ELECTRICALLY CONDUCTIVE DEVICE

Abstract

An electrically conductive element can include a first opening and a second opening. The first opening of the electrically conductive element can engage with a first element of a cell carrier to align the electrically conductive element at least partially with the cell carrier. The second opening of the electrically conductive element can engage with a second element of the cell carrier to couple the electrically conductive element to the cell carrier.

Description

INTRODUCTION

[0001] An electric vehicle includes battery cells connected to an electrically conductive element to provide power to the electric vehicle. SUMMARY

[0002] The present disclosure relates to a bus bar for a battery module. The bus bar may have at least one opening engageable with an insert (e.g., a pin) of a battery cell carrier (e.g., a box, a battery module box), wherein the pin may hot-stamp the bus bar to the cell carrier. The bus bar may include at least a second opening to receive at least one zero-point positioner (e.g., a two-way positioner and a four-way positioner) protruding from the cell carrier. The bus bar may include an overmold member, wherein the overmold member includes at least one retaining arm engaging an opening of the cell carrier to couple the bus bar and the overmold to the cell carrier. The bus bar may include a rim connectable (e.g.,welded). The busbar may include a module-to-module (“M2M”) terminal block. The M2M block may be coupled to the busbar, for example, by a welding process; the M2M terminal block may be a separate component coupled to the busbar, so that the M2M terminal block may include a different thickness or coating than the busbar. The busbar overmolding may include a retaining device to hold a cable (e.g., a ribbon cable of a voltage sense cable) to the busbar. The busbar overmolding may include, for example, a first retaining member for holding the end of the voltage sense cable and a second retaining member for holding a thermistor wire.

[0003] At least one aspect is directed to a device. The device may be an electrically conductive element. The electrically conductive element may include a first opening and a second opening. The first opening of the electrically conductive element may engage a first element of a cell carrier to at least partially align the electrically conductive element with the cell carrier. The second opening of the electrically conductive element may engage a second element of the cell carrier to couple the electrically conductive element to the cell carrier.

[0004] At least one aspect is directed to a system. The system may include a busbar, a cell carrier, and an element. The cell carrier may include a cell carrier opening. The element may include a support arm and an element opening. The support arm of the element may engage the cell carrier opening to couple the element to the cell carrier. The element opening may receive a projection of the cell carrier. The projection may be configured to expand within the element opening to couple the busbar to the cell carrier.

[0005] At least one aspect relates to a method. The method may include engaging a positioner of a cell carrier with a positioning opening of a busbar. The positioner may at least partially align the busbar with the cell carrier. The method may include engaging a hot-stamping insert of the cell carrier with a hot-stamping insert opening of the busbar, the hot-stamping insert serving to couple the busbar to the cell carrier.

[0006] These and other aspects and implementations are explained in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations and provide an overview or framework for understanding the nature and character of the claimed aspects and implementations. The drawings provide an illustrative representation and further understanding of the various aspects and implementations and are incorporated into this specification. The foregoing information and the following detailed descriptions and drawings include illustrative examples and should not be considered limiting. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The attached drawings are not to scale. Identical numbers and designations in the various drawings indicate identical elements. For clarity, not every component needs to be identified in every drawing. They show: Fig. 1 shows an exemplary electric vehicle according to some aspects. Fig. 2 shows an example of a battery pack according to some aspects. Fig. 3 shows an example of a battery module according to some aspects. Fig. 4 shows an example of a battery pack with a bus bar arrangement according to some aspects. Fig. 5 shows an example of a battery pack with a bus bar arrangement according to some aspects. Fig. 6 shows an example of a terminal block of a busbar assembly according to some aspects. Fig. 7 shows an example of a battery pack with a bus bar arrangement according to some aspects. Fig. 8 shows an example of a current collector coupled to a busbar assembly according to some aspects. Fig. 9 shows an example of a pantograph according to some aspects. Fig. 10 shows an example of a terminal block of a busbar assembly according to some aspects. Fig. 11 shows an example of a terminal block of a busbar assembly according to some aspects. Fig. 12 shows an example of a support arm of a busbar assembly according to some aspects. Fig. 13 shows an example of a support arm of a busbar assembly according to some aspects. Fig. 14 shows an example of a support arm of a busbar assembly according to some aspects. Fig. 15 is a detailed view of an example busbar assembly according to some aspects. Fig. 16 shows an example of a busbar assembly retention clip according to some aspects. Fig. 17 shows a cross-sectional view of an example battery cell according to some aspects. Fig. 18 shows a cross-sectional view of an example battery cell according to some aspects. Fig. 19 shows a cross-sectional view of an example battery cell according to some aspects. Fig. 20 is a flowchart of an example method for installing a bus bar assembly according to some aspects. DETAILED DESCRIPTION

[0008] The following describes in more detail various concepts related to and implementations of busbar methods, devices, and systems for battery packs or battery modules. The concepts introduced above and explained in detail below can be implemented in numerous ways.

[0009] The present disclosure relates to a bus bar for a battery module. The bus bar may include at least one opening engageable with an insert (e.g., a pin) of a cell carrier (e.g., a box, a battery module box, or other carrier), wherein the pin may hot-stamp the bus bar to the cell carrier. The bus bar may include at least a second opening to receive at least one zero-point positioner (e.g., a two-way positioner and a four-way positioner) protruding from the cell carrier. The bus bar may include an overmold member, wherein the overmold member includes at least one retaining arm extending therefrom. The retaining arm may engage an opening (e.g., a slot) of the cell carrier to couple the bus bar and the overmold to the cell carrier.The busbar may include an edge that can be connected (e.g., welded) to a fold-down flap of a module current collector. The busbar may include a module-to-module (“M2M” terminal block). The M2M block may be coupled to the busbar, for example, through a welding process; the M2M terminal block may be a separate component coupled to the busbar, so the M2M terminal block may include a thickness that differs from a thickness of the busbar. Because the busbar and the M2M terminal block may be separate components, the busbar may be coated, while the M2M terminal block may be uncoated (e.g., with no coating or a different type of coating). The busbar overmolding may include a retaining device to hold a cable (e.g., a ribbon cable of a voltage sense cable) to the busbar.The retaining device may, for example, be a prong, a clip, a latch, a cage, or other device. The busbar overmold may include a first retaining element for retaining the end of the voltage sensing cable and a second retaining element for retaining a thermistor wire.

[0010] Fig. 1 illustrates an exemplary cross-sectional view 100 of an electric vehicle 105 having at least one battery pack 110 installed therein. Electric vehicles 105 may include, but are not limited to, electric trucks, electric sport utility vehicles (SUVs), electric delivery vans, electric automobiles, electric cars, electric motorcycles, electric scooters, electric passenger vehicles, electric passenger or commercial vehicles, hybrid vehicles, or other vehicles such as marine or air transport vehicles, airplanes, helicopters, submarines, boats, or drones. The battery pack 110 may also be used as an energy storage system to power a building, such as a residence or commercial building. Electric vehicles 105 may be fully electric or partially electric (e.g., plug-in hybrid), and further, electric vehicles 105 may be fully autonomous, partially autonomous, or unmanned. Electric vehicles 105 may also be human-operated or non-autonomous.Electric vehicles 105, such as electric trucks or cars, may include on-board battery packs 110, batteries 115, or battery modules 115, or battery cells 120 to power the electric vehicles. The electric vehicle 105 may include a chassis 125 (e.g., a frame, an internal framework, or a support structure). The chassis 125 may support various components of the electric vehicle 105. The chassis 125 may extend across a front portion 130 (e.g., a hood portion), a body portion 135, and a rear portion 140 (e.g., a trunk, payload, or trunk portion) of the electric vehicle 105. The battery pack 110 may be installed or placed within the electric vehicle 105. For example, the battery pack 110 may be installed on the chassis 125 of the electric vehicle 105 in one or more of the front section 130, the body section 135, and the rear section 140.The battery pack 110 may include or be connected to at least one bus bar, e.g., a current collector element. For example, the first bus bar 145 and the second bus bar 150 may include electrically conductive material to connect or otherwise electrically couple the battery 115, the battery modules 115, or the battery cells 120 to other electrical components of the electric vehicle 105 to provide electrical power to various systems or components of the electric vehicle 105.

[0011] Fig. 2 shows an exemplary battery pack 110. Referring to Fig. 2, the battery pack 110 may, among other things, provide power to the electric vehicle 105. Battery packs 110 may include any arrangement or network of electrical, electronic, mechanical, or electromechanical devices to provide power to any type of vehicle, such as the electric vehicle 105. The battery pack 110 may include at least one enclosure 200. The enclosure 200 may include at least one battery module 115 or at least one battery cell 120, as well as other battery pack components. The battery module 115 may be or include one or more groups of prismatic cells, cylindrical cells, pouch cells, or other form factors of the battery cells 120. The enclosure 200 may include a shield on the bottom of the battery module 115 to protect the battery module 115 and / or cells 120 from external influences, for example, when the electric vehicle 105 is traveling over rough terrain (e.g.,in the terrain, trenches, rocks, etc.). The battery pack 110 may include at least one cooling line 205 that may distribute fluid throughout the battery pack 110 as part of a heat / temperature control or heat exchange system, which may also include at least one thermal component (e.g., cold plate) 210. The thermal component 210 may be disposed relative to an upper submodule and a lower submodule, such as between the upper and lower submodules, among others. The battery pack 110 may include any number of the thermal components 210. For example, there may be one or more thermal components 210 per battery pack 110 or per battery module 115. At least one cooling line 205 may be coupled to, part of, or independent of the thermal component 210.

[0012] Fig. 3 shows exemplary battery modules 115 and Fig. 17, Fig. 18 and Fig. 19 shows an exemplary cross-sectional view of a battery cell 120. The battery module 115 may include at least one submodule. For example, the battery modules 115 may include at least a first (e.g., upper) submodule 300 or at least a second (e.g., lower) submodule 305. At least one thermal component 210 may be disposed between the upper submodule 300 and the lower submodule 305. For example, a thermal component 210 may be configured for heat exchange with a battery module 115. The thermal component 210 may be disposed or thermally coupled between the upper submodule 300 and the lower submodule 305. A thermal component 210 may also be thermally coupled to more than one battery module 115 (or more than two submodules 300, 305).The thermal components 210, which are shown adjacent to one another, may be combined into a single thermal component 210 that spans the size of one or more submodules 300 or 305. The thermal component 210 may be disposed, among other things, below the submodule 300 and above the submodule 305, between the submodules 300 and 305, on one or more sides of the submodules 300, 305. The thermal component 210 may be disposed, among other things, in sidewalls, cross members, structural supports, and various other components of the battery pack, such as in the battery pack 110 described above. The battery submodules 300, 305 may together form a battery module 115. In some examples, each submodule 300, 305 may be considered a complete battery module 115 rather than a submodule.

[0013] The battery modules 115 may each include a plurality of battery cells 120. The battery modules 115 may be disposed within the housing 205 of the battery pack 110. The battery modules 115 may include battery cells 120 that are, for example, cylindrical cells or prismatic cells. The battery module 115 may operate as a modular unit of battery cells 120. For example, a battery module 115 may draw current or electrical power from the battery cells 120 contained within the battery module 115 and provide the current or electrical power as output of the battery pack 110. The battery pack 110 may include any number of battery modules 115. For example, the battery pack may have one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, or any other number of battery modules 115 disposed within the housing 205.It should also be noted that each battery module 115 may include an upper submodule 300 and a lower submodule 305, possibly with a thermal component 210 between the upper submodule 300 and the lower submodule 305. The battery pack 110 may include or define a plurality of areas in which the battery module 115 and / or the cells 120 may be disposed. The battery modules 115 may be square, rectangular, round, triangular, symmetrical, or asymmetrical. In some examples, the battery modules 115 may have different shapes, such that some battery modules 115 are rectangular and other battery modules 115 are square, among other possibilities. The battery module 115 may include or define a plurality of slots, holders, or containers for a plurality of battery cells 120.It should be noted that the illustrations and descriptions illustrated herein are provided only as examples and are not intended to be limiting. For example, the battery cells 120 may be inserted into the battery pack 110 without the battery submodules 300 and 305. Among other things, the battery cells 120 may be arranged in the battery pack 110 in a cell-to-pack configuration without the submodules 300 and 305.

[0014] As in the Fig. 4 and Fig. 5, the battery pack 110 may include, among other things, a bus bar assembly 400. The bus bar assembly 400 may include at least one bus bar 405 (e.g., an electrically conductive element 405). The bus bar 405 may be an electrically conductive element capable of conducting electricity. The bus bar 405 may, for example, be coupled to the battery cells 120 of the battery pack 110. The battery pack 110 may include the submodule 300 and the submodule 305 housed in a cell carrier 430 (e.g., a box 430, a battery box 430, a battery module box 430). The battery pack 110 may include a bus bar 405 coupled to each of the submodules 300 or 305.For example, the battery pack 110 may include at least one bus bar 405 electrically coupled to a first submodule 300 and a second bus bar 405 electrically coupled to a second submodule 305. As shown in FIG. Fig. 4, the battery pack 110 may include, for example, a first bus bar 405 coupled to the submodule 300 (e.g., a first module) and a second bus bar 405 coupled to the submodule 305 (e.g., a second module). As shown in Fig. 5, the battery pack 110 may include, among other things, a single bus bar 405 electrically coupled to both the submodule 300 and the submodule 305.

[0015] The busbar 405 may be electrically coupled to the battery cells 120 of the submodule 300 or the battery cells of the submodule 305. For example, the busbar 405 may be electrically coupled to a current collector 465. The current collector 465 may be coupled to the battery cells 120 (e.g., multiple battery cells 120) of the submodule 300 or the submodule 305. For example, the current collector 465 may include an electrically conductive material to electrically couple to each of the battery cells 120 within the submodule 300 or the submodule 305. The busbar 405 can be electrically coupled to the current collector 465 such that the busbar 405 can be electrically coupled to one or more of the battery cells 120 (e.g., all of the battery cells 120) of the submodule 300 or the submodule 305. The busbar 405 can thus conduct current provided by the battery cells 120 of the battery pack 110.The battery pack 110 may include multiple bus bars 405 with different polarities. For example, a bus bar 405 may have a positive polarity and be coupled to a positive terminal of the battery cells 120. The bus bar 405 may have a negative polarity and be coupled to a negative terminal of the battery cells 120. For example, the bus bar 405 (e.g., the one shown in FIG. Fig. 5) electrically connect the submodule 300 or the submodule 305 in series to enable electrical coupling of the positive terminals of the battery cells 120 of one module to the negative terminals of the battery cells 120 of another module. Unless otherwise noted, the features of the busbar 405 discussed below apply to busbars 405 of positive, negative, or other polarity.

[0016] The battery pack 110 may include the bus bar 405 coupled to the cell carrier 430. For example, the bus bar 405 may be mechanically coupled to the cell carrier 430. The bus bar 405 may be mechanically coupled to the cell carrier 430, with the bus bar 405 also being electrically coupled to the current collector 465. As shown in the Fig. 4 and Fig. 5, a busbar assembly 400 may include, among other things, the busbar 405 and a member 440 (e.g., an overmolding member 440), each of which may include one or more features to facilitate the arrangement and coupling of the busbar 405 with respect to the cell carrier 430. For example, the busbar 405 may include at least a first opening. The first opening may be a zero positioner opening, e.g., a first zero positioner opening 410 or a second zero positioner opening 415. For example, the busbar 405 may include a zero positioner opening 410 and a zero positioner opening 415. The zero positioner opening 410 and the zero positioner opening 415 may be openings (e.g., holes, apertures) defined through the busbar 405.The zero positioner opening 410 and the zero positioner opening 415 can be configured to receive at least one zero positioner to position the busbar 405 relative to the cell carrier 430.

[0017] The cell carrier 430 may, for example, include a first element. The first element may include a first zero positioner 425 or a second zero positioner 427. The cell carrier 430 may, for example, include at least one first zero positioner 425 and at least one second zero positioner 427. The first zero positioner 425 may engage (e.g., be received) with the first zero positioner 410. The second zero positioner 427 may engage (e.g., be received) with the second zero positioner opening 415. For example, the first zero positioner 425 may be a two-way zero positioner capable of positioning the busbar 405 in two directions (e.g., left and right), with the first zero positioner 425 engaging with the first zero positioner opening 410 of the busbar 405.The second zero-point positioner 427 may be a four-way zero-point positioner that can position the busbar 405 in four directions (e.g., left, right, up, down), with the second zero-point positioner 427 engaging (e.g., received) in the second zero-point positioner opening 415 of the busbar 405. For example, the busbar 405 may be aligned or at least partially aligned with the cell carrier 430 with the first zero-point positioner 425 engaging the first zero-point positioner opening 410 and the second zero-point positioner 427 engaging the second zero-point positioner opening 415. The busbar 405 may be aligned with the cell carrier 430 with the busbar 405 at or within a certain distance (e.g.,within two inches in either direction) of a position in which the bus bar 405 will be once coupled to the cell carrier 430, such as after a hot stamping operation, as described below with reference to FIG. Fig. 4 to 6. For example, the bus bar 405 may be partially aligned with the cell carrier 430, with a portion of the bus bar 405 (e.g., a side, an edge) lying at or within a certain distance (e.g., within two inches in any direction) of a position in which the bus bar 405 lies once coupled to the cell carrier 430. The bus bar 405 may be aligned with the cell carrier 430, with the bus bar 405 being arranged to couple to the current collector 465, as described below with reference to Fig. 9 and Fig. 10. For example, the position of the bus bar 405 on the cell carrier 430 may be a position in which the bus bar 405 may be coupled to the cell carrier 430 or electrically coupled to the current collector 465. For example, the bus bar 405 may be electrically coupled to the current collector 465 with the bus bar 405 at least partially aligned with the cell carrier 430 via an engagement between the first zero positioner 425 within the first zero positioner opening 410 and via an engagement between the second zero positioner 427 and the second zero positioner opening 415.

[0018] The busbar 405 may include at least a second opening 420. The second opening 420 may, for example, be a hot-stamp insert opening 420 that can receive a hot-stamp insert to couple the busbar 405 to the cell carrier 430. The opening 420 may, for example, be an opening defined by the busbar 405 (e.g., a hole, a cutout). The opening 420 may engage (e.g., receive) a projection 435 of the cell carrier 430. For example, the cell carrier 430 may include at least one projection 435 extending therefrom. The projection 435 may be an insert 435 (e.g., a hot-stamp insert 435). The projection 435 may expand when heated or otherwise exposed to heat.For example, the protrusion 435 may be configured to deform over the opening 420 of the bus bar 405 when heated to couple the bus bar 405 to the cell support 430. The diameter of the protrusion 435 may increase along at least a portion of the length of the protrusion as the protrusion is heated (e.g., by a heat gun or other heating device). An initial diameter of the protrusion 435 may be selected such that the protrusion 435 can be received within the opening 420 of the bus bar 405. For example, the protrusion 435 (or the cell support 430 more broadly) may be made of a polymeric or composite material that can be melted, deformed, expanded, or otherwise changed in shape when heated.

[0019] As in Fig. 6, the projection 435 may, among other things, have an end portion 605 after the projection 435 has been exposed to heat (e.g., during a hot stamping process). For example, the end portion 605 of the projection 435 may, after exposure to heat (e.g., during a hot stamping process), have a diameter 610 that may be larger than the diameter of the opening 420 of the busbar 405. The diameter 610 may be larger than the diameter of the opening 420, such that the end portion 605 of the projection 435 cannot fit through the opening 420. For example, the projection 435 may not be expanded prior to a hot stamping process, as described, among other things, in the Fig. 4-5, the protrusion 435 may extend through the opening 420 prior to the hot stamping process. Then, when the protrusion 435 extends at least partially through the opening 420, heat may be applied to the protrusion 435 to transform (e.g., melt, deform, shape) the protrusion 435 to create the end portion 605 having the diameter 610. The end portion 605 may be or include a disc- or puck-shaped element that may have the diameter 610. Because the diameter 610 may be larger than the diameter of the opening 420, the end portion 605 of the protrusion 435 may prevent the busbar 405 from separating from the cell carrier 430. For example, the busbar 405 may be coupled to the cell carrier 430, wherein the projection 435 of the box extends through the opening 420 of the busbar 405 and the projection 435 is hot stamped (e.g.to produce the end portion 605, which has the diameter 610).

[0020] The busbar 405 may include a plurality of openings 420, and each opening 420 may include a projection 435 of the cell carrier 430. Each of the projections 435 may expand when exposed to heat (e.g., during a hot stamping process) to cause the projection 435 to form the end portion 605 having the diameter 610. Each of the end portions 605 may couple the busbar 405 to the cell carrier 430. For example, the busbar 405 may be rigidly coupled to the cell carrier 430, with the projections 435 of the cell carrier 430 extending through the openings 420 of the busbar 405 and being hot stamped to form the end portions 605.By using at least one projection 435 engaging at least one opening 420, the busbar 405 can be coupled to the cell carrier 430 without requiring an adhesive between the busbar 405 and the cell carrier 430 to couple the busbar 405 to the cell carrier 430. For example, the busbar 405 can be coupled to the cell carrier 430 without requiring an adhesive between the busbar 405 and the cell carrier 430.

[0021] As in the Fig. 4-6, the bus bar assembly 400 may include, among other things, the overmold member 440. The overmold member 440 may be a polymer layer (e.g., a plastic layer) that can be coupled to at least one side of the bus bar 405. For example, the overmold member 440 may be a polymer element that can be molded over the bus bar 405 (e.g., by injection molding, compression molding, or otherwise) such that the overmold member 440 can be coupled to the bus bar 405. The overmold member 440 can generally conform to a form factor or shape of the bus bar 405. The overmold member 440 may have a shape or form factor that is different from a shape or form factor of the bus bar 405. The overmolding element 440 may include at least one holding arm 445 (e.g., a positioning arm 445), at least one overmolding opening 450 (e.g.,a hot stamping insert opening 450) and at least one zero point opening 480. The support arm 445 of the overmolding member 440 can engage an opening 455 (e.g., a support arm opening 455) of the cell carrier 430. For example, the cell carrier 430 can define at least one opening 455. The opening 455 can be an opening (hole, through-hole, opening, indentation, depression, pocket, or other feature) formed in the cell carrier 430. For example, the opening 455 can be a depression in the cell carrier 430 that can receive at least one support arm 445 of the overmolding member 440, as described below with reference to FIG. Fig. 11 to 13. The zero point opening 480 may coincide with (e.g., be at least partially aligned with, at least partially concentric with) the first zero point positioner opening 410 or the second zero point positioner opening 415 of the busbar 405.

[0022] The overmold opening 450 may be an opening (e.g., a cutout, a hole, or other opening) defined by the overmold member 440. The overmold opening 450 may be at least partially aligned with the opening 420 of the busbar 405. For example, the overmold opening 450 may be coaxial with the opening 420 of the busbar 405. The overmold opening 450 may have a diameter that is larger than the diameter of the opening 420. For example, the overmold opening 450 may have a diameter that is two, three, four, or some other multiple larger than the diameter of the opening 420. At least a portion of the busbar 405 may be visible through the overmold opening 450. For example, as shown in Fig. 6, among other things, because the overmold opening 450 may have a diameter that is larger than the diameter of the opening 420 of the bus bar 405, a portion of the bus bar 405 may be visible between an edge of the overmold opening 450 and an edge of the opening 420 of the bus bar 405. The overmold element 440 may enclose the overmold opening 450 with a diameter that is larger than the diameter 610 of the end portion 605 of the projection 435 after exposure to heat (e.g., a hot stamping process). For example, the projection 435 of the cell carrier 430 may extend at least partially through the opening 420 of the bus bar 405 and at least partially through the overmold opening 450. As described above, the projection 435 may expand (e.g., deform, melt, change shape) when exposed to heat (e.g.,during a hot stamping process) so that the end portion 605 of the protrusion 435 can form. The end portion 605 of the protrusion 435 can have a diameter 610 that is larger than the diameter of the opening 420 to couple the busbar 405 to the cell carrier 430. The end portion 605 can include a diameter 610 that is smaller than the diameter of the overmolding opening 450 so that the end portion 605 can be disposed on the busbar 405 and within the overmolding opening 450. For example, the end portion 605 can be flush with an outer surface of the overmolding element 440 or recessed relative to the overmolding element 440. The end portion 605 can extend beyond an outer surface of the overmolding element 440.

[0023] As in the Fig. 6-8, the bus bar assembly 400 may include the bus bar 405 coupled to a terminal block 600. The terminal block 600 may be an electrically conductive block that extends from the bus bar 405 (e.g., perpendicularly from the bus bar). For example, the terminal block 600 may be a metallic component that can conduct electricity to facilitate electrical coupling to the bus bar 405. The terminal block 600 may be a separate component that can be provided with the bus bar 405. For example, the terminal block 600 may be welded to the bus bar 405 (e.g., by laser welding or another process). The terminal block 600 may be a separate component that is provided with the bus bar 405, rather than being stamped or otherwise manufactured to form a unit with the bus bar 405. The terminal block 600 can be connected to another object (e.g.another bus bar, another bus bar coupled to another module, or another component). For example, the terminal block 600 may be electrically coupled directly or indirectly to another battery module (e.g., the submodule 300 or the submodule 305). The terminal block 600 may therefore facilitate the electrical coupling of the bus bar 405 to another component, such as another module (e.g., the submodule 300 or the submodule 305 or another bus bar 405 coupled to another module). The terminal block 600 may include a surface 705 to facilitate the electrical coupling of the terminal block 600 to another object. The terminal block 600 may include at least one coupling feature 800. As shown in FIG. Fig. For example, as shown in Figure 8, the terminal block 600 may include the coupling feature 800 in the form of an opening (e.g., a hole, an aperture, a threaded opening, or other opening) that may facilitate the mechanical coupling (e.g., attachment) of the terminal block 600 to another object. The coupling feature 800 may be an opening that passes completely or partially through the terminal block 600.

[0024] As in the Fig. 7 and Fig. 8, the terminal block 600 may, among other things, be provided with an interface 700 to the bus bar 405. The interface 700 may, for example, be an interface between a side of the terminal block 600 and an outer surface 725 of the bus bar 405. The terminal block 600 and the bus bar 405 may be electrically coupled via a contact between the terminal block 600 and the bus bar 405 at the interface 700. For example, the terminal block 600 may be welded (e.g., laser welded) to the bus bar 405 to electrically couple the terminal block 600 to the bus bar 405. For example, the terminal block 600 may be provided with a joint 715 at the interface 700. The joint 715 may be a portion of the busbar 405 that is provided with the terminal block 600 to mechanically couple the busbar 405 to the terminal block 600.The joint 715 may be a region of the busbar 405 adjacent to the interface 700. The joint 715 may, for example, be a weld joint 715. The weld joint 715 may be formed on or in a region of the busbar 405 adjacent to the interface 700. For example, the weld joint 715 may include a portion of the busbar 405 and a portion of the terminal block 600 at the interface 700, which may be fused, melted, or otherwise joined. The busbar 405 may be coupled to the terminal block 600 through a welding process to create the weld joint 715. For example, the terminal block 600 may be laser welded to the busbar 405 to mechanically and electrically couple the terminal block 600 to the busbar 405. A laser welding device may direct a laser beam onto a region of the busbar 405 adjacent to the interface 700 (e.g.align, deliver, provide). For example, the laser welding device may direct the laser beam onto a surface 710 (e.g., an inner surface 710) of the busbar 405, where the laser beam may penetrate the terminal block 600 via the busbar 405 to create the weld groove 715.

[0025] The terminal block 600 may have a terminal block material thickness 730 that may be greater than the material thickness 735 of the bus bar 405. Because the terminal block 600 may be a separate component from the bus bar 405, the bus bar 405 and the terminal block 600 may, for example, be made of or include a separate material with a separate thickness or gauge. For example, the terminal block 600 may include the terminal block material thickness 730, which may be greater (e.g., two times greater, three times greater, or some other multiple) than the material thickness 735 of the bus bar 405. The greater terminal block material thickness 730 may provide improved thermal properties of the terminal block 600 or the bus bar 405 when the terminal block 600 or the bus bar 405 conducts electricity.

[0026] The greater material thickness of the terminal block 730 provides a larger weld joint 715 between the terminal block 600 and the busbar 405. For example, the terminal block 600 may be coupled to an outer surface 725 of the busbar 405 at the interface 700. Because the terminal block 600 includes a material thickness 730 that may be greater than the material thickness 735 of the busbar 405, the weld joint 715 that connects the busbar 405 to the terminal block 600 may also be larger. The greater thickness of the weld joint 715 may provide greater mechanical strength of the weld joint 715. The greater thickness of the weld joint 715 may provide improved thermal properties when the busbar 405 and the terminal block 600 are electrically coupled.

[0027] The terminal block 600 may include a coating or the absence of a coating. The bus bar 405 may include a coating. Because the bus bar 405 and the terminal block may be separate components, the coating of the terminal block 600 does not need to be the same as the coating of the bus bar 405. For example, the bus bar 405 may undergo a coating process to obtain a first coating. The first coating may be an aluminum, copper, nickel, or other coating. The bus bar 405 may remain uncoated (e.g., without any coating). For example, the bus bar 405 may not undergo a coating process, such that the bus bar 405 is uncoated. The bus bar 405 may include the absence of a coating, such that the bus bar 405 is at least partially uncoated.The terminal block 600 may undergo a coating process separate from the coating of the busbar 405. For example, the terminal block 600 may undergo a coating process to obtain a second coating that is different from the first coating. The second coating may be a nickel plating, such as electroless nickel plating, or another coating. The terminal block 600 may remain uncoated. Because the terminal block 600 may include a coating (or lack of coating) that is different from the coating (or lack of coating) of the busbar 405, the coating for the terminal block 600 and the busbar 405 may be selected independently to optimize different parameters, such as electrical conductivity, weld adhesion, thermal properties, or another parameter.

[0028] The terminal block 600 may be coupled to the bus bar 405 to form a corner 720. For example, the terminal block 600 and the bus bar 405 may form the corner 720, where the corner 720 may be a sharp corner. The corner may be a 90° corner or a corner that has a different angle (e.g., 80°, 70°, 60°, or another angle). Since the bus bar 405 and the terminal block 600 may be separate components, the terminal block 600 may be coupled to the bus bar 405 at the interface 700. For example, one side of the terminal block 600 may abut the surface 725 of the bus bar 405 to form the interface 700, where the abutment of the terminal block 600 and the bus bar 405 forms the corner 720.

[0029] As in Fig. 9 and Fig. 10, among other things, the bus bar 405 may be coupled to the current collector 465. For example, the bus bar 405 may be electrically coupled to the current collector 465. The current collector 465 may include a tab 920. The tab 920 may be an electrically conductive element or a portion of the current collector 465 that may extend over an edge 910 of the bus bar 405. As previously mentioned, the bus bar 405 may, for example, be coupled to the cell carrier 430. In particular, the bus bar 405 may be coupled to a side of the cell carrier 430 such that the edge 910 of the bus bar 405 is disposed at or near (e.g., within one centimeter) an upper or lower level of the cell carrier 430.The current collector 465 can be disposed on the top or bottom of the cell carrier 430 to electrically couple to each of the battery cells 120 within the submodule 300 or the submodule 305, or within the cell carrier 430 (e.g., box, battery box, battery module box). For example, the current collector 465 can be disposed on or within an upper or lower level of the cell carrier 430, with the bus bar 405 disposed on one side of the cell carrier 430 and the edge 910 of the bus bar 405 disposed on or near the same upper or lower level of the cell carrier 430. The current collector 465 can include the tab 920 extending a length 1000 from the current collector 465. For example, the tab 920 may extend from an edge 1010 of the pantograph over a length 1000. The tab 920 may have a width 1005.The tab 920 may include a first portion 900 and a second portion 905. The first portion 900 may be a proximal portion of the tab 920 located near (e.g., at or within one inch) the edge 1010 of the current collector 465. The second portion 905 may be a distal portion of the tab 920. For example, the second portion 905 may be an outermost portion of the tab 920. The length 1000 of the tab 920 and the width 1005 of the tab 920 may be dimensionally optimized to maximize a surface area of ​​the tab 920 that may be available for electrically coupling the tab 920 to the bus bar 405.

[0030] The tab 920 may extend from the current collector 465 over the length 1000 such that the tab 920 may contact the edge 910 of the bus bar 405. The edge 910 of the bus bar 405 may be an exposed portion of the bus bar 405 that may be electrically coupled to the tab 920 of the current collector 465. For example, the edge 910 of the bus bar 405 may be a portion of the bus bar 405 that is not overmolded with the overmolding feature 440. Because the edge 910 is not overmolded with the overmolding feature 440, the edge 910 may facilitate the electrical coupling between the bus bar 405 and the tab 920 of the current collector 465. For example, the tab 920 may extend from the edge 1010 of the current collector 465 and over at least a portion of the edge 910 of the bus bar 405. The tab 920 may extend over (e.g., beyond) the edge 910 of the bus bar 405.The current collector 465 may be electrically coupled to the busbar 405 via a contact between the tab 920 and the edge 910 of the busbar 405. For example, the current collector 465 may be electrically coupled to the busbar 405 via a contact between the first portion 900 of the tab 920 and the edge 910 of the busbar 910. The first portion 900 of the tab 920 may be welded (e.g., laser welded) to the edge 910 of the busbar 405 to electrically couple the busbar 405 to the tab 920. For example, a laser welding device or other laser-emitting element may emit (e.g., align, deliver, aim) a laser beam in direction 915 (e.g., a downward direction) toward the first portion 900, where the first portion 900 is disposed at the edge 910 of the bus bar 405.For example, the laser welding device may output a laser beam in direction 915 to cause at least a portion of the tab 920 (e.g., the first portion 900) and at least a portion of the busbar 405 (e.g., the edge 910) to fuse, melt, or otherwise join. For example, the laser welding device may output a laser beam in direction 915 to create a weld seam between the tab 920 and the busbar 405 and to electrically couple the tab 920 to the busbar 405. As shown in FIG. Fig. 9 and Fig. 10, the current collector 465 may include, among other things, a plurality of tabs 920, each of which may be coupled (e.g., by a laser welding process) to the edge 910 of the bus bar 405 to electrically couple the current collector 465 to the bus bar 405. The tab 920 may be coupled to the edge 910 of the bus bar 405 by another process, such as ultrasonic welding, friction welding, electrically conductive adhesive, or another joining process.

[0031] The current collector 465 may include the tab 920 that folds over the edge 910 of the bus bar 405. For example, the current collector 465 may include the tab 920 that extends a length 1000 such that the tab 920 extends beyond the edge 910 of the bus bar 405. The tab 920 may extend beyond the edge 910 of the bus bar 405 such that the tab 920 may extend a length 930 along a surface 935 of the bus bar 405. For example, the second portion 905 of the tab 920 may fold over the edge 910 and along the surface 935 of the bus bar 405. Surface 935 of busbar 405 may be a portion of outer surface 725 of busbar 405 that is exposed (e.g., not overmolded with overmolding element 440). For example, surface 935 of busbar 405 may be an exposed, electrically conductive portion of busbar 405.The surface 935 may include a height 925. The height 925 may be a distance between the overmolding feature 440 and the edge 910 of the busbar 405. For example, the height 925 may be a height of the busbar 405 that is not overmolded with the overmolding feature 440. The tab 920 (e.g., the second portion 905 of the tab 920) may extend the length 930 along the surface 935 of the busbar 405, with the tab 920 folded over the edge 910 of the busbar 405. For example, the tab 920 may extend the length 930 along the surface 935 of the busbar, with the length 930 being at least 50% of the height 925 of the surface 935. The tab 920 can be folded over the edge 910 and extend the length 930 along the surface 935, wherein the tab 920 is electrically coupled to the edge 910 of the busbar.The second portion 905 of the tab 920 may be electrically coupled to the surface 935 of the busbar 405. For example, the second portion 905 may be welded or otherwise connected to the surface 935. The second portion 905 may be folded over the edge 910 and along the surface 935 without being mechanically or electrically coupled to the surface 935. For example, the second portion 905 may be folded over the edge 910 or may be capable of being folded over the edge 910 but may remain uncoupled to the surface 935. The length 930 over which the tab 920 extends along the surface 935 may be a length 930 over which the tab 920 would extend along the surface 935 if the tab 920 (e.g., the second portion 905) were disposed (butted) against the surface 935.

[0032] The current collector 465 may include a tab edge 940 that is spaced a distance 945 from a side 950 of the bus bar 405. For example, the current collector 465 may include an outermost tab 920. The outermost tab 920 may be a tab 920 that is closest (among the various tabs 920 of the current collector 465) to the side 950 of the bus bar 405. The outermost tab 920 may include a tab edge 940 that is parallel or at least partially parallel to the side 950 of the bus bar 405. For example, the side 950 of the bus bar 405 may be a surface of the bus bar 405 that is perpendicular or at least partially perpendicular to the surface 935 of the bus bar 405.The tab edge 940 of the outermost tab 920 may be spaced 945 from the side 950 of the busbar 405, where the distance 945 may be less than one centimeter, less than eight millimeters, 7.4 millimeters, or another distance. For example, the distance 945 may be a relatively small distance (e.g., less than thirty millimeters) because the tab 920 may have a width 1005 sufficient to cover a substantial portion (e.g., more than 80%) of the surface of the edge 910 of the busbar 405. The distance 945 may be 7.4 millimeters, less than 7.4 millimeters, or more than 7.4 millimeters.

[0033] As in the Fig. 11 through 13, the overmolding member 440 may include the retaining arm 445 (e.g., the positioning arm 445) that engages the cell carrier 430 to couple the busbar 405 to the cell carrier 430. For example, the busbar 405 may be coupled to the overmolding member 440, and the retaining arm 445 of the overmolding member 440 may engage the cell carrier 430 to couple the busbar 405 and the overmolding member 440 to the cell carrier 430. The retaining arm 445 may include a tip 1100 (e.g., an end 1100, a distal end 1100) that can be inserted into the opening 455 of the cell carrier 430. For example, the support arm 445 may extend from the overmolding element 440 toward the cell carrier 430, with the busbar 405 disposed between the overmolding element 440 and the cell carrier 430. The support arm 445 may extend around the busbar 405 (e.g.,around an outer side). The support arm 445 may extend through an opening 1105 (e.g., a support arm opening 1105) of the busbar 405. As shown in . Fig. 12, the retaining arm 445 may, for example, include the tip 1100 extending through the opening 1105 of the bus bar 405 before ultimately engaging the opening 455 of the cell carrier 430. The retaining arm 445 may include a first portion 1200 (e.g., a proximal end 1200). The first portion 1200 may extend from the overmolding member 440 in a direction opposite or different from a direction in which the tip 1100 extends. For example, the first portion 1200 may extend from the overmolding member 440 away from the cell carrier 430 or away from the bus bar 405, with the bus bar 405 disposed between the overmolding member 440 and the cell carrier 430. The first portion 1200 may be a looped or curved portion of the support arm 445 extending from an outer surface of the overmolding member 440.

[0034] The support arm 445 may include a support portion 1110. The support portion 1110 may be a projection, a sharp edge, a raised edge, or other feature extending from the support arm 445 near (e.g., within one inch, within one centimeter, or another length) the tip 1100. The support portion 1110 may be tapered. For example, the support portion 1110 may be tapered toward the tip 1100 of the support arm 445. The support portion 1110 may extend from the support arm 445 to engage a wall 1400 of the cell carrier 430. For example, the wall 1400 may be a wall that at least partially defines the opening 455 of the cell carrier 430. As shown in Fig. 13, the retention portion 1110 may, among other things, extend from the retention arm 445 to engage a rear surface 1305 of the wall 1300. The engagement (e.g., contact) between the retention portion 1110 and the wall 1300 may at least partially prevent the retention arm 445 from being removed or disengaged from the opening 455 of the cell carrier 430. For example, the engagement between the retention portion and the wall 1300 may at least partially prevent the overmolding member 440 from being separated from the cell carrier 430. The retention portion 1110 of the retention arm 445 of the overmolding member 440 may engage the opening 455 of the cell carrier 430 with the busbar 405 at least partially disposed between the overmolding member 440 and the cell carrier 430.For example, the holding portion 1110 of the holding arm 445 of the overmolding element 440 can engage the opening 455 of the cell carrier 430 to hold the busbar 405 and the overmolding element 440 to (e.g., against) the cell carrier 430.

[0035] The support arm 445 may be flexible or have at least some degree of elasticity. For example, the support arm 445 may be made of or include a polymeric material (e.g., a polymeric material used to overmold an entirety of the overmolding member 440). The support arm 445 may flex slightly to facilitate engagement or disengagement of the support arm 445 with the opening 455 of the cell carrier 430. For example, the support arm 445 may flex to allow the support arm 445 to enter or exit the opening 455 in a manner that is substantially unobstructed (e.g., at least 50% unobstructed) or substantially unobstructed (e.g., at least 50% unobstructed) by engagement between the support portion 1110 and the wall 1400 of the opening 455. The support arm 445 may bend when the tip 1100 is inserted into the opening 455.The retaining element can spring outward (e.g., toward the wall 1400) once the retaining portion 1110 moves past the wall 1400. The retaining arm 445 can be pushed or bent inward (e.g., away from the wall 1400) to release the retaining portion 1110 from the wall 1400, allowing the retaining portion 1110 and the tip 1100 to exit the opening 455. For example, the retaining arm 445 can be bent to release the retaining arm 445 from the opening 455 of the cell carrier 430.

[0036] The retaining arm 445 can releasably couple the busbar 405 and the overmolding element 440 to the cell carrier 430. For example, the retaining arm 445 can engage the opening 455 of the cell carrier 430 to position the busbar 405 and the overmolding element 440 relative to the cell carrier 430. The projection 435 of the cell carrier 430 can be hot-stamped (e.g., by localized heat) to form the end portion 605 on the projection 435 to rigidly couple the busbar 405 and the overmolding element 440 to the cell carrier 430. For example, the support arm 445 may engage the opening 455 of the cell carrier 430 while the first zero positioner 425 engages the first zero positioner opening 410 and while the second zero positioner 427 engages the second zero positioner opening 415 to releasably (e.g., temporarily) position the bus bar 405 and the overmolding element 440 on the cell carrier 430.The projection 435 of the cell carrier 430 may be hot stamped (e.g., by localized heat) to form the end portion 605 on the projection 435 to rigidly couple the busbar 405 and the overmolding member 440 to the cell carrier 430, with the retaining arm 445 engaging the opening 455 of the cell carrier 430, the first zero positioner 425 engaging the first zero positioner opening 410, and the second zero positioner 427 engaging the second zero positioner opening 415. The retaining arm 445 (e.g., the positioning arm 445) may facilitate the proper placement of the overmolding member 440 and the busbar 405 on the cell carrier 430.For example, engagement of the retaining arm 445 with the opening 455 of the cell carrier 430 may at least partially align the busbar 405 and the overmolding element 440 with the cell carrier 430 even without the first zero point positioner 425 or the second zero point positioner 427. The at least partial alignment of the busbar 405 and the overmolding element 440 with the cell carrier 430 may include, for example, aligning the edge 910 of the busbar 405 with the tab 920 of the current collector 465. The at least partial alignment of the busbar 405 and the overmolding element 440 with the cell carrier 430 may include aligning the projection 435 of the cell carrier 430 with the opening 420 of the busbar 405 to facilitate hot stamping or coupling the busbar 405 to the cell carrier 430.

[0037] As in Fig. 4 and in detail in the Fig. 14 and Fig. 15, the bus bar assembly 400 may include a retention clip 460. The retention clip 460 may be formed integrally with the overmolding member 440. For example, the retention clip 460 may be part of the overmolding member 440 or may be molded integrally therewith. The retention clip 460 may be a separate component coupled to the overmolding member 440. The retention clip may retain a cable 475, such as a ribbon cable 475. The cable 475 may include a connector 470. The connector 470 may facilitate the electrical connection of the cable 475 to another object, such as a battery voltage temperature monitor 1410 ("BVT" 1410) shown in Fig. 14. For example, the cable 475 may be a cable connected to a voltage monitoring device, such as a voltage sensing harness (VSH), which may monitor a voltage of the submodule 300 or the submodule 305. For example, the VSH may be coupled to the current collector 465 and include at least one voltage sensor to measure a voltage of the current collector 465, where the current collector 465 is coupled to the battery cells 120. The BVT 1410 may be a monitor, a module, a controller, or other device. The BVT 1410 may be coupled to the cell carrier 430, the bus bar assembly 400, or another component of the battery pack 110. For example, the BVT 1410 may monitor a voltage of the submodule 300, the submodule 305, or both the submodule 300 and the submodule 305 via a VSH coupled to the corresponding current collector 465.The BVT 1410 can monitor the voltage based on data or information provided by the VSH via cable 475 and connector 470.

[0038] As in Fig. 15, the overmolding member 440 may include, among other things, the retention clip 460 to retain the cable 475 to the overmolding member 440. For example, the retention clip 460 may include a first end 1500 and a second end 1505. The first end 1500 may be a free end 1500 that can be separated from the overmolding member 440 or selectively engaged with the overmolding member 440. For example, the first end 1500 may contact the overmolding member 440 via a spring force of the retention clip 460 (e.g., a biasing force that holds the first end 1500 to the overmolding member 440). The first end 1500 can be selectively separated from the overmolding member 440 to allow an object—such as the cable 475—to pass between the first end 1500 and the overmolding member 440. The first end 1500 can be secured to the overmolding member 440.For example, the first end 1500 may be attached, clipped, or otherwise connected to the overmolding member 440. The first end 1500 may then be detached, pinched, or released from the overmolding member 440 to allow an object—such as the cable 475—to pass between the first end 1500 and the overmolding member 440. The second end 1505 of the retaining clip 1505 may be coupled to the overmolding member 440. For example, the second end 1505 may be integrally molded with the overmolding member 440. The second end 1505 may be rigidly coupled to the overmolding member 440. The second end 1505 may be pivotally coupled to the overmolding member 440 such that the retaining clip 460 may rotate about the second end 1505 to allow an object, such as the cable 475, to pass between the retaining clip 460 and the overmolding member 440.

[0039] The retention clip 460 can hold the cable 475 to the overmolding member 440. For example, the retention clip 460 can enclose the first end 1500 and the second end 1505 of the retention clip 460 to apply a force to the cable 475 to cause the cable 475 to be pressed against the overmolding member 440. The retention clip 460 can enclose the first end 1500 and the second end 1505 of the retention clip 460 to prevent the cable 475 from detaching from the overmolding member 440. For example, the retention clip 460 can enclose the first end 1500 and the second end 1505 of the retention clip 460 to prevent the cable 475 from detaching from the overmolding member 440 by more than a certain distance (e.g., one centimeter, one inch).

[0040] The BVT 1410 may monitor a temperature of the submodule 300, the submodule 305, both the submodule 300 and the submodule 305, or another component of the battery pack 110. As in Fig. 14, for example, a cable 1405 may be coupled to the BVT 1410 to provide data or information regarding a temperature measurement to the BVT 1410. The cable 1405 may be a thermistor cable 1405. As shown in the Fig. 4, Fig. 14 and Fig. 16, the busbar assembly 400 may include at least one retention member 1400 coupled to a mounting feature 485 of the overmolding member 440. The overmolding member 440 may include the mounting feature 485 to which the retention member 1400 may be coupled. The mounting feature 485 may be, for example, a projection, bump, or raised surface of the overmolding member 440. The mounting feature 485 may be a recess, depression, or depressed surface of the overmolding member 440. The mounting feature 485 may include one or more raised edges. The mounting feature 485 may include at least one opening (e.g., an opening, depression, hole, threaded hole, or other feature). For example, the mounting feature 485 may include a threaded hole or a threaded pin to which the retaining element 1400 may be coupled.The mounting feature 485 may be integrally molded with the overmolding element 440. The overmolding element 485 may be a separate component coupled to the overmolding element 440.

[0041] The retaining element 1400 may be a clip, a loop, a clamp, or other retaining element that can hold the cable 1405. For example, the overmolding element 440 can be coupled to the retaining element 1400 such that the retaining element 1400 can hold the cable 1405 to the overmolding element 440. As shown in Fig. 16, the retention member 1400 may be, among other things, a clip or a loop that may define an opening 1600. The cable 1405 may be received within the opening 1600. For example, the cable 1405 may be received within the opening 1600 such that the retention member 1400 at least partially surrounds the cable 1405. The retention member 1400 may completely surround the cable 1405, with the cable 1405 disposed within the opening 1600. The cable 1405 may be retained on the overmolding member 440 with the cable 1405 within the opening 1600 of the retention member 1400. For example, the cable 1405 may be prevented or substantially prevented (e.g., prevented by at least 95%) from becoming detached from the overmolding member 440 or the busbar assembly 400.The cable 1405 can be passed through the opening 1600 to retain the cable 1405 to the overmolding member 440, making it less likely that the cable 1405 will be pinched, pulled, tugged, or otherwise damaged. The retaining member 1400 can be integrally formed with the overmolding member 440 or can be a separate component that can be coupled to the overmolding member 440.

[0042] As in the Fig. 17 to 19, the battery cell 120 may have a variety of form factors, shapes, or sizes, among others. For example, the battery cells 120 may have a cylindrical, rectangular, square, cubic, flat, pouch, oblong, or prismatic form factor. As shown in Fig. 17, the battery cell 120 may, for example, be cylindrical. As shown in Fig. 18, the battery cell 120 may, for example, be prismatic. As shown in Fig. 19, the battery cell 120 may include, for example, a pouch form factor. The battery cells 120 may be arranged, for example, by inserting a wound or stacked electrode roll (e.g., a jelly roll) including an electrolyte material into at least one battery cell housing 1700. The electrolyte material, e.g., an electrically conductive fluid or other material, may support electrochemical reactions at the electrodes to generate, store, or provide electrical power to the battery cell by enabling the conduction of ions between a positive and a negative electrode. The battery cell 120 may include an electrolyte layer, where the electrolyte layer may be or may include a solid electrolyte material capable of conducting ions. For example, the solid electrolyte layer may conduct ions without receiving a separate liquid electrolyte material.The electrolyte material, e.g., an electrically conductive fluid or other material, can promote ionic conduction between the electrodes to generate or provide electrical power to the battery cell 120. The housing 1700 can have various shapes, including, for example, cylindrical or rectangular. Electrical connections can be made between the electrolyte material and the components of the battery cell 120. For example, electrical connections to the electrodes can be formed with at least a portion of the electrolyte material at two points or regions of the battery cell 120, for example, to form a first polarity terminal 1705 (e.g., a positive terminal or anode terminal) and a second polarity terminal 1710 (e.g., a negative terminal or cathode terminal).The polarity terminals may be made of electrically conductive material to conduct electrical current from the battery cell 120 to an electrical load, such as a component or system of the electric vehicle 105.

[0043] For example, battery cell 120 may include at least one lithium-ion battery cell. In lithium-ion battery cells, lithium ions may be transferred between a positive and a negative electrode during charging and discharging of the battery cell. For example, the battery cell anode may include lithium or graphite, and the battery cell cathode may include a lithium-based oxide material. The electrolyte material may be disposed within battery cell 120 to separate the anode and cathode and facilitate the transfer of lithium ions between the anode and cathode. It should be noted that battery cell 120 may also be configured as a solid-state battery cell using solid electrodes and solid electrolytes. Solid electrodes or electrolytes may be inorganic solid electrolyte materials (e.g.,Oxides, sulfides, phosphides, ceramics), solid polymer electrolyte materials, hybrid solid-state electrolytes, or combinations thereof. In some embodiments, the solid electrolyte layer may include polyanionic or oxide-based electrolyte material (e.g., superionic lithium conductors (LISICONs), superionic sodium conductors (NASICONs), perovskites with the formula ABO3 (A = Li, Ca, Sr, La and B = Al, Ti), garnet-type with the formula A3B2(XO4)3 (A = Ca, Sr, Ba and X = Nb, Ta), lithium phosphorus oxynitride (Li. x PO y N z ). In some embodiments, the solid electrolyte layer may include a glassy, ​​ceramic and / or crystalline sulfide-based electrolyte (e.g., Li3PS4, Li7P3S 11 , Li2S-P2S5, Li2S-B2S3, SnS-P2S5, Li2S-SiS2, Li2S-P2S5, Li2S-GeS2, Li 10 GeP2S 12) and / or sulfide-based lithium argyrodites with the formula Li6PS5X (X = Cl, Br) such as Li6PS5Cl. Furthermore, solid polymer electrolyte materials may include a polymer electrolyte material (e.g., a hybrid or pseudo-solid-state electrolyte), e.g., polyacrylonitrile (PAN), polyethylene oxide (PEO), polymethyl methacrylate (PMMA), and polyvinylidene fluoride (PVDF), among others.

[0044] The battery cell 120 may be enclosed in the battery modules 115 or battery packs 110 to power components of the electric vehicle 105. The battery cell housing 1700 may be disposed in the battery module 115, the battery pack 110, or a battery array installed in the electric vehicle 105. The housing 1700 may have any shape, such as, but not limited to, a cylindrical shape with a circular shape (e.g., as shown, among others, in Fig. 17), elliptical or oval base. The shape of the housing 1700 can also be prismatic with a polygonal base, as in Fig. 18. As shown in Fig. 19, the housing 1700 may include, among other things, a pouch form factor. The housing 1700 may include other form factors, such as a triangle, a square, a rectangle, a pentagon, and a hexagon, among others. In some embodiments, the battery pack may not include battery modules (e.g., module-free). For example, the battery pack may have a "module-free" or "cell-to-pack" configuration, where the battery cells are arranged directly within a battery pack without being arranged in a module.

[0045] The housing 1700 of the battery cell 120 may include one or more materials with different electrical conductivity or thermal conductivity, or a combination thereof. The electrically conductive and thermally conductive material for the housing 1700 of the battery cell 120 may include a metallic material, such as, but not limited to, aluminum, an aluminum alloy with copper, silicon, tin, magnesium, manganese, or zinc (e.g., 1000, 4000, or 5000 series aluminum), iron, an iron-carbon alloy (e.g., steel), silver, nickel, copper, and a copper alloy. The electrically insulating and thermally conductive material for the housing 1700 of the battery cell 120 may include, but not limited to, a ceramic material (e.g., and including, silicon nitride, silicon carbide, titanium carbide, zirconium dioxide, beryllium oxide) and a thermoplastic material (e.g., polyethylene, polypropylene, polystyrene, polyvinyl chloride, or nylon).In examples where the housing 1700 of the battery cell 120 is prismatic (e.g., as shown in, among others, . Fig. 18) or cylindrical (e.g. as shown in Fig. 17), the housing 1700 may include a rigid or semi-rigid material such that the housing 1700 is rigid or semi-rigid (e.g., cannot be easily deformed or fabricated into a different shape or form factor). In examples where the housing 1700 has a pouch form factor (e.g., as shown in, among others, Fig. 19), the housing 1700 may include a flexible, deformable, or non-rigid material so that the housing 1700 may be bent, deformed, or machined into a different form factor or shape.

[0046] The battery cell 120 may include at least one anode layer 1715, which may be disposed in the cavity 1720 defined by the housing 1700. The anode layer 1715 may include a first redox potential. The anode layer 1715 may accept electrical current into the battery cell 120 and release electrons during operation of the battery cell 120 (e.g., charging or discharging the battery cell 120). The anode layer 1715 may include an active substance. The active substance may be, for example, activated carbon or a material interspersed with conductive materials (e.g., artificial or natural graphite or a mixture thereof), lithium titanate (Li4Ti5O 12) or a silicon-based material (e.g., silicon metal, oxide, carbide, pre-lithiated) or other lithium alloy anodes (Li-Mg, Li-Al, Li-Ag alloy, etc.) or composite anodes consisting of lithium and carbon, silicon and carbon, or other compounds. The active substance may be graphitic carbon (e.g., ordered or disordered carbon with sp 2-hybridization), a Li-metal anode, or a silicon-based carbon composite anode, or other anodes made of lithium alloys (Li-Mg, Li-Al, Li-Ag alloy, etc.), or composite anodes made of lithium and carbon, silicon and carbon, or other compounds. In some examples, an anode material may be formed within a current collector material. For example, an electrode may include a current collector (e.g., copper foil) with an in-situ formed anode (e.g., Li-metal) on a surface of the current collector facing the separator or solid electrolyte. In such examples, the assembled cell does not include an anode active material in an uncharged state.

[0047] The battery cell 120 may include at least one cathode layer 1725 (e.g., a composite cathode layer, interconnect cathode layer, interconnect cathode, composite cathode, or cathode). The cathode layer 1725 may include a second redox potential that may be different from the first redox potential of the anode layer 1715. The cathode layer 1725 may be disposed within the cavity 1720. The cathode layer 1725 may deliver electrical current from the battery cell 120 and may accept electrons during discharging of the battery cell 120. The cathode layer 1725 may also accept lithium ions during discharging of the battery cell 120. Conversely, the cathode layer 1725 may deliver electrical current into the battery cell 120 and may deliver electrodes during charging of the battery cell 120. The cathode layer 1725 can release 120 lithium ions during charging of the battery cell.

[0048] The battery cell 120 may include a layer 1730 disposed within the cavity 1720. The layer 1730 may include a solid electrolyte layer. The layer 1730 may include a separator wetted by a liquid electrolyte. The layer 1730 may include a polymer material. The layer 1730 may include a polymer separator. The layer 1730 may be disposed between the anode layer 1715 and the cathode layer 1725 to separate the anode layer 1715 and the cathode layer 1725. The polymer separator may physically separate the anode and cathode from a cell short circuit. A separator may be wetted with a liquid electrolyte. The liquid electrolyte may be diffused into the anode layer 1715. The liquid electrolyte can be diffused into the cathode layer 1725. The layer 1730 can help to trap ions (e.g., Li +-ions) between the anode layer 1715 and the cathode layer 1725. The layer 1730 can be used during the discharge process of the battery cell 120 Li + -cations are transferred from the anode layer 1715 to the cathode layer 1725. The layer 1730 can transfer lithium ions from the cathode layer 1725 to the anode layer 1715 during the charging process of the battery cell 120.

[0049] The redox potential of layers (e.g., the first redox potential of the anode layer 1715 or the second redox potential of the cathode layer 1725) may vary based on a chemistry of the respective layer or a chemistry of the battery cell 120. For example, lithium-ion batteries may include an LFP (lithium iron phosphate) chemistry, an LMFP (lithium manganese iron phosphate) chemistry, an NMC (nickel manganese cobalt) chemistry, an NCA (nickel cobalt aluminum) chemistry, an OLO (overlithiated oxide) chemistry, or an LCO (lithium cobalt oxide) chemistry for a cathode layer (e.g., the cathode layer 1725). Lithium-ion batteries may include a graphite chemistry, a silicon-graphite chemistry, or a lithium metal chemistry for the anode layer (e.g., the 1715 anode layer).

[0050] For example, lithium-ion batteries can contain olivine phosphate (LiMPO4, M = Fe and / or Co and / or Mn and / or Ni)), LISICON or NASICON phosphates (Li3M2(PO4)3 and LiMPO4Ox , M = Ti, V, Mn, Cr and Zr), for example lithium iron phosphate (LFP), lithium iron manganese phosphate (LMFP), examples of layered oxides (LiMO2, M = Ni and / or Co and / or Mn and / or Fe and / or Al and / or Mg), NMC chemistry (nickel manganese cobalt), an NCA chemistry (nickel cobalt aluminum) or an LCO chemistry (lithium cobalt oxide) for a cathode layer, lithium-rich layered oxides (Li1+ x M 1-x O2) (Ni and / or Mn and / or Co), (OLO or LMR), spinel (LiMn2O4) and high voltage spinels (LiMn 1,5 Ni 0,5 O4), disordered rock salt, fluorophosphates Li2FePO4F (M = Fe, Co, Ni), and fluorosulfates LiMSO4F (M = Co, Ni, Mn) (e.g., the cathode layer 1725). Lithium-ion batteries can include a graphite chemistry, a silicon-graphite chemistry, or a lithium metal chemistry for the anode layer (e.g., the anode layer 1715). For example, a cathode layer with an LFP chemistry can have a redox potential of 3.4 V versus Li / Li+ while an anode layer with a graphite chemistry has a redox potential of 0.2 V compared to Li / Li + can have.

[0051] Electrode layers may include anode active material or cathode active material, typically in addition to a conductive carbon material, a binder, and other additives, as well as a coating on a current collector (metal foil). The chemical composition of the electrode layers can influence the redox potential of the electrode layers. For example, cathode layers (e.g., the 1725 cathode layer) may include lithium transition metal oxide with a medium to high nickel content (50 to 80% or equal to 80% Ni), such as a particulate lithium nickel manganese cobalt oxide ("LiNMC"), a lithium nickel cobalt alumina ("LiNCA"), a lithium nickel manganese cobalt alumina ("LiNMCA"), or lithium metal phosphates, such as lithium iron phosphate ("LFP") and lithium iron manganese phosphate ("LMFP"). Anode layers (e.g., anode layer 21715) may include conductive carbon materials such as graphite, carbon black, carbon nanotubes, and the like.Anode layers can include, for example, Super P carbon black, Ketjen black, acetylene black, SWCNT, MWCNT, graphite, carbon nanofiber or graphene.

[0052] Electrode layers may also include chemical bonding materials (e.g., binders). Binders may include polymer materials such as polyvinylidene fluoride ("PVDF"), polyvinylpyrrolidone ("PVP"), styrene-butadiene or styrene-butadiene rubber ("SBR"), polytetrafluoroethylene ("PTFE"), or carboxymethylcellulose ("CMC").Binder materials may include: agar, alginate, amylose, gum arabic, carrageenan, casein, chitosan, cyclodextrins (carbonyl-beta), ethylene propylene diene monomer (EPDM) gum, gelatin, gellan gum, guar gum, karaya gum, cellulose (natural), pectin, poly(3,4-ethylenedioxythiophene)polystyrenesulfonate (PEDOT-PSS), polyacrylic acid (PAA), poly(methyl acrylate) (PMA), poly(vinyl alcohol) (PVA), poly(vinyl acetate) (PVAc), polyacrylonitrile (PAN), polyisoprene (PIpr), polyaniline (PANi), polyethylene (PE), polyimide (PI), polystyrene (PS), polyurethane (PU), polyvinyl butyral (PVB), polyvinylpyrrolidone (PVP), starch, Styrene butadiene rubber (SBR), tara gum, tragacanth gum, fluoroacrylate (TRD202A), xanthan gum, or mixtures of any two or more thereof.

[0053] Current collector materials (e.g., a current collector foil to which an electrode active material is laminated to form a cathode layer or an anode layer) may include a metal material. For example, current collector materials may include aluminum, copper, nickel, titanium, stainless steel, or carbon-containing materials. The current collector material may be formed as a metal foil. For example, the current collector material may be an aluminum (Al foil) or copper (Cu foil) foil. The current collector material may be a metal alloy made of Al, Cu, Ni, Fe, Ti, or a combination thereof. The current collector material may be a metal foil coated with a carbon material, such as carbon-coated aluminum foil, carbon-coated copper foil, or another carbon-coated foil material.

[0054] Layer 1730 may include or be made of a liquid electrolyte material. For example, layer 1730 may be or include at least one layer of polymeric material (e.g., polypropylene, polyethylene, or other material), including pores that are wetted (e.g., saturated, soaked, filled, or accommodated) with a liquid electrolyte substance to enable the movement of ions between the electrodes. The liquid electrolyte material may include a lithium salt dissolved in a solvent. The lithium salt for the liquid electrolyte material for layer 1730 may include, for example, lithium tetrafluoroborate (LiBF4), lithium hexafluorophosphate (LiPF6), and lithium perchlorate (LiClO4), among others. The solvent may include, for example, dimethyl carbonate (DMC), ethylene carbonate (EC), and diethyl carbonate (DEC), among others.The liquid electrolyte is not necessarily located near layer 1730, but the liquid electrolyte can fill the battery cells 120 in various ways. Layer 1730 can include or be made of a solid electrolyte material, such as, but not limited to, a ceramic electrolyte material, a polymer electrolyte material, or a glassy electrolyte material, or any combination thereof.

[0055] In some embodiments, the solid electrolyte film may include at least one layer of a solid electrolyte. Solid electrolyte materials of the solid electrolyte layer may include inorganic solid electrolyte materials (e.g., oxides, sulfides, phosphides, ceramics), polymer solid electrolyte materials, hybrid solid-state electrolytes, or combinations thereof. In some embodiments, the solid electrolyte layer may include polyanionic or oxide-based electrolyte material (e.g., superionic lithium conductors (LISICONs), superionic sodium conductors (NASICONs), perovskites with the formula ABO3 (A = Li, Ca, Sr, La and B = Al, Ti), garnet-type with the formula A3B2(XO4)3 (A = Ca, Sr, Ba and X = Nb, Ta), lithium phosphorus oxynitride (Li x PO y N z ). In some embodiments, the solid electrolyte layer may include a glassy, ​​ceramic and / or crystalline sulfide-based electrolyte (e.g., Li3PS4, Li7P3S 11, Li2S-P2S5, Li2S-B2S3, SnS-P2S5, Li2S-SiS2, Li2S-P2S5, Li2S-GeS2, Li 10 GeP2S 12 ) and / or sulfide-based lithium argyrodites with the formula Li6PS5X (X = Cl, Br) such as Li6PS5Cl. Furthermore, solid polymer electrolyte materials may include a polymer electrolyte material (e.g., a hybrid or pseudo-solid-state electrolyte), e.g., polyacrylonitrile (PAN), polyethylene oxide (PEO), polymethyl methacrylate (PMMA), and polyvinylidene fluoride (PVDF), among others.

[0056] In examples where layer 1730 includes a liquid electrolyte material, layer 1730 may include a non-aqueous polar solvent. The non-aqueous polar solvent may include a carbonate such as ethylene carbonate, propylene carbonate, diethyl carbonate, ethyl methyl carbonate, dimethyl carbonate, or a mixture of any two or more thereof. Layer 1730 may include at least one additive. The additives may include vinylidene carbonate, fluoroethylene carbonate, ethyl propionate, methyl propionate, methyl acetate, ethyl acetate, or a mixture of any two or more thereof. Layer 1730 may include a lithium salt material. The lithium salt may be lithium perchlorate, lithium hexafluorophosphate, lithium bis(fluorosulfonyl)imide, lithium bis(trifluorosulfonyl)imide, or a mixture of any two or more thereof. The lithium salt may be present in layer 1730 from greater than 0 M to about 1.5 M.Once disposed within the battery cell 120, the liquid electrolyte may be present and contact the battery subcomponents present within the battery cell 120. The battery subcomponents may include the cathode, the anode, the separator, the current collector, etc.

[0057] Fig.20 illustrates, among other things, a method 2000. The method 2000 may be, for example, a method of installing a bus bar assembly 400 on a cell carrier 430. The method 2000 may include one or more ACTIVITIES 2005-2030. The method 2000 may include providing a bus bar assembly at ACTIVITY 2005. The bus bar assembly may be the bus bar assembly 400 described herein. The bus bar assembly 400 may include the bus bar 405 and the overmolding member 440. The bus bar 405 may be, for example, an electrically conductive component defining at least one opening 420. The bus bar 405 may include at least one first zero positioner opening 410 and at least one second zero positioner opening 415. The overmolding element 440 may be a polymeric element that is overmolded onto the busbar 405.The overmolding element 440 may include at least one support arm 445 and at least one opening 450. The opening 450 of the overmolding element 440 may align with the opening 420 of the busbar 405. The overmolding element 440 may include at least one opening 480 (e.g., holes, vias, apertures) that align with each of the first zero-point positioner openings 410 and each of the second zero-point positioner openings 415 of the busbar 405.

[0058] The method 2000 may include engaging a positioner in ACTIVITY 2010. For example, the method 2000 may include engaging at least one first zero positioner 425 and at least one second zero positioner 427 of the cell carrier 430 with the first zero positioner opening 410 and the second zero positioner opening 415 of the bus bar 405, respectively. The cell carrier 430 may include one or more first zero positioners 425 that are engageable with (e.g., received within, at least partially received by) the first zero positioner opening 410 of the bus bar 405. The engagement of the first zero positioner 425 of the cell carrier 430 with the first zero positioner opening 410 of the bus bar 405 may at least partially align the bus bar 405 with the cell carrier 430.For example, engagement of the first zero positioner 425 of the cell carrier 430 with the first zero positioner opening 410 of the bus bar 405 may restrict movement of the bus bar 405 relative to the cell carrier 430 in at least two directions (e.g., left and right). The cell carrier 430 may include one or more second zero positioners 427 that may engage (e.g., be received within, at least partially received by) the second zero positioner opening 415 of the bus bar 405. The engagement of the second zero positioner 427 of the cell carrier 430 with the second zero positioner opening 415 of the bus bar 405 may at least partially align the bus bar 405 with the cell carrier 430.For example, the engagement of the second zero positioner 427 of the cell carrier 430 with the second zero positioner opening 415 of the bus bar 405 may restrict movement of the bus bar 405 relative to the cell carrier 430 in at least four directions (e.g., left, right, up, and down).

[0059] The method 2000 may include engaging the retaining arm in ACT 2015. For example, the method 2000 may include engaging the retaining arm 445 of the overmolding member 440 with at least one opening 455 of the cell carrier 430. The opening 455 of the cell carrier 430 may be configured to receive a tip 1100 of the retaining arm 445. For example, the tip 1100 of the retaining arm 445 may be inserted into the opening 455 such that a retaining member 1110 of the retaining arm 445 may engage the wall 1300 of the cell carrier 430. The engagement between the retaining arm 445 and the wall 1300 of the cell carrier 430 may couple the overmolding member 440 to the cell carrier 430. For example, the overmolding element 440 can be detachably coupled to the cell carrier 430, wherein the holding arm 445 of the overmolding element 440 engages the opening 455 of the cell carrier 430.The support arm 445 can be coupled to the cell carrier 430, wherein the busbar 405 is at least partially arranged between the overmolding element 440 and the cell carrier 430.

[0060] The method 2000 may include engaging a hot stamping insert in OPERATION 2020. The method 2000 may include, for example, engaging the protrusion 435 (e.g., the hot stamping insert 435) of the cell carrier 430 with the opening 420 of the bus bar 405. The protrusion 435 may extend outwardly from the cell carrier 430 and engage (e.g., be received within) the opening 420 of the bus bar. The protrusion 435 may be made of or include a polymeric material such that the protrusion can be configured to expand, deform, or otherwise change shape when exposed to heat. OPERATIONS 2010 through 2020 may be performed concurrently or substantially concurrently.For example, the first zero positioner 425 may be received in the first zero positioner opening 410 and the second zero positioner 427 may be received in the second zero positioner opening 415 at the same time that the support arm 445 may engage the opening 455, which may also occur at the same time that the projection 435 may engage the opening 420.

[0061] The method 2000 may include applying heat in OPERATION 2025. For example, the method 2000 may include applying heat to the protrusions 435 of the cell carrier 430 in OPERATION 2025. In OPERATION 2025, heat may be applied to the protrusion 435 to expand, deform, or otherwise change the shape of the protrusion 435. For example, heat may be applied to the protrusion 435 as the protrusion 435 extends through the opening 420. Heat may be applied locally to the protrusion 435 (e.g., with a heat gun, iron, or other device, such as during a hot stamping process). The protrusion 435 may expand or deform to couple the busbar 405 to the cell carrier 430. For example, the application of heat to the protrusion 435 may result in the formation of an end portion 605 of the protrusion, wherein the end portion 605 may include the diameter 610.The diameter 610 may be larger than a diameter of the opening 420. Since the diameter 610 of the end portion 605 may be larger than the diameter of the opening 420, the end portion 605 may prevent the busbar 405 from detaching from the cell carrier 430.

[0062] The method 2000 may include coupling a current collector in ACTIVITY 2030. For example, the method 2000 may include coupling the current collector 465 to the bus bar 405. For example, the bus bar 405 may be disposed on the cell carrier 430, and the current collector 465 may be disposed on or along a bottom surface of the submodule 300 or the submodule 305. The current collector 465 may include at least one tab 920 extending beyond an edge 910 of the bus bar 405. For example, the tab 920 may extend beyond the edge 910 and be folded over the bus bar 405. The tab 920 of the current collector 465 may be electrically coupled to the bus bar 405. The tab 920 of the current collector 465 can be electrically coupled to the busbar 405. The tab 920 of the current collector 465 can be welded to the busbar 405.For example, a laser welding device or other device may emit (e.g., direct, deliver) a laser beam in direction 915 to weld the first portion 900 of the tab 920 to the edge 910 of the busbar 405. The busbar 405 may be electrically coupled to the battery cells 120 of the submodule 300 or the submodule 305 via the electrical coupling of the tab 920 of the current collector 465 to the edge 910 of the busbar 405.

[0063] Although the operations in the drawings are illustrated in a particular order, these operations are not required to be performed in the order shown, nor do all of the illustrated operations need to be performed. The actions described herein may be performed in a different order.

[0064] Having described some illustrative implementations, it is obvious that the foregoing is illustrative and not limiting, having been presented as an example. Although many of the examples presented herein involve specific combinations of procedures or system elements, these acts and elements may be combined in other ways to achieve the same goals. Acts, elements, and features discussed in connection with one implementation are not intended to preclude them from playing a similar role in other implementations.

[0065] The phraseology and terminology used herein is for the purpose of description and should not be considered limiting. The use of "including," "comprising," "including," "containing," "containing," "characterized by," "characterized in that," and variations thereof herein is intended to encompass the items listed below, their equivalents, and additional items, as well as alternative implementations consisting solely of the items listed below. In one implementation, the systems and methods described herein consist of one, any combination of more than one, or all of the described elements, acts, or components.

[0066] Any reference to implementations or elements or acts of the systems and methods referred to herein in the singular may also include implementations that include a plurality of those elements, and any reference to an implementation or element or act herein in the plural may also include implementations that include only a single element. References to the singular or plural are not intended to limit the presently disclosed systems or methods, their components, acts, or elements to any single or multiple configurations. References to an act or element being based on information, an act, or an element may include implementations where the act or element is based at least in part on information, an act, or an element.

[0067] Any implementation disclosed herein may be combined with any other implementation or embodiment, and references to "an implementation," "some implementations," "an implementation," or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described in connection with the implementation may be included in at least one implementation or embodiment. The terms used herein do not necessarily all refer to the same implementation. Any implementation may be combined with any other implementation, including, but not limited to, in any manner consistent with the aspects and implementations disclosed herein.

[0068] References to "or" can be understood as all-inclusive, so that any term described with "or" can refer to any one, more than one, or all of the described terms. References to at least one term from a conjunctive list of terms can be understood as an inclusive OR to refer to any one, more than one, or all of the described terms. For example, a reference to "at least one of "A" and "B"" can include only "A," only "B," or both "A" and "B." Such references, used in conjunction with "comprehensive" or other open-ended terminology, can include further items.

[0069] Where technical features are provided with reference signs in the drawings, the detailed description, or a claim, the reference signs have been included to enhance the clarity of the drawings, the detailed description, and the claims. Therefore, neither the reference signs nor their absence have any limiting effect on the scope of the individual claim elements.

[0070] Modifications to the described elements and acts, such as variations in sizes, dimensions, structures, shapes, and proportions of the various elements, values ​​of parameters, arrangements for mounting, use of materials, colors, and orientations, may occur without materially affecting the teachings and advantages of the subject matter disclosed herein. For example, elements depicted as integral may be comprised of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of individual elements or positions may be altered or varied. Other substitutions, modifications, changes, and omissions may also be made in the design, operating condition, and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure.

[0071] For example, descriptions of positive and negative electrical properties may be reversed. For example, bus bar 405 may be a negative bus bar or a positive bus bar. Elements described as negative elements may instead be configured as positive elements, and elements described as positive elements may instead be configured as negative elements. For example, elements described as having a first polarity may instead have a second polarity, and elements described as having a second polarity may instead have a first polarity. Other relative parallel, perpendicular, vertical, or other arrangement or orientation descriptions include variations within + / -10% or + / -10 degrees of the pure vertical, parallel, or perpendicular arrangement.References to "about," "substantially," or other terms include variations of + / -10% from the specified measurement, unit, or range unless expressly stated otherwise. Coupled elements may be electrically, mechanically, or physically coupled to one another, directly or with intervening elements. The scope of the systems and methods described herein is therefore indicated by the appended claims rather than the foregoing description, and changes that come within the meaning and range of equivalence of the claims are intended to be embraced therein.

Claims

[1] Facility comprising: an electrically conductive element having a first opening and a second opening; wherein the first opening is configured to engage a first member of a cell carrier to at least partially align the electrically conductive member with the cell carrier; and wherein the second opening is configured to engage a second element of the cell carrier to couple the electrically conductive element to the cell carrier. [2] Device according to claim 1, comprising: an edge configured to electrically couple the electrically conductive element to a tab of a current collector, the tab being folded over the edge when the electrically conductive element is coupled to the current collector. [3] Device according to claim 1, comprising: an edge configured to electrically couple the electrically conductive element to a tab of a current collector, the tab being folded over the edge when the electrically conductive element is coupled to the current collector, one side of the electrically conductive element being disposed less than 1 centimeter from a tab edge of the tab. [4] Device according to claim 1, comprising: the electrically conductive element coupled to an overmolding element, wherein the overmolding element comprises a retaining element configured to retain a cable to the overmolding element. [5] Device according to claim 1, comprising: the electrically conductive element coupled to an overmolding element, wherein the overmolding element comprises a retaining element and a retaining clip, wherein the retaining element is configured to retain a cable to the overmolding element, wherein the retaining clip is configured to retain a ribbon cable to the overmolding element. [6] Device according to claim 1, comprising: the second element of the cell carrier comprising a hot stamping insert, the hot stamping insert being configured to expand when heated to couple the electrically conductive element to the cell carrier. [7] Device according to claim 1, comprising: the second element of the cell carrier comprising a hot stamping insert, the hot stamping insert being configured to deform over the second opening when heated to couple the electrically conductive element to the cell carrier. [8] Device according to claim 1, comprising: the electrically conductive element coupled to an overmolding element, the overmolding element comprising an overmolding opening at least partially aligned with the second opening of the electrically conductive element; the second element of the cell carrier comprising a hot stamping insert, the hot stamping insert being configured to expand upon heating within the overmolding opening to couple the electrically conductive element to the cell carrier. [9] The device of claim 1, comprising the electrically conductive element coupled to an overmolding element, the overmolding element comprising a retaining arm configured to engage a cell carrier opening of the cell carrier to couple the overmolding element to the cell carrier, the electrically conductive element being at least partially disposed between the overmolding element and the cell carrier, the retaining arm engaging the cell carrier opening. [10] Device according to claim 1, comprising: the electrically conductive element coupled to an overmolding element, the overmolding element comprising a support arm and an overmolding opening, the support arm configured to engage a cell carrier opening of the cell carrier to couple the overmolding element to the cell carrier, the electrically conductive element being at least partially disposed between the overmolding element and the cell carrier, the support arm engaging the cell carrier opening; the second element of the cell carrier comprising a hot stamping insert, the hot stamping insert being configured to expand within the overmolding opening when heated to couple the electrically conductive element to the carrier. [11] Device according to claim 1, comprising: the electrically conductive element configured to be coupled to a terminal block, wherein the terminal block has a terminal block material thickness that is greater than a material thickness of the electrically conductive element. [12] Device according to claim 1, comprising: the electrically conductive element configured to be coupled to a terminal block, wherein the terminal block has a terminal block material thickness greater than a material thickness of the electrically conductive element, wherein the terminal block has a coating that is different from a coating of the electrically conductive element. [13] Device according to claim 1, comprising: the electrically conductive element configured to be coupled to a terminal block, the terminal block having a terminal block material thickness greater than a material thickness of the electrically conductive element, a corner being defined by the electrically conductive element and the terminal block, the electrically conductive element being coupled to the terminal block. [14] The device according to claim 1, wherein the electrically conductive element is a bus bar for a battery module, and wherein the cell carrier is a box for the battery module. [15] System comprising: a busbar; a cell carrier comprising a cell carrier opening; and an element comprising a support arm and an element opening, the support arm configured to engage the cell carrier opening to couple the element to the cell carrier; and the element opening configured to receive a projection of the cell carrier, the projection configured to expand within the element opening to couple the busbar to the cell carrier. [16] Device according to claim 15, comprising: the cell carrier including at least one positioning element that engages at least one positioning opening of the busbar to at least partially align the busbar and the element with the cell carrier. [17] Device according to claim 15, comprising: the member comprising a retaining member and a retaining clip, wherein the retaining member is configured to retain a cable to the overmolding member, and the retaining clip is configured to retain a ribbon cable to the overmolding member. [18] Method comprising: Engaging a positioner of a cell carrier with a positioning opening of a busbar, the positioner at least partially aligning the busbar with the cell carrier; Engaging a hot stamping insert of the cell carrier with a hot stamping insert opening of the busbar, wherein the hot stamping insert serves to couple the busbar to the cell carrier. [19] A method according to claim 18, comprising: Engaging a retaining arm of an overmolding element with a cell carrier opening of the cell carrier to couple the overmolding element to the cell carrier, wherein the busbar is at least partially disposed between the overmolding element and the cell carrier. [20] A method according to claim 18, comprising: Applying heat to the hot stamping insert of the cell carrier, whereby the hot stamping insert engages the opening of the busbar, whereby the hot stamping insert expands when heated to couple the busbar to the cell carrier.

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