate the terminals 44 of the battery cells 24. In one embodiment, each cell terminal opening 62 can accommodate one terminal 44 from a single battery cell 24 in the cell stack 30. In another embodiment, the size of each cell terminal opening 62 can be designed to receive terminals 44 from multiple adjacent battery cells 24 in the cell stack 30.

[0065] One or more support legs 64 may project outward from both the top wall 56 and the bottom wall 58 of the busbar frame 40 (see...) Figure 5 ), protruding only from the top wall 56 (see Figure 7 ), or simply protruding outward from the bottom wall 58 (see Figure 8The total number, size, shape, and position of the support legs 64 may depend on the structure and assembly requirements of the battery array 22, as well as other factors. Therefore, this disclosure is not intended to be limited to the specific design shown in the figures.

[0066] Each leg 64 can be configured to establish an interface between the busbar frame 40 and the top cover 34 and / or bottom cover 36 of the array housing 32. Each leg 64 may each include a flat surface 66 for directly securing the busbar frame 40 to the array housing 32.

[0067] The legs 64 may be spaced apart from each other along the top wall 56 and / or the bottom wall 58 to provide a gap 70 in the busbar frame 40. The distance between adjacent legs 64 of the busbar frame 40 (and thus the size of the gap 70) may depend on the structural and assembly requirements of the battery array 22 and other factors.

[0068] Currently, the main reference is... Figures 9 to 10 Adhesive 68 can be applied to the flat surface 66 of each leg 64 to directly secure the busbar frame 40 to the top cover 34 and / or bottom cover 36 of the array housing 32. Adhesive 68 can be epoxy resin, thermal interface material, compressible material, etc. Notably, adhesive 68 is not a mechanical fastener, such as a screw, bolt, or rivet. Therefore, the legs 64 can facilitate a fastenerless mechanical connection between the busbar frame 40 and the array housing 32. Advantageously, this fastenerless connection does not require drilling through any part of the array housing 32, which prevents coolant C leakage. The proposed design also saves packaging space by eliminating the need for external or internal mechanical fasteners to establish the connection between the busbar frame 40 and the array housing 32.

[0069] With the battery array 22 assembled, each gap 70 of the busbar frame 40 can establish a coolant flow channel 72 (see...). Figure 9 A coolant flow channel 72 is provided between the cell stack 30 and the array housing 32 to allow coolant C, circulated by the thermal management system, to flow between the array housing 32 and the cell stack 30. The coolant flow channel 72 provides space between the cell stack 30 and the array housing 32 to allow coolant C to flow above and / or below the top of the battery cells 24 for immersion cooling of the cell stack 30.

[0070] Currently, the main reference is... Figure 5 , Figure 6 and Figure 11 One or more retainers 74 may be disposed on a first side 63 of the busbar frame 40. Each retainer 74 may provide an interface for engaging the cell spacer 48 to the busbar frame 40. In one embodiment, each retainer 74 is U-shaped. However, other configurations are contemplated within the scope of this disclosure.

[0071] Adhesive 76 (see) can be used Figure 11 The cell spacer 48 is secured within the retainer 74. For example, the adhesive 76 can be an epoxy-based adhesive or a polyurethane-based adhesive. Once adhesively secured within the retainer 74, the cell spacer 48 and / or busbar frame 140 are substantially restrained and cannot move, thereby increasing the structural integrity of the battery array 22. The adhesive 76 can also be used to seal any gas paths between the busbar frame 40 and the cell spacer 48, thus preventing heat from moving between adjacent battery cell groups of the cell stack 30.

[0072] Figures 12 to 14 Another exemplary busbar frame 140 that can be utilized within the aforementioned battery array 22 is shown. The busbar frame 140 is similar to the busbar frame 40 described above. However, in this exemplary embodiment, the busbar frame 140 includes a modified retainer 174 for engaging the cell spacers 48.

[0073] For example, each retainer 174 may include one or more pairs of flexible hook structures 180. The flexible hook structures 180 may be configured to move relative to the busbar frame 140 as the cell spacer 48 is inserted into the retainer 174. As the cell spacer moves further into the retainer 174, the flexible hook structures 180 may bend outward away from the cell spacer 48 and then bend inward toward the cell spacer 48. The flexible hook structures 180 may engage slots 182 formed in the cell spacer 48 to retain the cell spacer 48 relative to the busbar frame 140.

[0074] The exemplary battery array disclosed herein includes a busbar frame with novel features for facilitating internal connectivity and thermal management of the battery array. The busbar frame includes legs that facilitate a mechanically fastener-free design and establish coolant flow channels for circulating coolant through the array for thermal management. The busbar frame also provides cell spacer holders for providing a structurally integrated array design.

[0075] While different non-limiting embodiments are shown having specific components or steps, the embodiments disclosed herein are not limited to those particular combinations. Some of the components or features from any of the non-limiting embodiments may be used in combination with features or components from any of the other non-limiting embodiments.

[0076] It should be understood that the same reference numerals identify corresponding or similar elements throughout all the figures. It should be understood that although particular arrangements of components are disclosed and shown in these exemplary embodiments, other arrangements may also benefit from the teachings of this disclosure.

[0077] The foregoing description should be interpreted as illustrative and not restrictive. Those skilled in the art will understand that certain modifications may be made within the scope of this disclosure. For these reasons, the appended claims should be examined to determine the true scope and content of this disclosure.

Claims

1. A battery array for a traction battery pack, comprising: Array housing; as well as A battery cell stack, housed within the array housing and comprising a plurality of battery cells arranged between a first busbar frame and a second busbar frame. Each of the first busbar frame and the second busbar frame includes a first leg configured to dock with the array housing.

2. The battery array of claim 1, wherein the first leg abuts against the top cover of the array housing, and optionally, the battery array includes an adhesive disposed between the flat surface of the first leg and the top cover.

3. The battery array according to claim 1 or 2, wherein the first leg abuts against the bottom cover of the array housing, and optionally, the battery array includes an adhesive disposed between the flat surface of the first leg and the bottom cover.

4. The battery array according to any of the preceding claims, wherein the first leg abuts against the top cover of the array housing, and the second leg of each of the first busbar frame and the second busbar frame abuts against the bottom cover of the array housing, and optionally, the battery array includes a first adhesive disposed between a first flat surface of the first leg and the top cover and a second adhesive disposed between a second flat surface of the second leg and the bottom cover.

5. The battery array according to any of the preceding claims, wherein each of the first busbar frame and the second busbar frame includes a second leg configured to dock with the array housing, and further wherein a gap extends between the first leg and the second leg, and optionally wherein the gap establishes a coolant flow channel within the array housing.

6. The battery array according to any of the preceding claims, wherein each of the first busbar frame and the second busbar frame includes a retainer configured to dock with a cell spacer of the cell stack.

7. The battery array of claim 6, wherein the retainer is U-shaped, and the battery array further comprises an adhesive disposed between the retainer and the cell spacer.

8. The battery array of claim 6, wherein the retainer comprises a pair of flexible hook structures configured to engage slots formed in the cell spacers.

9. A battery array for a traction battery pack, comprising: Array housing; as well as A battery cell stack, housed within the array housing and comprising a plurality of battery cells and a plurality of cell spacers, the plurality of battery cells and the plurality of cell spacers being arranged to extend laterally between a first busbar frame and a second busbar frame. Each of the first busbar frame and the second busbar frame includes: a first leg configured to dock with the array housing; And a first retainer configured to dock with a first cell spacer among the plurality of cell spacers.

10. The battery array of claim 9, wherein the first retainer is U-shaped, and the battery array further comprises an adhesive disposed between the first retainer and the first cell spacer.

11. The battery array of claim 9, wherein the first retainer comprises a pair of flexible hook structures configured to engage slots formed in the first cell spacer.

12. The battery array according to any one of claims 9 to 11, wherein the first leg abuts against the top cover of the array housing, and the battery array includes an adhesive disposed between the flat surface of the first leg and the top cover.

13. The battery array according to any one of claims 9 to 11, wherein the first leg abuts against the bottom cover of the array housing, and the battery array includes an adhesive disposed between the flat surface of the first leg and the bottom cover.

14. The battery array according to any one of claims 9 to 11, wherein the first leg is mated to the top cover of the array housing, and the second leg of each of the first busbar frame and the second busbar frame is mated to the bottom cover of the array housing.

15. The battery array according to any one of claims 9 to 14, wherein each of the first busbar frame and the second busbar frame includes a second leg configured to dock with the array housing, and further wherein a gap extends between the first leg and the second leg, and optionally wherein the gap establishes a coolant flow channel within the array housing.

Images