BATTERY MODULE ARRANGEMENT

Abstract

A battery module can include features to support and protect its components from external stress and certain electrical conditions. In particular, a battery module can be provided with components that divert forces away from electrical connection areas, such as the terminals of a battery cell. Such forces can be directed to other structures that do not define electrical connection areas. A battery module can also include features such as a busbar that electrically connects sets of battery cells, thereby improving protection against certain electrical conditions. An arrangement for such a battery module can provide guidance for aligning and securing the assembled components, as well as for fixing them with a potting compound during assembly.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims the benefits of the preliminary US application No. 63 / 684,233 entitled “BATTERY MODULE ASSEMBLY”, filed on August 16, 2024, and the preliminary US application No. 63 / 807,457 entitled “BATTERY MODULE ASSEMBLY”, filed on May 16, 2025, the entire contents of which are hereby incorporated by reference. INTRODUCTION

[0002] Batteries are frequently used as a power source, including for electric vehicles, which have wheels driven by an electric motor that receives power from the batteries. A battery can contain multiple battery cells housed in a module and / or a carrier.

[0003] Aspects of the technology in question can help to improve the durability and / or longevity of electric vehicle batteries, which can help to mitigate climate change by reducing greenhouse gas emissions. SUMMARY

[0004] A battery module can include features to support and protect its components from external stress and certain electrical conditions. In particular, a battery module can be provided with components that divert forces away from electrical connection areas, such as the terminals of a battery cell. Such forces can be directed to other structures that do not define electrical connection areas. A battery module can also include features such as a busbar that electrically connects sets of battery cells, thereby improving protection against certain electrical conditions. An arrangement for such a battery module can provide guidance for aligning and securing the assembled components, as well as for fixing them with a potting compound during assembly.

[0005] According to one or more implementations of the present disclosure, a battery sub-assembly is described. The battery sub-assembly can include a cover, a frame for bearing against an outer edge of a battery cell, and a current collector arrangement between the frame and the cover, wherein the cover is configured to redirect forces acting upon it away from an encapsulation material between the cover and a central section of the battery cell and toward the outer edge of the battery cell.

[0006] The current collector arrangement can include a first connection section and a second connection section. The encapsulation material can be configured to include a first area where the first connection section is connected to a first terminal of the battery cell, and a second area where the second connection section is connected to a second terminal of the battery cell.

[0007] The frame can define an opening to expose (i) the central portion of the battery cell for connection to the first connection section and (ii) a portion of the outer edge for connection to the second connection section. The cover can form an inner surface that defines a concave shape to face the encapsulation material and the central portion of the battery cell. The encapsulation material can have a modulus of elasticity lower than the modulus of elasticity of both the cover and the frame. The battery subassembly can include a layer of foam on the side of the cover opposite the frame. The battery subassembly can include a base, a potting dam extending along one end of the frame to the base, and potting material between the cover and the base.

[0008] The battery cell can belong to a first set of battery cells. The battery sub-assembly can include a row busbar for electrically connecting the first set of battery cells to a second set of battery cells, the row busbar occupying a plane occupied by the current collector assembly. The frame can be a first frame, the battery sub-assembly further comprising a second frame, the first frame and the second frame each serving to cover a respective section of the first set of battery cells and the second set of battery cells.

[0009] The first frame can include first engagement elements for forming a 4-way data link with the first set of battery cells and second engagement elements for forming a 2-way data link with the first set of battery cells. The first frame can include third engagement elements for forming a 4-way data link with the current collector arrangement. The first frame can include fourth engagement elements to form a 4-way data link with the cover.

[0010] According to one or more implementations of the present disclosure, a series busbar is described. The series busbar can include a first terminal, a second terminal, and several fuse elements that connect the first terminal and the second terminal in parallel, each of the several fuse elements having a different cross-sectional dimension.

[0011] The fuse elements can include a first fuse element of the multiple fuse elements on a first side of the row busbar, configured for connection to a current collector assembly and having a first cross-sectional dimension, and a second fuse element of the multiple fuse elements on a second side of the row busbar opposite the first side, configured to point away from the current collector assembly and having a second cross-sectional dimension larger than the first cross-sectional dimension. The first connection, the second connection, and the multiple fuse elements can form a monolithic structure. A non-conductive container can surround the multiple fuse elements.

[0012] According to one or more implementations of the present disclosure, a method for assembling a battery sub-assembly is described. The method may include providing a first set of battery cells and a second set of battery cells, wherein each of the battery cells of the first set of battery cells and of the second set of battery cells defines a central section with a first terminal and an outer edge with a second terminal, providing one or more frames that abut the outer edge of each of the battery cells, connecting a current collector arrangement to the first terminal and the second terminal of each of the battery cells, providing an encapsulation material over the central section of each of the battery cells, and providing a cover over the current collector arrangement and any encapsulation material.

[0013] A row busbar can be connected to the first set of battery cells and the second set of battery cells, with the cover extending over the row busbar. A base can be provided to support a first set of battery cells and a second set of battery cells. One or more potting dams can be provided, each extending along one end of the frame(s) to the base. Potting compound can be provided between the cover and the base. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Certain features of the technology in question are set forth in the accompanying claims. However, for illustrative purposes, several embodiments of the technology in question are shown in the following figures. Fig. 1A and Fig. Figure 1B illustrates schematic perspective side views of example implementations of a vehicle with a battery pack according to one or more implementations of the present disclosure. Fig. Figure 1C illustrates a schematic perspective view of a building with a battery pack according to one or more implementations of the present disclosure. Fig. Figure 2A illustrates a schematic perspective view of a battery pack according to one or more implementations of the present disclosure. Fig. Figure 2B illustrates schematic perspective views of various battery modules that may be enclosed in a battery pack according to one or more implementations of the present disclosure. Fig. Figure 2C illustrates a cross-sectional end view of a battery cell according to one or more implementations of the present disclosure. Fig. 2D illustrates a perspective cross-sectional view of a cylindrical battery cell according to one or more implementations. Fig. Figure 2E illustrates a perspective cross-sectional view of a prismatic battery cell according to one or more implementations of the present disclosure. Fig. Figure 2F illustrates a perspective cross-sectional view of a pouch battery cell according to one or more implementations of the present disclosure. Fig. Figure 3 illustrates a perspective view of an exemplary battery cell according to one or more implementations of the present disclosure. Fig. Figure 4 illustrates a perspective exploded view of a battery module according to one or more implementations of the present disclosure. Fig. Figure 5 illustrates a cutaway side view of a section of a battery module according to one or more implementations of the present disclosure. Fig. Figure 6 illustrates a top view of several battery cells of a battery module according to one or more implementations of the present disclosure. Fig. Figure 7 illustrates a bottom view of a first section of a frame on battery cells of a battery module according to one or more implementations of the present disclosure. Fig. Figure 8 illustrates a bottom view of a second section of a frame on battery cells of a battery module according to one or more implementations of the present disclosure. Fig. Figure 9 illustrates a top view of a current collector arrangement on a frame and battery cells of a battery module according to one or more implementations of the present disclosure. Fig. Figure 10 illustrates a top view of a section of a frame on a battery cell of a battery module according to one or more implementations of the present disclosure. Fig. Figure 11 illustrates a top view of a section of a current collector arrangement on the frame and battery cell of Fig. 10 according to one or more implementations of the present disclosure. Fig. Figure 12 illustrates a top view of encapsulation materials on a frame and battery cells of a battery module according to one or more implementations of the present disclosure. Fig. 13A illustrates a perspective view of a cover according to one or more implementations of the present disclosure. Fig. Figure 13B illustrates a perspective view of a cover according to one or more implementations of the present disclosure. Fig. Figure 13C illustrates a perspective view of a cover according to one or more implementations of the present disclosure. Fig. Figure 13D illustrates a top view of a cover according to one or more implementations of the present disclosure. Fig. Figure 13E illustrates a perspective view of a section of the cover of Fig. 13D according to one or more implementations of the present disclosure. Fig. Figure 13F illustrates a perspective view of a cover according to one or more implementations of the present disclosure. Fig. Figure 13G illustrates a bottom view of a cover according to one or more implementations of the present disclosure. Fig. Figure 13H illustrates a perspective view of a cover according to one or more implementations of the present disclosure. Fig. Figure 14A illustrates a perspective exploded view of a cover over a current collector arrangement of a battery module according to one or more implementations of the present disclosure. Fig. Figure 14B illustrates a top view of a cover on a frame of a battery module according to one or more implementations of the present disclosure. Fig. Figure 15A illustrates a perspective view of a busbar of a battery module according to one or more implementations of the present disclosure. Fig. Figure 15B illustrates a perspective view of the busbar of Fig. 15A with a housing according to one or more implementations of the present disclosure. Fig. Figure 16A illustrates a perspective view of a section of a busbar of a battery module according to one or more implementations of the present disclosure. Fig. Figure 16B illustrates a perspective view of a first section of a container for a busbar according to one or more implementations of the present disclosure. Fig. Figure 16C illustrates a perspective view of a second section of a container for a busbar according to one or more implementations of the present disclosure. Fig. Figure 16D illustrates a perspective view of a section of a busbar with a first section of a container according to one or more implementations of the present disclosure. Fig. Figure 17 illustrates a perspective view of a potting dam of a battery module according to one or more implementations of the present disclosure. Fig. Figure 18 illustrates a perspective view of a battery module with a potting dam according to one or more implementations of the present disclosure. Fig. Figure 19 illustrates a perspective view of a section of a battery module with a potting dam according to one or more implementations of the present disclosure. Fig. Figure 20 illustrates a perspective view of a section of a battery module with multiple potting dams according to one or more implementations of the present disclosure. Fig. Figure 21 illustrates a perspective view of a section of a battery module with a base and frame containing battery cells, according to one or more implementations of the present disclosure. Fig. Figure 22 illustrates a bottom view of a section of a battery module with a base supporting a battery cell, according to one or more implementations of the present disclosure. Fig. Figure 23 illustrates a cutaway view of a section of a battery module with a base supporting a battery cell, according to one or more implementations of the present disclosure. Fig. Figure 24 illustrates a perspective view of a section of a battery module with a base supporting a battery cell, according to one or more implementations of the present disclosure. Fig. Figure 25 illustrates a perspective view of a section of a battery module with a base supporting a battery cell, according to one or more implementations of the present disclosure. Fig. Figure 26 illustrates a perspective view of a section of a battery module with a balancing voltage and temperature (“BVT” module) according to one or more implementations of the present disclosure. Fig. Figure 27 illustrates a top view of a section of a battery module with a current collector arrangement connected to a battery cell according to one or more implementations of the present disclosure. Fig. Figure 28 illustrates a top view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 29 illustrates a top view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 30 illustrates a top view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 31 illustrates a top view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 32 illustrates a top view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 33 illustrates a top view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 34 illustrates a sectional view of a section of a current collector arrangement and a voltage sensing arrangement according to one or more implementations of the present disclosure. Fig. Figure 35 illustrates a sectional view of a section of a current collector arrangement according to one or more implementations of the present disclosure. Fig. Figure 36 illustrates a perspective view of a section of a battery module with a current collector arrangement and a frame stacked on top of and over battery cells, according to one or more implementations of the present disclosure. Fig. Figure 37 illustrates a sectional view of a section of a battery module with a cover, a current collector arrangement and a frame aligned with a conical tool, according to one or more implementations of the present disclosure. Fig. 38 illustrates a flowchart showing an example of a process that can be carried out to assemble a battery module according to one or more implementations of the present disclosure. Fig. 39 illustrates a flowchart showing an example of a process that can be carried out to assemble a battery module according to one or more implementations of the present disclosure. Fig. Figure 40 illustrates a perspective view of a device for assembling a battery module according to one or more implementations of the present disclosure. Fig. Figure 41 illustrates a top view of a device for assembling a battery module according to one or more implementations of the present disclosure. Fig. 42 illustrates a flowchart showing an example of a process that can be carried out to assemble a battery module according to one or more implementations of the present disclosure. DETAILED DESCRIPTION

[0015] The detailed description given below is intended as a description of various configurations of the technology in question and is not meant to represent the only configurations in which the technology in question can be practiced. The accompanying drawings are included herein and form part of the detailed description. The detailed description includes specific details for the purpose of providing a thorough understanding of the technology in question. However, it will be clear and obvious to those skilled in the art that the technology in question is not limited to the specific details set forth herein and can be practiced without them. In some cases, well-known structures and components are shown in the form of block diagrams to avoid obscuring the concepts of the technology in question.

[0016] A battery module can include features for supporting and protecting its components from external stress and specific electrical conditions. In particular, a battery module can be provided with components that divert forces away from electrical connection areas, such as the terminals of a battery cell. These forces can be directed to other structures that do not define electrical connection areas. A battery module can also include features such as a busbar that electrically connects sets of battery cells, thereby improving protection against specific electrical conditions. An arrangement for such a battery module can provide guidance for aligning and securing the assembled components, as well as for fixing them with a potting compound during assembly.

[0017] Fig. Figure 1A illustrates an example implementation of a movable device as described herein. In the example of Fig. 1A is a movable device implemented as a vehicle 100. As shown, the vehicle 100 can include one or more battery packs, such as battery pack 110. Battery pack 110 can be coupled to one or more electrical systems of the vehicle 100 to provide power to those electrical systems.

[0018] In some embodiments, the vehicle 100 can be an electric vehicle comprising one or more electric motors that drive the wheels 102 of the vehicle 100 using electrical power from the battery pack 110. In some embodiments, the vehicle 100 can also, or alternatively, include one or more drives or motors, including chemically driven motors, such as a gas-powered engine or a fuel cell-powered engine. In some embodiments, for example, the vehicle 100 includes one or more electric motors and has the form of a fully electric or partially electric vehicle (e.g., hybrid or plug-in hybrid).

[0019] In the example of Fig. In Figure 1A, the vehicle 100 is implemented as a flatbed truck (e.g., a pickup) with a battery pack 110. As shown, the battery pack 110 can include one or more battery modules 115, which can contain one or more battery cells 120. As shown in Figure 110, the battery pack 110 can include one or more battery modules 115, which can contain one or more battery cells 120. Fig. As shown in Figure 1A, the battery pack 110 can also include one or more battery cells 120 that are mounted directly in the battery pack 110 (e.g., in a cell-to-pack configuration). In some embodiments, the battery pack 110 can be provided without the battery modules 115 and with the battery cells 120 that are mounted directly in the battery pack 110 (e.g., in a cell-to-pack configuration) and / or in other battery units installed in the battery pack 110. The battery pack 110 can include multiple energy storage devices that may be arranged in units such as battery modules or battery units. A battery unit or battery module can include an array of cells that can be combined with other elements (e.g., structural frames, thermal management devices) that can protect the array of cells from heat, impact, and / or vibration.

[0020] Each of the battery cells 120 can include a battery, a battery unit, a battery module and / or a battery pack for supplying components of the vehicle 100. For example, a battery cell housing of the battery cells 120 can be arranged in the battery module 115, the battery pack 110, a battery array or another battery unit installed in the vehicle 100.

[0021] As discussed in more detail below, the battery cells 120 can be provided with a battery cell housing, which can be provided with any of several different external shapes. In some implementations, the battery cell housing can be a rigid housing (e.g., for cylindrical or prismatic battery cells). Alternatively, in some implementations, the battery cell housing can also be configured as a pouch or other flexible or malleable housing for the battery cell. In several other implementations, the battery cell housing can be provided with any other suitable external shape, such as a triangular, square, rectangular, pentagonal, hexagonal, or any other suitable external shape. In some implementations, the battery pack 110 may not include any modules (e.g.,The battery pack can be module-free. For example, the battery pack 110 can have a module-free or cell-to-pack configuration, in which the battery cells 120 are arranged directly within a battery pack 110 without being arranged within a module 115. In some embodiments, the vehicle 100 can include one or more busbars, electrical connectors, or other charge-collecting, current-collecting, and / or coupling components to provide electrical power from the battery pack 110 to various systems or components of the vehicle 100. In some embodiments, the vehicle 100 can include control switching logic, such as a power stage circuit, which can be used to convert direct current from the battery pack 110 into alternating current for one or more components and / or systems of the vehicle (e.g., including one or more power outlets of the vehicle).The power stage circuit can be provided as part of the battery pack 110 or separately from the battery pack 110 inside the vehicle 100.

[0022] Fig. Figure 1B illustrates another implementation where vehicle 100 is implemented as a Sport Utility Vehicle (SUV), such as an electric Sport Utility Vehicle. In the example of Fig. 1B The vehicle 100 may include a cargo storage area enclosed within the vehicle 100 (e.g., behind a row of seats in an interior space of the vehicle 100). In other implementations, the vehicle 100 may be implemented as a different type of electric pickup truck, electric van, electric automobile, electric vehicle, electric motorcycle, electric scooter, electric bicycle, electric passenger car, electric touring or utility pickup truck, hybrid vehicle, an aircraft, a watercraft, and / or any other mobile installation that incorporates a battery pack 110 (e.g., a battery pack or other battery unit that powers propulsion or drive components of the mobile installation).

[0023] In some embodiments, the battery pack 110, the battery modules 115, the battery cells 120 and / or any other battery unit as described herein can also, or alternatively, be implemented as an electrical power supply and / or energy storage system in a building, such as a residential or commercial building. For example, the following illustrates Fig. Figure 1C is an example where a battery pack 110a is implemented in a building 180. The building 180 can be a residential building, a commercial building, or any other type of building. As shown, in some embodiments, the battery pack 110a can be mounted on a wall of the building 180.

[0024] As shown, the battery pack 110a, installed in the building 180, can be coupled (e.g., electrically coupled) to the battery pack 110b in the vehicle 100, such as via a cable / connector 106 that can be connected to the charging port 130 of the vehicle 100, an electric vehicle supply equipment (EVSE) 170, a power stage circuit 172, and / or a cable / connector 174. For example, the cable / connector 106 can be connected to the EVSE 170, which can be connected to the battery pack 110a via the power stage circuit 172 and / or to an external power source 190. In this way, either the external power source 190 or the battery pack 110a can be used as an external power source to charge the battery pack 110b in some applications. In some embodiments, the battery pack 110a can also, or alternatively, (e.g.The external power source 190 can be connected to the battery pack 110b (via a cable / connector 174, the power stage circuit 172, and the EVSE 170). The external power source 190 can be a solar power source, a wind power source, and / or an electrical grid of a city or other geographical region (e.g., an electrical grid supplied by a remote power plant). In situations where, for example, battery pack 110b is not connected to battery pack 110a, battery pack 110a can be connected to the external power source 190 (e.g., using the power stage circuit 172) to charge and store electrical energy. In some applications, this stored electrical energy in battery pack 110a can later be used to charge battery pack 110b (e.g., to charge a power supply).during times when solar or wind power is unavailable, in the event of a regional or local power outage for building 180 and / or during a period of high access rates to the power grid).

[0025] In some embodiments, the power stage circuit 172 can electrically couple the battery pack 110a to an electrical system of the building 180. For example, the power stage circuit 172 can convert direct current from the battery pack 110a into alternating current for one or more loads in the building 180. Exemplary loads that are coupled to the battery pack 110a via one or more sockets can include one or more lights, lamps, appliances, fans, heaters, air conditioners, and / or any other electrical components or electrical loads. The power stage circuit 172 can include control switching logic that is operational to switch the battery pack 110a between the external power source 190 and one or more sockets and / or other electrical loads in the building 180's electrical system. In some embodiments, the vehicle 100 can have a power stage circuit (in Fig. 1C not shown) include, which can be used to convert power received from the EVSE 170 into direct current, which is used to power / charge the battery pack 110b, and / or to convert direct current from the battery pack 110 into alternating current for one or more electrical systems, components and / or loads of the vehicle 100.

[0026] In one or more use cases, battery pack 110a can be used as an electrical power source for building 180, such as during times when solar or wind power is unavailable, in the event of a regional or local power outage affecting building 180, and / or during periods of high grid access, to name just a few examples. In one or more other use cases, battery pack 110b can be used to charge battery pack 110a and / or to power the electrical system of building 180 (e.g., in a use case where battery pack 110a has little or no energy stored and solar or wind power is unavailable, a regional or local power outage affecting building 180 occurs, and / or during periods of high grid access, to name just a few examples).

[0027] Fig. Figure 2A represents an exemplary battery pack 110 according to one or more implementations. As shown, the battery pack 110 can enclose an energy volume enclosure 205 (e.g., a battery pack enclosure, sometimes referred to here as a housing). For example, the energy volume enclosure 205 can contain or enclose an energy volume 207 for the battery pack 110, the energy volume 207 including one or more battery modules 115 and / or one or more battery cells 120 and / or other battery pack components. In one or more implementations, the energy volume enclosure 205 can include or form a shielding structure on an outer surface thereof (e.g., a base thereof and / or beneath one or more battery modules 115, battery units, batteries, and / or battery cells 120) to protect the battery module 115, battery units, batteries, and / or battery cells 120 from external conditions (e.g.,(when the battery pack 110 is installed in a vehicle 100 and the vehicle 100 is driven over rough terrain such as off-road terrain, ditches, rocks, rivers, streams, etc.).

[0028] The battery pack 110 can include, within the energy volume 207 and the energy volume housing 205, several battery cells 120 (e.g., installed directly within the battery pack 110 or within batteries, battery units, battery sub-assemblies, and / or battery modules 115 as described herein) and / or battery modules 115, and one or more conductive coupling elements for coupling a voltage generated by the battery cells 120 to a power-consuming component, such as the vehicle 100 and / or an electrical system of a building 180. For example, the conductive coupling elements can include internal connectors and / or contactors that couple several battery cells 120, battery units, batteries, battery sub-assemblies, and / or several battery modules 115 within the energy volume housing 205 to generate a desired output voltage for the battery pack 110.

[0029] As shown, the battery pack 110 can also include a modular electrical component assembly 290 (e.g., including a modular housing for electronic components or a modular housing for electrical components) attached to the energy volume housing 205. In one or more implementations, the modular electrical component assembly 290 can include one or more conductive coupling elements for conducting current from the battery cells 120 and / or battery modules 115 within the energy volume housing 205 (e.g., within the energy volume 207) to one or more external connection terminals, such as an electrical contact 203 (e.g., a high-voltage terminal, port, or connector).For example, an electrical cable or wiring harness can be connected between the electrical contact 203 and an electrical system of the vehicle 100 or the building 180 to provide electrical power to the vehicle 100 or the building 180. The energy volume enclosure 205 can have a front end 267 and a rear end 269. In one or more implementations, when the battery pack 110 is installed in the vehicle 100, the front end 267 can be located closer to the front end 131 of the vehicle and the rear end 269 closer to the rear end 133 of the vehicle. As shown, the modular electrical component assembly 290 can be attached to or near the rear end 269 of the energy volume enclosure 205 (e.g., to a cover 277 of the energy volume enclosure 205) in one or more implementations.

[0030] In one or more implementations, the battery pack 110 can include one or more additional features such as thermal control structures (e.g., cooling lines and / or plates and / or heating lines and / or plates). For example, the thermal control structures and / or fluids can couple thermal control structures and / or fluids to the battery modules 115, battery units, batteries and / or battery cells 120 within the energy volume housing 205, such as by distributing fluid through the battery pack 110.

[0031] For example, the thermal control structures can form part of a thermo / temperature control or heat exchange system that includes one or more thermal components, such as plates or bladders, which are in thermal contact with one or more battery modules 115 and / or battery cells 120 arranged within the energy volume housing 205. For example, a thermal component can be in contact with one or more battery modules 115, battery units, batteries, and / or battery cells 120 arranged within the energy volume housing 205. In one or more implementations, the battery pack 110 can include one or more thermal control structures and / or other thermal components for each of several upper and lower battery module pairs. As shown, the battery pack 110 can include an electrical contact 203 (e.g.,a high-voltage connector or terminal) through which an external load (e.g. the vehicle 100 or an electrical system of the building 180) can be electrically coupled to the battery modules and / or battery cells in the battery pack 110.

[0032] As shown, the energy volume housing 205 of the battery pack 110 can enclose a cover 277. For example, the cover 277 can cover one or more battery modules 115, battery cells 120, and / or other battery sub-assemblies within the energy volume housing 205. In the example of Fig. 2A The cover 277 can be a deep-drawn structure forming a top 257 and one or more side walls 259 (e.g., four side walls) of the energy volume enclosure 205. As discussed in more detail below, the energy volume enclosure 205 can also include a shell or other enclosure structure (e.g., at the bottom of the energy volume enclosure) connected to the cover 277 to enclose one or more battery modules 115, battery cells 120, and / or other battery sub-assemblies within the energy volume enclosure 205 (e.g., within a space defined by the top 257 and the side walls 259 of the cover 277). For example, the energy volume enclosure 205 can include a shell plate that is removable to expose an opening in the bottom of the cover 277.

[0033] In the example of Fig. 2A the cover 277 is provided with ribs 275 (e.g. for additional strength). In the example of Fig. 2A The battery pack 110 includes one or more fastening features 273 (e.g., for fastening the battery pack 110 to one or more body structures of a vehicle such as the vehicle 100). As in Fig. As shown in Figure 2A and discussed in more detail below, the energy volume enclosure 205 can include one or more side wall structures 271. The side wall structures 271 can be attached to and / or extend along a side wall 259 of the lid 277 and can provide shock absorption and / or redistribution functions to dissipate energy from a side impact on the battery pack 110 (e.g., from a side impact on a vehicle 100) away from and / or around the one or more battery modules 115, battery cells 120, and / or other battery sub-assemblies within the energy volume enclosure 205.

[0034] Fig. Figure 2B shows various examples of battery modules 115 that can be arranged in the battery pack 110 (e.g., within the energy volume housing 205 of Fig. 2A). In the example of Fig. Figure 2B shows a battery module 115A that includes a battery module housing 223 with a rectangular cuboid shape and a length substantially similar to its width. In this example, the battery module 115A includes several battery cells 120 implemented as cylindrical battery cells. Specifically, the battery module 115A includes rows and columns of cylindrical battery cells coupled together by an intermediate connection structure 200 (e.g., a current connector assembly, CCA). For example, the intermediate connection structure 200 can couple the positive terminals of the battery cells 120 together and / or the negative terminals of the battery cells 120 together. As shown, the battery module 115A can include a charge collector or busbar 202.For example, the busbar 202 can be electrically coupled to the intermediate connection structure 200 to collect the charge generated by the battery cells 120 in order to provide a high voltage that is output by the battery module 115A.

[0035] Fig. Figure 2B also shows a battery module 115B with an elongated shape, in which the length of the battery module housing 223 (e.g., extending along a direction from a front end of the battery pack 110 to a rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110) is substantially greater than a width (e.g., in a transverse direction to the direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110) of the battery module housing 223. For example, one or more battery modules 115B can span the entire length of a battery pack within the energy volume housing 205 from front to back. As shown, the battery module 115B can also include a busbar 202 that is electrically coupled to the intermediate connection structure 200.For example, the busbar 202 can be electrically coupled to the intermediate connection structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage that is output by the battery module 115B.

[0036] In the implementations of battery module 115A and battery module 115B, the battery cells 120 are implemented as cylindrical battery cells. However, in other implementations, a battery module can include battery cells with other form factors, such as battery cells with a right prismatic outer shape (e.g., a prismatic cell) or a pouch cell implementation. As an example, [reference to relevant section] Fig. Figure 2B also includes a battery module 115C with a battery module housing 223 having a rectangular cuboid shape with a length substantially similar to its width and enclosing several battery cells 120 implemented as prismatic battery cells. In this example, the battery module 115C includes rows and columns of prismatic battery cells coupled to one another by an intermediate connection structure 200 (e.g., a current collector assembly, CCA). For example, the intermediate connection structure 200 can couple the positive terminals of the battery cells 120 to one another and / or couple the negative battery terminals of the battery cells 120 to one another. As shown, the battery module 115C can include a charge collector or busbar 202.For example, the busbar 202 can be electrically coupled to the intermediate connection structure 200 to collect the charge generated by the battery cells 120 in order to provide a high voltage that is output by the battery module 115C.

[0037] Fig. Figure 2B also shows a battery module 115D, which includes prismatic battery cells and has an elongated shape, where the length of the battery module housing 223 (e.g., extending in a direction from a front end of the battery pack 110 to a rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110) is substantially greater than a width (e.g., in a transverse direction to the direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110) of the battery module housing 223. For example, one or more battery modules 115D with prismatic battery cells can span the entire length of a battery pack within the energy volume housing 205 from front to back. As shown, the battery module 115D can also include a busbar 202 which is electrically coupled to the intermediate connection structure 200.For example, the busbar 202 can be electrically coupled to the intermediate connection structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage that is output by the battery module 115D.

[0038] As another example, Fig. 2B also includes a battery module 115E with a battery module housing 223 having a rectangular cuboid shape with a length substantially similar to its width, and enclosing several battery cells 120 implemented as pouch battery cells. In this example, the battery module 115C includes rows and columns of pouch battery cells coupled together by an intermediate connection structure 200 (e.g., a current collector arrangement or CCA). For example, the intermediate connection structure 200 can couple the positive terminals of the battery cells 120 together and the negative battery terminals of the battery cells 120 together. As shown, the battery module 115E can include a charge collector or busbar 202.For example, the busbar 202 can be electrically coupled to the intermediate connection structure 200 to collect the charge generated by the battery cells 120 in order to provide a high voltage that is output by the battery module 115E.

[0039] Fig. Figure 2B also shows a battery module 115F, which includes pouch battery cells and has an elongated shape, where the length of the battery module housing 223 (e.g., extending in a direction from a front end of the battery pack 110 to a rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110) is substantially greater than a width (e.g., in a transverse direction to the direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110) of the battery module housing 223. For example, one or more battery modules 115E with pouch battery cells can span the entire length of a battery pack within the energy volume housing 205 from front to back. As shown, the battery module 115E can also include a busbar 202 which is electrically coupled to the intermediate connection structure 200.For example, the busbar 202 can be electrically coupled to the intermediate connection structure 200 to collect the charge generated by the battery cells 120 in order to provide a high voltage that is output by the battery module 115E.

[0040] In various implementations, a battery pack 110 can be provided with one or more of the battery modules 115A, 115B, 115C, 115D, 115E, and 115F. In one or more other implementations, a battery pack 110 can be provided without battery modules 115 (e.g., in a cell-to-pack implementation). In one or more implementations, a battery pack 110 can be provided with three elongated battery modules (e.g., three of the battery modules 115B, 115D, and / or 115F).

[0041] In one or more implementations, multiple battery modules 115 can be used in any of the implementations of Fig. 2B is coupled to a current collector of the battery pack 110 (e.g., in series). In one or more implementations, the current collector can be coupled to one or more external connectors (e.g., electrical contact 203) on the battery pack 110 via a high-voltage wiring harness. In one or more implementations, the battery pack 110 can be provided without any battery modules 115. For example, the battery pack 110 can have a cell-to-pack configuration in which the battery cells 120 are arranged directly within a battery pack 110 without being arranged within a battery module 115 (e.g., without including a separate battery module housing 223). For example, the battery pack 110 (e.g., the energy volume housing 205) can include or define a variety of structures for arranging the battery cells 120 directly within the energy volume housing 205.

[0042] Fig. Figure 2C illustrates a cross-sectional end view of a section of a battery cell 120. As shown, the battery cell 120 can include an anode 208, an electrolyte 210, and a cathode 212. As shown, the anode 208 can include or be electrically coupled to a first current collector 206 (e.g., a metal layer such as a layer of copper foil or another metal foil). Furthermore, the cathode 212 can include or be electrically coupled to a second current collector 214 (e.g., a metal layer such as a layer of aluminum foil or another metal foil). The battery cell 120 can further include a terminal 216 (e.g. a negative terminal) that is coupled to the anode 208 (e.g. via the first current collector 206) and a terminal 218 (e.g. a positive terminal) that is coupled to the cathode (e.g. via the second current collector 214).In various implementations, the electrolyte 210 can take the form of a liquid electrolyte layer or a solid electrolyte layer. In some embodiments where the electrolyte 210 is a liquid electrolyte layer, the battery cell 120 can include a separator layer 220 that separates the anode 208 from the cathode 212. In some embodiments where the electrolyte 210 is a solid electrolyte layer, the electrolyte 210 can function as both a separator layer and an electrolyte layer.

[0043] In some embodiments, the battery cell 120 can be implemented as a lithium-ion battery cell in which the anode 208 is formed from a carbon-containing material (e.g., graphite or silicon carbon). In these implementations, lithium ions can move from the anode 208 through the electrolyte 210 to the cathode 212 during discharge of the battery cell 120 (and, for example, through the electrolyte 210 from the cathode 212 to the anode 208 during charging of the battery cell 120). For example, the anode 208 can be formed from a graphite material coated on a copper foil corresponding to the first current collector 206. In these lithium-ion implementations, the cathode 212 can be formed from one or more metal oxides (e.g., a lithium cobalt oxide, a lithium manganese oxide, a lithium nickel manganese cobalt oxide (NMC), or the like) and / or a lithium iron phosphate.In an implementation where the battery cell 120 is implemented as a lithium-ion battery cell, the electrolyte 210 can enclose a lithium salt in an organic solvent.

[0044] The separating layer 220 can be formed from one or more insulating materials (e.g., a polymer such as polyethylene, polypropylene, polyolefin, and / or polyamide, or other insulating materials such as rubber, glass, cellulose, or the like). The separating layer 220 can prevent contact between the anode 208 and the cathode 212 and can be permeable to the electrolyte 210 and / or ions within the electrolyte 210. In some embodiments, the battery cell 120 can be implemented as a lithium-polymer battery cell with a dry solid polymer electrolyte and / or a gel polymer electrolyte.

[0045] Although some examples are described herein in which the battery cell 120 is implemented as a lithium-ion battery cell, the battery cell 120 can be implemented using other battery cell technologies, such as nickel-metal hydride battery cells, lead-acid battery cells, and / or ultracapacitor cells. For example, in a nickel-metal hydride battery cell, the anode 208 can be formed from a hydrogen-absorbing alloy, and the cathode 212 can be formed from a nickel oxide hydroxide. In the example of a nickel-metal hydride battery cell, the electrolyte 210 can be formed from an aqueous potassium hydroxide in one or more examples.

[0046] The battery cell 120 can be implemented as a lithium-sulfur battery cell in one or more other implementations. For example, in a lithium-sulfur battery cell, the anode 208 can be at least partially composed of lithium, the cathode 212 can be at least partially composed of sulfur, and the electrolyte 210 can be composed of a cyclic ether, a short-chain ether, a glycol ether, an ionic fluid, a supersaturated salt-solvent mixture, a polymer-gelled organic medium, a solid polymer, a solid inorganic glass, and / or other suitable electrolyte materials. In various implementations, the anode 208, the electrolyte 210, and the cathode 212 can be enclosed in a battery cell casing of any of the different shapes and / or dimensions and / or be composed of any of the different suitable materials.For example, the battery cell 120 can have a cylindrical, rectangular, square, cube-shaped, flat, pouch, oblong or prismatic outer shape.

[0047] As in Fig. Represented in 2D, battery cell 120 can be implemented as a cylindrical cell. Accordingly, battery cell 120 includes dimension 222a (e.g., cylinder diameter, battery cell diameter) and dimension 222b (e.g., cylinder length). Battery cell 120 and other battery cells described herein may include size information derived from a 4-digit code. For example, in some embodiments, battery cell 120 includes an XXYY battery cell, where "XX" refers to dimension 222a in millimeters (mm) and "YY" refers to the dimension in mm. Accordingly, if battery cell 120 includes a "2170" battery cell, dimension 222a is 21 mm, and dimension 222b is 70 mm. Alternatively, if battery cell 120 includes a “4680” battery cell, dimension 222a is 46 mm and dimension 222b is 80 mm.The preceding examples of size characteristics for battery cell 120 are not intended to be limiting, and battery cell 120 and other cylindrical form factor battery cells described herein may include various dimensions. For example, dimension 222a and dimension 222b may be larger than 46 mm and 80 mm, respectively.

[0048] Fig. Figure 2D illustrates a battery cell 120 enclosing a cell casing 224 with a cylindrical outer shape. As shown in the enlarged view, the anode 208, the electrolyte 210, and the cathode 212 can be wound into one or more windings 221. The one or more windings 221 can, as a non-limiting example, include one or more substantially cylindrical windings. As shown, one or more windings 221 can include the anode 208, the electrolyte 210, and the cathode 212 (and, for example, one or more separating layers, such as those shown in Figure 2). Fig. The separating layer 220 shown in Figure 2C is located within the cell housing 224. For example, a separating layer can be arranged between adjacent windings of one or more windings 221. Additionally, the battery cell 120, in its implementation as a cylindrical cell, includes Fig. Figure 2D includes a terminal 216 and a terminal 218. Terminal 218 can include a first polarity terminal, such as a positive terminal, coupled to the cathode 212. Terminal 216 can include a second polarity terminal, such as a negative terminal, coupled to the anode 208. Terminals 216 and 218 can be made of electrically conductive materials to carry electrical current from the battery cell 120 directly or indirectly (e.g., via a current carrier arrangement, a busbar, and / or other electrical coupling structures) to an electrical load, such as a component or system of a vehicle or building shown and / or described herein. The cylindrical cell implementation of Fig. However, 2D is only for illustrative purposes and other implementations of the battery cells 120 are being considered.

[0049] Fig. Figure 2E illustrates an example in which the battery cell 120 is implemented as a prismatic cell. As shown, the battery cell 120 can have a cell casing 224 having a right-hand prismatic outer shape. Furthermore, one or more layers of the anode 208, the cathode 212, and the electrolyte 210 arranged between them (e.g., with separating materials between the layers) can be arranged within the cell casing 224. For example, several layers of the anode 208, electrolyte 210, and cathode 212 can be stacked (e.g., with separating materials between each layer), or a single layer of the anode 208, electrolyte 210, and cathode 212 can be formed into a flattened spiral shape and provided in the cell casing 224. The cell casing 224 can enclose a cross-sectional width 217, which is relatively thick and formed from a rigid material.For example, the cell housing 224 can be formed from a welded, stamped, deep-drawn, and / or extruded metal sheet, such as a welded, stamped, deep-drawn, and / or extruded aluminum sheet. The cross-sectional width 217 of the cell housing 224 can be equal to or greater than 1 millimeter (mm) to provide a rigid housing for the prismatic battery cell. In some embodiments, a terminal 216 and a terminal 218 can be provided in the prismatic cell implementation of . Fig. 2E may be formed from a feedthrough conductor that is insulated from the cell housing 224 (e.g., a glass-to-metal feedthrough), if the conductor runs to the cell housing 224 to expose terminal 216 and terminal 218 outside the cell housing 224 to contact an intermediate connection structure (e.g., the one in Fig. 2B intermediate connection structure 213). This implementation of Fig. However, 2E is also illustrative and further implementations of the battery cell 120 are being considered.

[0050] Fig. Figure 2F illustrates an example in which the battery cell 120 is implemented as a pouch cell. As shown, the battery cell 120 can enclose a cell housing 224, which forms a flexible or deformable pouch housing. One or more layers of the anode 208, the cathode 212, and the electrolyte 210 arranged between them can be positioned within the cell housing 224 (e.g., with separating materials between the layers). In the implementation of Fig. 2F allows the cell housing 224 to enclose a cross-sectional width 219, which is relatively thin. For example, the cell housing 224 can be used in the implementation of Fig. 2F may be formed from a flexible or deformable material (e.g., a foil, such as a metal foil, or a film, such as an aluminum-coated plastic film). The cross-sectional width 219 of the cell housing 224 may be as low as or less than 0.1 mm, 0.05 mm, 0.02 mm, or 0.01 mm to provide a flexible or deformable housing for the pouch battery cell. In some embodiments, a terminal 216 and a terminal 218 may be provided in the pouch cell implementation of Fig. 2F are formed from conductive tabs (e.g., foil tabs) that are coupled (e.g., welded) to the anode 208 and the cathode 212, respectively, and sealed to the pouch, which in these implementations forms the cell housing 224. In the examples of Fig. 2C, Fig. 2E and Fig. In 2F, terminals 216 and 218 are formed on the same side (e.g., a top) of battery cell 120. However, this is merely illustrative, and in other implementations, terminals 216 and 218 may be formed on two different sides (e.g., opposite sides, such as a top and a bottom) of battery cell 120. Terminals 216 and 218 may be located on the same side or on opposite sides of the cylindrical cell in different implementations. Fig. be formed in 2D.

[0051] In some embodiments, a battery module, battery pack, battery unit, or any other battery may include some battery cells implemented as solid-state battery cells and other battery cells implemented with liquid electrolytes for lithium-ion or other liquid-electrolyte battery cells. In some embodiments, one or more of the battery cells may include a battery module or battery pack, such as for providing electrical power to components of a previously described vehicle and / or building, or other electrically powered component or device. A battery cell housing may be arranged within the battery module or battery pack, or installed in any electrically powered component or device of the vehicle, building, or other device.

[0052] Fig. Figure 3 illustrates a perspective view of an example of a battery cell 120, which is implemented as a cylindrical cell with a cylindrical cell casing 524 according to one or more implementations. In the example of Fig. In the embodiment 5, the battery cell 120 is enclosed by a cap 500, which includes a central section 502 and an outer rim 504. In some embodiments, the central section 502 can be implemented as a terminal, such as a positive terminal of the battery cell 120. In some embodiments, the outer rim 504 can be implemented as a terminal, such as a negative terminal of the battery cell 120. In some embodiments, the battery cell 120 can include a seal 506, which is located at least partially below the outer rim 504. For example, the seal 506 can seal an inner cavity of the battery cell 120 (e.g., enclosed by the cylindrical cell housing 524 and the cap 500) from the external environment of the battery cell 120.

[0053] Fig. Figure 4 illustrates a perspective exploded view of a battery module 115. The battery module 115 includes a cover 460, one or more encapsulation materials 450, a current collector assembly 400, a row busbar 600, one or more frames 510, 512 and / or 514, one or more separator layers 590, one or more sets 122 of battery cells 120 and a base 302.

[0054] The cover 460 can be arranged on the top side of the battery module 115, and the base 302 can be arranged on the bottom side of the battery module 115. The base 302 can be provided as a single piece or in multiple parts. The battery cells 120 can be inserted as sets 122 into a box structure formed by the base 302. One or more of the sets 122 of battery cells 120 can be positioned on opposite sides of a cooling element (not shown) and / or within the side walls of the base 302.

[0055] In some embodiments, each of the frames 510, 512, and / or 514 can take the form of a monolithic unit body (e.g., a body molded from plastic and / or other materials) and include a top section and / or side walls. Each of the frames 510, 512, and / or 514 can extend over at least a portion of each of the sets 122 of battery cells 120. The frames 510, 512, and / or 514 can be connected to one another when attached to the battery cells 120. If multiple frames 510, 512, and / or 514 are provided, two of the frames can form end sections of a connected structure, and one or more additional frames can form a middle section of the connected structure. Thus, by selecting a suitable set of frames, any desired configuration, number, and / or length of sets 122 of battery cells 120 can be enabled.Each set 122 can attach its battery cells 120 to one another along a certain length. Furthermore, multiple frames 510, 512 and / or 514 can be attached to one or more of the sets 122 to secure them relative to each other along the length of the sets 122 of battery cells 120.

[0056] As in Fig. As shown in Figure 4, a CCA 400 is provided. As explained in more detail below, the CCA 400, when assembled with the battery module 115, can take the form of a device that connects the respective terminals of the battery cells 120 of the battery module 115 to the busbar(s) 320. Multiple busbars can be integrated. For example, a busbar 320 (e.g., a positive busbar) can be electrically coupled to the respective first terminals (e.g., the positive terminals) of the battery cells of the battery module 115, and a busbar 320 (e.g., a negative busbar) can be electrically coupled to the respective second terminals (e.g., the negative terminals) of the battery cells of the battery module 115. As shown in Figure 4, the CCA 400 can be electrically coupled to the battery cells of the battery module 115. Fig. As shown in Figure 4, a series busbar 600 can also be provided (e.g., at an end opposite the frames 510, 512, and / or 514 from the end of the respective cell carriers on which the busbar(s) 320 are mounted). As used herein, the series busbar 600 can supply one or more of the Fig. 2B illustrates busbars 202.

[0057] As in Fig. As further shown in Figure 4, one or more encapsulation materials 450 can be provided, each being located between the cover 460 and a corresponding battery cell 120. The encapsulation materials 450 can surround an area where the CCA 400 is connected to the terminals of the corresponding battery cells 120. The encapsulation materials 450 can further extend to cover and / or contact sections of the frames 510, 512 and / or 514.

[0058] The busbar 600 can be provided to connect sets 122 of battery cells 120. For example, the busbar 600 can be provided to connect first sets 122 of battery cells 120 on a first side of the cooling element 306 with second sets 122 of battery cells 120 on a second side of the cooling element 306. The busbar 600 can be provided on one or more of the frames 510, 512, and / or 514. In some embodiments, the busbar 600 is provided in the same plane as the current collector assembly 400 and / or the encapsulation materials 450. Such an arrangement makes it possible to surround the busbar 600 with the same frame and cover that surrounds other components, such as the current collector assembly 400 and / or the encapsulation materials 450.The busbar 600 can also be provided with one or more alignment features to align it with one or more other structures, such as the frames 510, 512 and / or 514. Accordingly, the arrangement with the busbar 600 can be aligned with other components of the battery module 115.

[0059] In some embodiments, a voltage and temperature compensation module (“BVT” module) 314 is communicatively coupled to a thermistor arrangement 316. The BVT module 314 can take the form of a modular arrangement of various electrical components for monitoring and / or controlling components of the battery module 115. For example, the BVT module 314 can include a printed circuit board attached to a housing of the BVT module 314. The BVT module 314 can include various connectors for coupling to, for example, a thermistor, a voltage sensor, and / or a communication device, as non-limiting examples. The thermistor can measure the temperature of the battery module 115 and / or one of its battery cells 120. The voltage sensor or equalizer can detect or control the voltage flowing through the battery module 115 and / or one of its battery cells 120.The communication device can receive, transmit or analyze data associated with the battery module 115 and / or one of its battery cells 120.

[0060] In some embodiments, the BVT module 314 may include processing switching logic. Such processing switching logic may include monitoring and / or control switching logic, such as temperature and voltage balancing (BVT) switching logic. For example, the BVT switching logic may include an electrical control unit (ECU) that receives data (e.g., voltage data, such as cell voltage data, and / or temperature data, such as one or more temperatures at one or more locations within the battery pack or energy volume) from one or more sensors within the battery pack or energy volume. The one or more sensors may be, or include, a voltage sensor, a current sensor, a temperature sensor, a pressure sensor, and / or a gas sensor.The BVT can process the sensor data to monitor battery cell voltages, monitor one or more temperatures, and / or perform cell balancing operations for the battery cells. In some embodiments, the BVT module 314 can provide sensor data and / or processed data derived from the sensor data to additional processing switching logic (e.g., a battery management system ("BMS")) via a wired or wireless connection. Fig. Figure 5 illustrates a sectional view of a section of a battery module. As shown in Fig. As shown in Figure 5, the cover 460 can extend over an encapsulation material 450 that surrounds an upper part of a battery cell 120. The frame 510 can rest on the outer edge 504 of the battery cell 120, while the middle section 502 remains free. The CCA 400 (e.g., with the first connection section 422 and the second connection section 424) can extend beyond the frame 510 to the battery cell 120. The encapsulation material 450 can enclose a contact area between a first connection section 422 and the middle section 502 (e.g., terminal) of the battery cell 120. The encapsulation material 450 can enclose a contact area between a second connection section 424 and the outer edge 504 (e.g., terminal) of the battery cell 120. The encapsulation material 450 can extend to the frame 510. The cover 460 can have a shape that accommodates the encapsulation materials 450.For example, the cover 460 can have a concave shape facing the battery cell 120 (e.g., and / or the encapsulation material 450). Alternatively, the cover 460 can have a convex shape facing away from the battery cell 120. The cover 460 can rest on and / or engage with the CCA 400 and / or the frame 510. The cover 460 can be substantially rigid. The cover 460 can be made of a material such as metal (e.g., steel).

[0061] In some embodiments, the cover 460 is integrally (e.g., monolithically) formed with one or more frames (e.g., frames 510, 512, and / or 514). For example, the cover and / or the frame(s) can be extruded on opposite sides of the CCA 400. The CCA 400 can provide electrical conductivity within such an integrated structure.

[0062] The cover 460 can absorb forces and / or other loads from above, for example, from an upper layer 464 and / or through a compressible layer 462. For example, the compressible layer 462 can enclose a compressible material such as foam and / or rubber. Forces acting on the upper layer 464 can be dampened by the compressible layer 462. Forces acting on the cover 460 can be directed around and away from the encapsulation material 450, the first connection section 422, the second connection section 424, and / or the middle section 502 of the battery cell 120. Alternatively, the forces can be directed onto parts of the outer edge 504 of the battery cell 120 (e.g., via the CCA 400 and / or the frame 510). Thus, the connection between the first connection section 422 and the middle section 502 (e.g.,The encapsulation material 450 protects the connection between the first connection section 422 and the middle section 502 (e.g., terminal) of the battery cell 120 and between the second connection section 424 and the outer edge 504 (e.g., terminal) of the battery cell 120 despite the forces acting on the cover 460. In some embodiments, the encapsulation material 450 has a modulus of elasticity that is lower than the modulus of elasticity of the cover 460 and the modulus of elasticity of the frame 510. When forces are transmitted to the encapsulation material 450, these forces can be dampened before they reach the connection between the first connection section 422 and the middle section 502 (e.g., terminal) of the battery cell 120 and between the second connection section 424 and the outer edge 504 (e.g., terminal) of the battery cell 120.By protecting the battery cells 120 with these and / or other features, the battery module 115 and / or a battery pack containing one or more battery modules 115 can be positioned on or near the floor of the vehicle cabin. Since, for example, the cover 460 and / or the encapsulation materials 450 are assumed to provide sufficient protection for the battery cells 120, the thickness of other intermediate structures between the battery pack and the floor of the vehicle cabin can be minimized. For example, the quantity and / or number of additional damping materials can be reduced. Consequently, the overall height of the structure under the floor of the vehicle cabin can be minimized, resulting in a fully assembled product with greater space efficiency.

[0063] With reference to the Fig. 6, Fig. 7 to Fig. 8. Positioning features can be provided to facilitate the alignment of battery module components during assembly. Each positioning feature can include one or more components and / or an arrangement of components that form a datum. In the sense used herein, a datum refers to one or more components and / or an arrangement of components that constrains the relative movement of two or more components with respect to each other in one or more degrees of freedom. In some embodiments, the degrees of freedom are defined as directions along one or more axes of a coordinate system (e.g., including two opposite directions along a single axis). For example, a two-way datum constrains the relative movement of two or more components with respect to each other in two degrees of freedom, such as along two opposite directions of a common axis.Furthermore, a 4-way datum, for example, restricts the relative movement of two or more components to each other in four degrees of freedom, such as along two opposite directions on each of two distinct (e.g., orthogonal) axes. It is understood that a positioning feature of a particular component, based on an interaction with another feature of the other component, forms a datum for that component. If a single positioning feature interacts with multiple other components, one or more degrees of freedom can be provided for each of the other components with respect to the positioning feature in a common direction and / or along a common axis.

[0064] Fig. Figure 6 illustrates a top view of several frames on battery cells of a battery module. Each of the frames 510, 512 and / or 514 can include one or more positioning features for engaging the battery cells 120. In some embodiments, as shown in Fig. Figure 6 shows that the first intervention elements 520 form a 4-way datum and the second intervention elements 530 form a 2-way datum.

[0065] Fig. Figure 7 illustrates a bottom view of the first section of a frame on battery cells of a battery module. As in Fig. As shown in Figure 7, the frame 510 can include several first (e.g., three or more) engagement elements 520 extending between one or more battery cells 120. Each of the first engagement elements 520 can be configured as a pin or post extending parallel to a height of the battery cells 120. The first engagement elements 520 can be distributed around each of the battery cells 120. Accordingly, the first engagement elements 520 can form a 4-way datum to constrain the movement of the frame 510 with respect to the battery cells 120 in two different (e.g., orthogonal) axes.

[0066] Fig. Figure 8 illustrates a bottom view of a second section of a frame on battery cells of a battery module. As in Fig. As shown in Figure 8, the frame 510 can include a second engagement element 530 extending between one or more battery cells 120. The second engagement element 530 can be configured as a rib parallel to a height of the battery cells 120 and with a length perpendicular to the height of the battery cells 120. The second engagement element 530 can be positioned between any two or more battery cells 120. Accordingly, the second engagement element 530 can form a two-way datum to restrict the movement of the frame 510 relative to the battery cells 120 along one axis. The combination of the first engagement element 520 and the second engagement element 530 can further restrict the rotation of the frame 510 relative to the battery cells 120.

[0067] Fig. Figure 9 illustrates a top view of a current collector assembly on a frame and battery cells of a battery module. Each of the frames 510, 512, and / or 514 can include one or more positioning features for engaging the CCA 400. For example, each of the third engagement features 540 can form a two-way data point. As shown in Fig. As further shown in Figure 9, each of the frames 510, 512, and / or 514 can include one or more third engagement elements 540 extending into the openings 440 of the CCA 400. Each of the third engagement elements 540 can be configured as a pin or post extending in a direction opposite to that of the first and second engagement elements. Each of the third engagement elements 540 can project into a corresponding opening 440 of the CCA 400. In some embodiments, the shape, size, and / or orientation of the opening 440 allows movement of the CCA 400 along one axis and restricts movement of the CCA 400 along another (e.g., orthogonal) axis. If the openings 440 corresponding to the individual frames 510, 512 and / or 514 (e.g., overlap) differ (e.g., in shape, size and / or orientation), the permissible and restricted directions of movement may differ.While each of the third engagement elements 540 and its corresponding opening 440 can form a 2-way datum to restrict the movement of the CCA 400 with respect to the frame in one axis, the combination of several third engagement elements 540 and their corresponding openings 440 can form a 4-way datum to restrict the movement of the CCA 400 with respect to the frames 510, 512 and / or 514 in two axes.

[0068] With reference to the Fig. 10, Fig. 11 to Fig. 12. A frame can provide openings for access to one or more of the battery cells it covers. Fig. Figure 10 illustrates a top view of a frame section on a battery cell of a battery module. As in Fig. As shown in Figure 10, the frame 510 can define an opening 550 that is aligned with sections of the battery cell 120. The opening 550 can expose the central section 502 of the battery cell 120, thereby also exposing a terminal located there. The frame 510 can enclose a structure that is aligned to overlap portions of the outer edge 504 of the battery cell 120. Furthermore, the opening 550 can have a cutout 552 that exposes a portion of the outer edge 504, thereby also exposing a terminal located there. Thus, both the central section 502 and a portion of the outer edge 504 of the battery cell 120 can be exposed to provide a connection at the terminals located there.

[0069] Fig. Figure 11 illustrates a top view of a section of a current collector arrangement on the frame and battery cell of Fig. 10. The CCA 400 establishes a connection (e.g., mechanical and electrical) with several battery cells 120 of a battery module. The CCA 400 defines an opening 440 that overlaps sections of the battery cell 120. A first connecting section 422 and a second connecting section 424 extend into the opening 440 of the CCA 400 and the opening of the frame for connection with the battery cell 120. The first connecting section 422 of the CCA 400 is connected to the central section 502 of the battery cell 120. The second connecting section 424 of the CCA 400 is connected to the outer edge 504 of the battery cell 120. The first connecting section 422 and the second connecting section 424 can project into the opening 440 from different directions.While the first connecting section 422 can protrude into the opening 550 of the frame 510, the second connecting section 424 can protrude into the cutout 552, which exposes a section of the outer edge 504 of the battery cell 120.

[0070] Fig. Figure 12 illustrates a top view of encapsulation materials on a frame and battery cells of a battery module. As shown in Fig. As shown in Figure 12, each of the encapsulation materials 450 can be provided on a top surface of the corresponding battery cell 120. For example, each encapsulation material 450 can cover the central section 502 and at least a section of the outer rim 504 of the corresponding battery cell 120. Thus, the encapsulation material 450 can extend into the opening 550, including at least a portion of the cutout 552.

[0071] Dias encapsulation material 450 can extend to and / or overlap a section of the frame 510 and / or the CCA 400, including the connecting sections (not shown) that are connected to the battery cell 120.

[0072] Fig. Figures 13A to G illustrate various examples of a cover 460. In one or more embodiments, the cover 460 can be a composite protective cover with molded structural domes 466 and channels 468 that help to dissipate loads in the Z-direction (e.g., orthogonal to the surface of the cover 460) and prevent deformation of the underlying battery cells, thereby preventing thermal runaway. The molded structural domes 466 and channels 468 can accommodate the encapsulation adhesive to protect the welds between the battery cells and the current collector assembly.

[0073] Fig. Figure 13A illustrates a perspective view of a cover according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 13A, the cover 460 can enclose one or more domes 466, each forming a concave shape on a first side of the cover 460 and a convex shape on a second side of the cover 460. As shown in Fig. As further shown in Figure 13A, the cover 460 can enclose one or more channels 468. The channels 468 can extend between and / or be connected to two or more of the domes 466, so that the separate spaces, which are partially enclosed by the connected domes, are connected and form a continuous space.

[0074] Fig. Figure 13B illustrates a perspective view of a cover according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 13B, the cover 460 can enclose one or more domes 466, the domes 466 being able to have a similar (e.g., identical) shape and / or different shapes relative to one another. If the shape and / or size of individual domes 466 varies, one or more domes 466 with a common first shape and / or size can be arranged in a common first row and / or column, and one or more domes 466 with a common second shape and / or size that differs from the first shape and / or size can be arranged in a common second row and / or column. As shown in Fig. As further shown in Figure 13B, the cover 460 can optionally omit one or more channels.

[0075] Fig. Figure 13C illustrates a perspective view of a cover according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 13C, the cover 460 can enclose one or more channels 468. The channels 468 can extend parallel between and / or to opposite ends of the cover 460. As shown in Fig. As further shown in Figure 13C, cover 460 can optionally omit one or more domes.

[0076] Fig. 13D and Fig. Figure 13E illustrates a top view of a cover according to one or more implementations of the present disclosure. The cover 460 can include several sections, for example, a first cover section 460A and a second cover section 460B. Both the first cover section 460A and the second cover section 460B can include one or more domes 466 and one or more channels 468. The first cover section 460A and the second cover section 460B can have complementary shapes at their ends for joining with each other. For example, the cover 460, as shown in Fig. Figure 13E shows an opening 467 through which one or more other components of the arrangement extend and / or can be accessed. One or more openings 467 can be closed to be fully defined either at the first cover section 460A or at the second cover section 460B. One or more openings 467 can be open to be partially defined at either the first cover sections 460A and 460B and / or in a space between the first cover section 460A and the second cover section 460B.

[0077] Fig. Figure 13F illustrates a perspective view of a cover according to one or more implementations of the present disclosure. In some embodiments, the cover 460 may be integrated with one or more potting dams 790. For example, a potting dam 790 may be provided at one or both opposite ends of the cover 460. Furthermore, for example, several potting dams 790 may surround one or more domes 466 and / or one or more channels 468. The potting dams 790 may be formed from a material such as foam (e.g., die-cut). Each of the potting dams 790 may be connected to the cover 460, for example, using a pressure-sensitive adhesive (PSA) and / or another adhesive and / or fastening mechanism.

[0078] Fig. Figure 13G illustrates a bottom view of a cover according to one or more implementations of the present disclosure. The cover 460 can, for example, include an adhesive 465 on its underside for attachment to an underlying structure of the arrangement. For example, the cover 460 can be bonded to the underlying layers by means of a pressure-sensitive adhesive tape (PSA) and / or another adhesive and / or fastening mechanism. Furthermore, the adhesive 465 can, for example, be applied to the cover 460 by roll application. The adhesive 465 can be provided between, beside, and / or above one or more domes 466 and / or one or more channels 468. In some embodiments, the adhesive 465 can be provided at multiple locations and / or in different directions to provide security against forces that may act from different directions.In some embodiments, the cover 460 can be joined to the underlying layers by adhesive, heat contact rivets, pressure clamps, welding, rivets and / or combinations thereof.

[0079] Fig. Figure 13H illustrates a perspective view of a cover according to one or more implementations of the present disclosure. In some embodiments, the cover 460 may be integrated with one or more potting dams 790. In some embodiments, the cover 460 defines one or more through-holes 792 at each of its opposite ends. Each of the through-holes 792 may accommodate a projection or bolt (e.g., made of plastic) which is secured by heat-contact riveting to secure the cover 460 in place by being brought into a mold (e.g., a dome) by heat-contact riveting and / or melting.

[0080] Fig. Figure 14A illustrates a perspective exploded view of a cover over a current collector assembly of a battery module. As shown in Fig. As shown in Figure 14A, the cover 460 can be provided over the frame 510, 512 and / or 514, the CCA 400 and / or the encapsulation materials.

[0081] Fig. Figure 14B shows a top view of a cover on a frame of a battery module. Each of the frames 510, 512, and / or 514 can include one or more positioning features for engaging the cover 460. For example, each of the fourth engagement features 542 can form a two-way date. As shown in Fig. As further shown in Figure 14B, each of the frames 510, 512, and / or 514 can include one or more fourth engagement elements 542 projecting into the openings 472 of the cover 460. Each of the fourth engagement elements 542 can be configured as a pin or post extending in a direction opposite to that of the first and second engagement elements. Each of the fourth engagement elements 542 can project into a corresponding opening 454 of the cover 460. In some embodiments, the shape, size, and / or orientation of the opening 472 allows movement of the cover 460 along one axis and restricts movement of the cover 460 along another (e.g., orthogonal) axis. If the openings 472 corresponding to the individual frames 510, 512 and / or 514 (e.g., overlap) differ (e.g., in shape, size and / or orientation), the permissible and restricted directions of movement may differ.While each of the fourth engagement elements 542 and its corresponding opening 454 can form a 2-way datum to restrict the movement of the cover 460 relative to the frame in one axis, the combination of several fourth engagement elements 542 and their corresponding openings 454 can form a 4-way datum to restrict the movement of the cover 460 relative to the frames 510, 512 and / or 514 in two axes.

[0082] With reference to the Fig. From 15A to 16D, a series busbar can be provided to connect different sets (e.g., rows) of battery cells. Such a series busbar can provide robust conductivity between the different sets of battery cells while also providing one or more fuses to disconnect the electrical connection between them under certain conditions.

[0083] Fig. Figure 15A illustrates a perspective view of a 600 series busbar of a battery module. As in Fig. As shown in Figure 15A, the busbar 600 includes a first terminal 610 and a second terminal 612. In some embodiments, the first terminal 610 and the second terminal 612 can include one or more alignment features 608 for receiving one or more engagement elements (e.g., posts, pins, extensions, and / or the like) of a frame (not shown). For example, the alignment features 608 can include one or more openings. The openings can form 2-way and / or 4-way connections with the frame's engagement elements. For example, one or more of the alignment features 608 can receive the frame's engagement elements and allow a limited range of movement within the respective opening of the alignment features 608. The busbar 600 can be heat-riveted or otherwise attached to the frame at or near a location of the alignment features 608.

[0084] In some embodiments, the first terminal 610 can be configured to be connected (e.g., mechanically and electrically) to a first set of battery cells (e.g., via a CCA), and the second terminal 612 can be configured to be connected (e.g., mechanically and electrically) to a second set of battery cells (e.g., via the CCA). The busbar 600 can further include a fuse 620, which can contain multiple fuse elements 622, 624, and / or 626. The fuse 620 can connect the first terminal 610 and the second terminal 612 in parallel (e.g., mechanically and electrically). Although four fuse elements are illustrated, it is understood that any number of fuse elements can be provided.The safety elements 622, 624 and / or 626 offer the possibility of tripping in the event of excessive electrical current and thereby, under certain conditions, separating the first set of battery cells from the second set of battery cells.

[0085] In some embodiments, each of the multiple fuse elements 622, 624, and / or 626 has a different cross-sectional dimension. As used here, the cross-sectional dimension can be a width, thickness, height, diameter, and / or another dimension defined in a cross-section of the fuse elements 622, 624, and / or 626. One of the fuse elements 622, 624, and / or 626 can have the smallest cross-sectional dimension. Accordingly, the fuse element 622, 624, and / or 626 with the smallest cross-sectional dimension can have the lowest threshold for the electric current at which it trips. Upon tripping, the current through the remaining fuse elements 622, 624, and / or 626 can increase. Although the electric current at which they trip can be higher, such an increase can approach this threshold.For example, the first fuse element 622 on a first side 602 of the busbar 600 can have a first cross-sectional dimension. The second fuse element 624 between the first fuse element 622 and the third fuse element 626 can have a second cross-sectional dimension (e.g., different from and / or larger than the first cross-sectional dimension). The third fuse element 626 on a second side 604 opposite the first side 602 of the busbar 600 can have a third cross-sectional dimension (e.g., different from and / or larger than the first cross-sectional dimension and / or the second cross-sectional dimension). The first side 602 can face the CCA and / or other components of the battery module. The second side 604 can face away from the CCA and / or other components of the battery module.If fuse 620 receives an excessive electrical current, the first fuse element 622, which is closest to the other components of the battery module, may trip first, since the electrical current is relatively lower there. One or more of the other fuse elements, including the third fuse element 626, which is furthest from the other components of the battery module, may trip later if the electrical current is relatively higher there.

[0086] In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., the fuse elements 622, 624, and / or 626) are made of a conductive material (e.g., aluminum, copper, combinations thereof, and the like). In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., the fuse elements 622, 624, and / or 626) form a monolithic structure.

[0087] Fig. 15B illustrates a perspective view of the busbar of Fig. 15A with a housing. As in Fig. As shown in Figure 15B, the busbar 600 can include a fuse housing and / or a container 690 for receiving and / or surrounding the fuse 620, including the fuse elements 622, 624, and / or 626. The container 690 can be made of a non-conductive material (e.g., rubber). In some embodiments, the container 690 is provided in several (e.g., two) parts, for example, as a first container section 691 and / or a second container section 695. The first container section 691 and the second container section 695 are assembled on opposite sides of the fuse 620. The first container section 691 and the second container section 695 can be joined to one another, for example, by ultrasonic welding and / or the like. In some embodiments, the container 690 encloses a space within it, and an encapsulation material is provided at one or more of the spaces within it.For example, the container 690 can be filled with one or more materials serving as encapsulation material. For example, the encapsulation material can enclose a quantity of an electrically insulating material (e.g., quartz sand, other electrically insulating grains, and the like). The encapsulation material can fill spaces between the parts of the container 690 and / or the fuse 620. In some embodiments, the container 690 is filled with the encapsulation material (e.g., quartz sand), and then a sealing plug (e.g., by press-fitting) is fitted to retain the encapsulation material.

[0088] Fig. Figure 16A illustrates a perspective view of a section of another 600 series busbar of a battery module. As shown in Fig. As shown in Figure 16A, the busbar 600 includes a first terminal 610 and a second terminal 612, which may have one or more features as described with reference to the busbar 600. Fig. 15A and Fig. 15B described. The busbar 600 can also include a fuse 620, which can include one or more fuse plates 632. The fuse 620 can connect the first terminal 610 and the second terminal 612 in parallel (e.g., mechanically and electrically). Although two fuse plates 632 are illustrated, it is understood that any number of fuse plates can be provided. The fuse plates 632 each define one or more fuse elements 636, which are arranged in one or more columns (e.g., two columns, as in Fig. (as shown in Figure 16A) are arranged and separated from each other by one or more openings 638, each located between a pair of fuse elements 636. The openings 638 can be round (e.g., circular) or of another shape. Accordingly, the fuse elements 636 can each have a variable cross-sectional dimension along their respective length. The fuse elements 636 provide the possibility of tripping in the event of excessive electrical current and thereby, under certain conditions, disconnecting the first set of battery cells from the second set of battery cells.

[0089] In some embodiments, one or more (e.g., two or more) locking plates 632 are provided between the first terminal 610 and the second terminal 612. In some embodiments, each locking plate 632 has one or more (e.g., two or more) columns of locking elements 636 and / or openings 638. In some embodiments, the locking elements 636 and / or openings 638 provide a variable (e.g., curved, round, and / or circular) cross-sectional shape along their respective lengths and / or a consistent (non-variable) cross-sectional shape along their respective lengths.

[0090] In some embodiments, each of the multiple locking elements 636 has a different cross-sectional dimension than one or more of the other locking elements 636. As used here, the cross-sectional dimension can be a width, thickness, height, diameter, and / or another dimension defined in a cross-section of the locking elements 636. One of the locking elements 636 can have a smallest cross-sectional dimension relative to one or more of the other locking elements 636. Accordingly, the locking element 636 with the smallest cross-sectional dimension can have a lowest threshold for the electric current at which it trips. Upon tripping, the current through the remaining locking elements 636 can increase. Although the electric current at which they trip can be higher, such an increase can approach this threshold.For example, the first fuse elements 636 on the first side 602 may be smaller than the fuse elements 636 on the second side 604. Accordingly, if the fuse 620 receives an excessive electrical current, the smaller fuse elements 636 located closest to other components of the battery module may trip first, since the electrical current is relatively lower there. The one or more other fuse elements 636 located furthest from the other components of the battery module may trip later if the electrical current is relatively higher there. In some embodiments, the fuse elements 636 may have a common cross-sectional dimension (e.g., a minimum cross-sectional dimension).

[0091] In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., the fuse plates 632) are made of a conductive material (e.g., aluminum, copper, combinations thereof, and the like). In some embodiments, the first terminal 610, the second terminal 612, and the fuse 620 (e.g., the fuse plates 632) are an arrangement of separate parts. This makes it possible to mount several fuse plates 632 in parallel between the first terminal 610 and the second terminal 612.

[0092] Fig. Figure 16B illustrates a perspective view of a first container section 691 of a container for a busbar according to one or more implementations of the present disclosure. In some embodiments, the first container section 691 includes a first body 692 and one or more engagement elements 693 (e.g., posts, pins, extensions, and / or the like) extending from the first body 692. For example, the engagement elements 693 may each extend in a common direction. In some embodiments, the engagement elements 693 may have the same size, shape, and / or other features. In some embodiments, the first container section 691 may provide symmetry over one or more axes.The first container section 691 can provide and / or be provided with an adhesive 694 on one or more surfaces, for example a surface from which the engagement elements 693 extend.

[0093] Fig. Figure 16C illustrates a perspective view of a second container section 695 of a container for a busbar according to one or more implementations of the present disclosure. In some embodiments, the second container section 695 includes a second body 696 and one or more openings 697 (e.g., cavities, recesses, holes and / or the like) extending within the second body 696.

[0094] For example, the openings 697 can each extend in a common direction. In some embodiments, one or more of the openings 697 can have the same size, shape, and / or other features. In some embodiments, one or more of the openings 697 can have different sizes, shapes, and / or other features. The openings 697 can form a 2-way and / or 4-way connection with the engagement elements 693 of the first container section 691. For example, one or more of the openings 697 can accommodate engagement elements 693 of the first container section 691 and allow a limited range of movement for these elements within the respective opening 697 of the second container section 695. In some embodiments, the second container section 695 can provide symmetry over one or more axes.The second container section 695 can provide and / or be provided with an adhesive 698 on one or more surfaces, for example a surface into which the engagement elements 697 extend.

[0095] Fig. Figure 16D illustrates a perspective view of a section of a busbar with a first section of a container according to one or more implementations of the present disclosure. In some embodiments, as in Fig. As shown in Figure 16D, the busbar 600 (e.g., near or at the fuse 620) can include one or more alignment features 634 for receiving engagement elements 693 (e.g., posts, pins, extensions, and / or the like) of the first container section 691. For example, the alignment features 6345 can be formed at or near the first terminal 610 and / or the second terminal 612. In some embodiments, the alignment features 634 can include one or more openings. The openings can form 2-way and / or 4-way connections with the engagement elements 693 of the first container section 691. For example, one or more of the alignment features 634 can receive engagement elements 693 of the first container section 691 and allow a limited range of movement for them within the respective opening of the alignment features 634.

[0096] With reference to the Fig. 17, Fig. 18, Fig. 19 to Fig. 20. A battery module 115 can be equipped with features to facilitate potting and handling, and to support its components. For example, one or more potting dams can be provided to limit the penetration of potting material.

[0097] Fig. Figure 17 illustrates a perspective view of a potting dam of a battery module. As in Fig. As shown in Figure 17, a potting dam 700 can include a structure that complements the shape of other components of a battery module and provides a seal against the penetration of a potting material. In some embodiments, the potting dam 700 includes a transverse structure 710 and one or more longitudinal structures 720. The one or more longitudinal structures 720 can extend transversely to the transverse structure 710. It is understood that the potting dam 700 can have one or more different shapes and / or sizes to provide a seal at the edges and / or corners of a battery module. The potting dam 700 can be made of a flexible, compressible, and / or compliant material, such as a polymer (e.g., neoprene), rubber, and / or foam. The potting dam 700 can be substantially impermeable to a potting material.

[0098] Fig. Figure 18 illustrates a perspective view of a section of a battery module with a potting dam. As in Fig. As shown in Figure 18, the potting dam 700 can extend along the outer edges of one or more components of the battery module 115. For example, the transverse structure 710 can extend along one end of the cover 460. The one or more longitudinal structures 720 can extend between the cover 460 and the base 302, for example, at their end faces. It is understood that the potting dam 700 can include one or more other sections that extend along and / or abut other components of the battery module 115.

[0099] Fig. Figure 19 illustrates a perspective view of a section of a battery module with a potting dam. As in Fig. As shown in Figure 19, the battery module 115 can be provided in a configuration to receive a potting compound. For example, the battery module 115 can be installed in a reversed orientation relative to the one shown in Figure 19. Fig. The orientation shown in Figure 18 is provided. In such a configuration, the transverse structure 710 of the potting dam 700 can extend horizontally along a bottom section at a terminal end of the battery module 115. Furthermore, in such a configuration, the longitudinal structures 720 of the potting dam 700 can extend vertically along the edges and corners of the battery module 115. Moreover, in such a configuration, the battery module 115 is prepared to receive potting material, for example, a liquid that hardens into a solid. Accordingly, the potting dam 700 can help to keep the potting material within the limits defined by the periphery of the battery module 115.

[0100] Fig. Figure 20 illustrates a perspective view of a section of a battery module with multiple potting dams. As in Fig. As shown in Figure 20, a support frame 800 can support multiple battery modules (not shown) between opposing pairs of potting dams 700. For example, the support frame 800 can include multiple receiving recesses 810, each to receive one of several battery modules. The battery modules can be positioned between opposing pairs of potting dams 700, and potting material can be applied to the battery modules and / or within the multiple receiving recesses 810 of the support frame 800. Accordingly, the potting dam 700 can retain the potting material in the receiving recesses 810.

[0101] With reference to the Fig. 21 and Fig. 22. A battery module can provide 115 features that facilitate potting and support its components. For example, openings in a base and / or frame facilitate the penetration of potting material into the entire assembly and venting in the event of a thermal event.

[0102] Fig. Figure 21 illustrates a perspective view of a section of a battery module 115 with a base 302 and a frame containing battery cells 120, according to one or more implementations of the present disclosure. Fig. Figure 22 illustrates a bottom view of a section of a battery module 115 with a base 302 supporting a battery cell 120, according to one or more implementations of the present disclosure.

[0103] As in Fig. As shown in Figure 21, a battery module 115 can include a base 302 and a frame 510 (and / or frames 512 and / or 514, not shown). The base 302 can include a base plate 304 defining multiple base plate openings 372. Each of the multiple base plate openings 372 can extend through the base plate 304 to provide access to a first side of each of the multiple battery cells 120. The base 302 can further include base walls 360 extending from an inside of the base plate 304 to opposite edges of the base plate 304. Each of the base walls 360 can define multiple base wall openings 370, each extending through a corresponding base wall 360. In some embodiments, each of the base wall openings 370 is arranged opposite a corresponding base plate opening 372.In some embodiments, the base walls 360 also define multiple base recesses 362 that point away from one another, and base projections 364 that are configured to point away from the frame. The multiple base recesses 362 can facilitate the engagement of a carrying tool or other object that acts upon the base 302 (e.g., for moving and / or rotating the battery module 115).

[0104] The frame 510 can include a frame plate defining multiple frame openings 550. Each of the multiple frame openings 550 can extend through the frame plate to provide access to a second side of the respective multiple battery cells 120. The frame 510 can further include frame walls 560 extending from an inside of the frame plate to opposite edges of the frame plate. Each of the frame walls 560 can define multiple frame wall openings 570, each extending through one of the frame walls 560. The base plate openings 372, the base wall openings 370, and the frame wall openings 570 provide flow paths for a potting material that travels along the multiple battery cells 120 to an outside of the battery subassembly. In some embodiments, each of the frame wall openings 570 is arranged opposite a corresponding frame plate opening (not shown).In some embodiments, the base walls 360 further define several frame recesses 562 that point away from one another, and frame projections 564 that are configured to point away from the base 302. The multiple frame recesses 562 can facilitate the engagement of a lifting tool or other object that acts upon the frame 510 (e.g., to move the assembly).

[0105] With reference to the Fig. 22, Fig. 23 to Fig. 24 In some embodiments, the arrangement includes support structures that separate rows of battery cells from each other and provide resistance to bending. Fig. Figure 23 illustrates a sectional view of a section of a battery module 115 with a base 302 supporting a battery cell 120, according to one or more implementations of the present disclosure. Fig. Figure 24 illustrates a perspective view of a section of a battery module 115 with a base 302 supporting a battery cell 120, according to one or more implementations of the present disclosure.

[0106] As in the Fig. 22, Fig. 23 to Fig. As shown in Figure 24, a base 302 for a battery module 115 can enclose a plate 304 defining rows of multiple openings 372, each of the multiple openings 372 extending through the plate 304. The base 302 can include projections 380 of the plate 304, each extending radially inward into a corresponding multiple opening 372 to support a corresponding multiple battery cell 120. A maximum cross-sectional dimension across each of the multiple openings 372 is larger than a maximum cross-sectional dimension of any of the respective battery cells 120. A minimum cross-sectional dimension across each of the multiple openings 372, defined by at least one of the projections 380, is smaller than the maximum cross-sectional dimension of the respective battery cell 120.

[0107] As in Fig. As shown in Figure 23, the base 302 can further include inner rays 352, each extending from an inner side of the plate 304 and between a respective pair of rows of the multiple battery cells 120. The base 302 can further include outer rays 354, each extending from an outer side of the plate 304 between a respective pair of rows of multiple openings. In some embodiments, the number of outer rays 354 is greater than the number of inner rays 352. In some embodiments, each of the inner rays 352 is aligned with a corresponding outer ray 354. In some embodiments, the outer rays 354 include at least two outer rays 354 extending between a given pair of rows of multiple openings. In some embodiments, the outer rays 354 have a first height that is less than a second height of the inner rays 352.

[0108] As in Fig. As shown in Figure 24, various types of openings can be provided. For example, frame plate openings 372 can be provided, and the plate 304 can further define additional openings 358 extending between the at least two outer beams 354 and providing a fluid connection between the inside and outside of the plate 304. As shown in Fig. As further shown in Figure 24, different types of openings can be provided. For example, the outer rays can be first outer rays 354 and the base 302 can further include second outer rays 356 that extend over one or more of the rows of multiple openings to connect several of the first outer rays 354.

[0109] With reference to Fig. 25 The base can provide one or more features for attaching battery cells to it. Fig. Figure 25 illustrates a perspective view of a section of a battery module 115 with a base 302 supporting a battery cell 120, according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 25, a base 302 of a battery module 115 can enclose an adhesive strip 390 (e.g., made of or containing a pressure-sensitive adhesive) to connect the battery cells 120 to the base 302 along opposite edges of adjacent rows. The strip 390 can be arranged to contact only certain sides of the battery cells 120 in different rows. For example, when the battery cells 120 are provided at the base 302, the adhesive strip 390 can be brought into contact with the first sides of battery cells 120 arranged in a first and a second row. Accordingly, the strip 390 can extend along an inner surface of the base 302 such that the adhesive strip 390 is connected to opposite sections of the battery cells 120 of the first and second rows.Subsequently, one or more frames can be provided as abutting the second sides of the battery cells 120, with the second sides of the battery cells 120 facing the first sides of the battery cells 120. The current collector assembly 400 can be arranged on the first set of battery cells 120. One or more potting dams can extend along each end of the frame to the base 302. Potting material can then be provided between the frame and the base 302.

[0110] Fig. Figure 26 illustrates a perspective view of a section of a battery module 115 with a voltage and temperature compensation module (“BVT” module) according to one or more implementations of the present disclosure.

[0111] In some embodiments, a BVT module 314 is provided at one end of the battery module 115. The BVT module 314 is communicatively coupled to one or more temperature sensors, such as a thermistor arrangement 316 and / or 317. The BVT module 314 can take the form of a modular arrangement of various electrical components for monitoring and / or controlling components of the battery module 115. For example, the BVT module 314 can include a printed circuit board 338 mounted on a housing 330 of the BVT module 314. The BVT module 314 can include various connectors for coupling to, for example, a thermistor, a voltage sensor arrangement 328, and / or a communication device, as non-limiting examples. The voltage sensor arrangement 328 can include a cable harness 326 for connection to the BVT module 314.The voltage sensor or equalizer can detect or control the voltage flowing through the battery module 115 and / or one or more of its battery cells 120. The communication device can receive, transmit, or analyze data associated with the battery module 115 and / or one of its battery cells 120. In some embodiments, the BVT module 314 can include one or more terminals 324 and / or one or more test pads 322 for testing and / or connecting to other devices. As shown in... Fig. As further shown in Figure 26, the battery module 115 can include one or more busbars 320 for connection to one or more other devices and / or components. The one or more busbars 320 can include and / or define connections for supplying another device and / or component with electrical energy. The busbars 320 can each be provided with a seal 318 or other barrier surrounding parts of them.

[0112] With reference to the Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32 to Fig. 33 A current collector arrangement (CCA) can be provided to connect one or more battery cells. Fig. Figure 27 illustrates a top view of a section of a battery module 115 with a current collector arrangement 400 connected to a battery cell 120 according to one or more implementations of the present disclosure. As shown in Fig. As shown in Figure 27, the CCA 400 has a weld tab geometry that provides a certain degree of overlap with a corresponding connection of the battery cell 120.

[0113] As in Fig. As shown in Figure 27, the battery module 115 is assembled by attaching a current collector assembly 400 to one or more battery cells 120. Each of the one or more battery cells 120 includes a central section 502, which defines a first connection, and an outer edge 504, which defines a second connection. In some embodiments, a battery module 115 can include one or more battery cells 120, each of which includes a central section 502, which defines a first connection, and an outer edge 504, which defines a second connection. The current collector assembly 400 can include one or more first connection sections 422 and one or more second connection sections 424. The one or more first connection sections 422 can each be welded to a respective central section 502 of each of the one or more battery cells 120.The one or more second connecting sections 424 can each be welded to a corresponding outer edge 504 of the respective one or more battery cells 120.

[0114] In some embodiments, each of the one or more first connection sections 422 of the current collector arrangement 400 is welded to one or more first weld areas 432 to a respective central section 502 of each of the one or more battery cells. In some embodiments, each of the one or more second connection sections 424 of the current collector arrangement 400 is welded to one or more second weld areas 434 to a respective outer edge 504 of each of the one or more battery cells 120.

[0115] In some embodiments, each of the one or more second connecting sections 424 terminates in a respective concave edge 430 that extends along a concave shape of the respective outer edge 504 of the respective one or more battery cells 120. In some embodiments, the respective concave edge 430 of each of the one or more second connecting sections 424 is positioned such that several sections along the respective concave edge 430 have a common distance from the respective central section 502 of the respective one or more battery cells 120. Thus, the distance between the concave edge 430 and the central section 502 can be maintained at an approximately constant distance across different sections. The distance can be selected to minimize and / or prevent dielectric breakdown between the concave edge 430 and the central section 502.

[0116] Fig. Figure 28 illustrates a top view of a section of a current collector arrangement 400 according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 28, the current collector arrangement 400 can include a first conductor 442 and a second conductor 444. The first conductor 442 can have one or more sections that terminate adjacent to each of the one or more first connecting sections 422. For example, the second conductor 444 can define ends (e.g., terminal ends) that terminate at a location from which a corresponding connecting section extends into an opening 440 of the CCA 400. The second conductor 444 can overlap with the first conductor 442 and define at least a portion of each of the one or more first connecting sections 422.

[0117] In some embodiments, the first conductor 442 is welded to the second conductor 444 at one or more CCA weld areas 480. In some embodiments, the one or more CCA weld areas 480 extend in one or more rows along one or more sections of the first conductor 442. In some embodiments, each of the one or more first connection sections 422 extends from a respective one or more sections of the first conductor 442.

[0118] Fig. Figure 29 illustrates a top view of a section of a current collector arrangement 400 with enlarged views of the connecting sections 422 and 424 according to one or more implementations of the present disclosure. In some embodiments, each of the connecting sections 422 and / or 424 extends into an opening 440 of the CCA 400. For example, a pair consisting of a connecting section 422 and a connecting section 424 may extend into a common opening 440.

[0119] Fig. Figure 30 illustrates a top view of a section of a current collector arrangement 400 according to one or more implementations of the present disclosure. In some embodiments, each of the one or more first connection sections 422 (e.g., defined as a section of the first conductor 442) extends from a respective section of the second conductor 444, which includes one or more CCA weld areas 480. For example, as shown in Figure 30, the first conductor 442 extends from a section of the second conductor 444, which includes one or more CCA weld areas 480. Fig. As shown in Figure 30, the first connecting section 422 can be defined as a section of the first conductor 442 extending into an opening 440 of the CCA 400. The first connecting section 422 can extend from a section of the second conductor 444, on which several (e.g., three) CCA weld areas 480 are provided to couple the first conductor 442 to the second conductor 444. This provides improved fastening of the first conductor 442 to the second conductor 444 at a location where additional forces can act (e.g., via the first connecting section 422).

[0120] With reference to the Fig. 31, Fig. 32 to Fig. 33 CCA welds can be provided in one or more different shapes to provide secure coupling between conductor layers.

[0121] Fig. Figure 31 illustrates a top view of a section of a current collector arrangement 400 according to one or more implementations of the present disclosure. In some embodiments, as in Fig. As shown in Figure 31, each of the one or more CCA welding areas defines a spiral shape. Such a shape can provide redundant protection within an area (e.g., across multiple turns of the spiral) while avoiding excessive energy input during the welding process. For example, a spiral can be designed with gradual turns (e.g., without corners) without crossing its own path. This allows the energy input to be uniform along the entire length to ensure a consistent weld depth.

[0122] Fig. Figure 32 illustrates a top view of a section of a current collector arrangement 400 according to one or more implementations of the present disclosure. In some embodiments, as in Fig. As shown in Figure 32, each of the one or more CCA welding areas 480 defines (and / or is part of) a continuous series of multiple loops extending along a length of the first conductor 442. Such a configuration can provide redundant protection within an area (e.g., across multiple loops) while avoiding excessive energy input during the welding process. For example, the loops can be designed with gradual turns (e.g., without corners). The loops may intersect their paths but can be spaced apart to allow sufficient cooling of the previously welded area before the intersection occurs. This allows the energy input to be uniform over the entire length to ensure a consistent weld depth. The continuous aspect of the multiple loops provides continuous protection over the entire length.

[0123] Fig. Figure 33 illustrates a top view of a section of a current collector arrangement 400 according to one or more implementations of the present disclosure. In some embodiments, as in Fig. As shown in Figure 33, each of the one or more CCA welding areas 480 defines (and / or is part of) a wave-like shape extending along a length of the first conductor 442. Such a shape can provide redundant reinforcement within an area (e.g., across multiple waves) while avoiding excessive energy input during the welding process. For example, the loops can be designed with gradual turns (e.g., without corners) without intersecting each other. This allows the energy input to be uniform over the entire length to ensure a consistent weld depth. The continuous aspect of the wave shape (e.g., with multiple waves) provides continuous fastening over the entire length.

[0124] With reference to the Fig. 34 and Fig. 35 layers of a current collector arrangement can be welded together to provide fastening and electrical conductivity. Fig. Figure 34 illustrates a sectional view of a section of a current collector arrangement 400 and a voltage sensor arrangement 328 according to one or more implementations of the present disclosure. As shown in Fig. As shown in Figure 34, the CCA 400 can include several layers, including one or more layers of conductors (e.g., the first conductor 442 and / or the second conductor 444) and one or more layers of cover sheets (e.g., an upper cover sheet 482 and / or a lower cover sheet 488). The first conductor 442 and / or the second conductor 444 can include an electrically conductive material (e.g., aluminum, copper, nickel, and / or combinations thereof). The upper cover sheet 482 and / or the lower cover sheet 488 can include an electrically insulating material (e.g., PET, another polymer, and / or combinations thereof). The upper cover sheet 482 and the lower cover sheet 488 can surround the first conductor 442 and / or the second conductor 444 in different areas of the CCA 400 to provide electrical insulation.

[0125] Providing the first conductor 442 and the second conductor 444 in separate layers facilitates an efficient welding process. In some embodiments, the first conductor 442 can be thinner (e.g., have a smaller thickness) than the second conductor 444. Such relative dimensions allow a relatively thinner layer (e.g., the first conductor 442) to fuse, melt, and / or weld with a relatively thicker layer (e.g., the second conductor 444). The combined thickness of the first conductor 442 and the second conductor 444 can ensure sufficient electrical conductivity. The second conductor 444 can provide continuity into the connection sections 422 and / or 424, such that sections of the second conductor 444 form the connection sections 422 and / or 424. The connecting sections 422 and / or 424 are then welded to the battery cells as described herein.Accordingly, the second conductor 444 provides the material that can be melted and / or welded into the relevant sections (e.g. middle sections and / or outer edges) of the battery cells.

[0126] As in Fig. As further shown in Figure 34, the voltage sensor arrangement 328 can include several layers, including one or more layers of conductors (e.g., the VS conductor 334) and one or more layers of cover layers (e.g., an upper VS cover layer 332 and / or a lower VS cover layer 336). It is understood that the voltage sensor arrangement 328 may extend over only a portion of the CCA 400. The VS conductor 334 can include an electrically conductive material (e.g., aluminum, copper, nickel, and / or combinations thereof). The upper VS cover layer 332 and / or a lower VS cover layer 336 can include an electrically insulating material (e.g., PET, another polymer, and / or combinations thereof). The upper VS cover layer 332 and / or a lower VS cover layer 336 can surround the VS conductor 334 in various areas of the voltage sensor arrangement 328 to provide electrical insulation.

[0127] As in Fig. Figure 34 further shows that a layer of adhesive 452 is provided to attach the CCA 400 to a frame (not shown). The adhesive 452 can include a pressure-sensitive adhesive. By applying pressure or force (e.g., pressing), the CCA 400 (e.g., on the lower cover layer 488) can be securely attached to the frame. Such adhesion can occur after the CCA 400 is aligned with respect to the frame, as further described herein. Accordingly, the adhesive 452 can attach the CCA 400 to the frame, and welds at the joint sections can attach the CCA 400 to the battery cells.

[0128] Fig. Figure 35 illustrates a sectional view of a section of a CCA 400 according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 35, the second conductor 444 can have a thickness Tr. For example, the thickness Tr can be between 0.2 mm and 0.8 mm (e.g., 0.5 mm) in one or more implementations. As another example, in one or more implementations, the thickness of the first conductor 442 can be between 0.1 mm and 0.7 mm (e.g., 0.3 mm). As shown, the depth of the CCA welds 480 to the second conductor 444 can be within the thickness Tr of the second conductor 444. For example, in a method for welding the first conductor 442 to the second conductor 444, it may be permitted that the CCA weld(s) 480 penetrate to and / or completely penetrate the second conductor 444 in some cases (e.g., with or without extension to another substrate, such as the bottom cover layer 488). In the example of Figure 35, the thickness Tr can be between 0.1 mm and 0.7 mm (e.g., 0.3 mm). Fig. Figure 35 includes the CCA weld 480, which connects the first conductor 442 to the second conductor 444, and several weld sections 480A, 480B, and 480C, which can represent sections of a continuous weld. For example, the multiple weld sections 480A, 480B, and 480C can represent multiple turns of a spiral shape, multiple loops of a continuous shape, and / or multiple waves of a corrugated shape.

[0129] With reference to the Fig. 36 and Fig. 37. An alignment tool and a method for aligning multiple components of a battery subassembly can be provided. In some embodiments, the alignment features can enable interactions with an alignment tool that need not be part of the resulting battery module. The layers of the subassembly also include positioning features for alignment.

[0130] Fig. Figure 36 illustrates a perspective view of part of a battery module 115, which includes a current collector arrangement 400 and a frame 510 stacked one above the other and over battery cells 120, according to one or more implementations of the present disclosure. In some embodiments, as in Fig. As shown in Figure 36, the battery module 115 includes a current collector assembly 400 and / or a frame 510 (and / or frames 512 and / or 514, not shown). The current collector assembly 400 can be positioned under a cover (not shown) and includes connection sections 422 and / or 424 for electrical connection to terminals and / or one or more battery cells 120. The current collector assembly 400 can define a CCA opening 402 extending through the current collector assembly 400, forming a shape with a second dimension smaller than a first dimension (e.g., the cover). The frame 510 can define a frame opening 516 extending through the frame, forming a shape with a third dimension smaller than the second dimension. The current collector arrangement 400 can be connected to the one or more battery cells 120 through additional frame openings in the frame 510.

[0131] Fig. Figure 37 illustrates a sectional view of a section of a battery module 115 with a cover 460, a current collector arrangement 300, and a frame 510, aligned using a conical tool, according to one or more implementations of the present disclosure. As in Fig. As shown in Figure 37, the cover opening, the CCA opening, and the frame opening can be concentrically aligned. The cover 460 can overlap the current collector assembly 400, which in turn can overlap the frame 510. In some embodiments, the cover 460 can define a cover opening 472 that extends through the cover 460 and forms a shape with a first size. For example, the CCA opening 402 of the current collector assembly 400 can be aligned concentrically with the frame opening 516 of the frame 510 between the current collector assembly 400 and the one or more battery cells. Furthermore, for example, the cover opening 472 of the cover 460 can be aligned concentrically with the CCA opening of the current collector assembly 400. Such alignment can be performed sequentially or simultaneously. For example, an alignment tool 490 can be provided.The alignment tool 490 can have a conical or other shape that engages in the cover opening 472 of the cover 460, the CCA opening 402 of the current collector assembly 400, and the frame opening 516 of the frame 510. Based on the respective shapes and / or sizes of the cover opening 472, the CCA opening 402, and the frame opening 516, the alignment tool 490 can force each of the corresponding structures to be concentric with each other. For example, the cover opening 472, the CCA opening 402, and the frame opening 516 can have the same or a similar shape with different sizes (e.g., progressively larger or smaller in the stacking direction). Thus, the alignment tool 490 can force the cover 460, the current collector assembly 400, and the frame 510 into alignment with each other.

[0132] Fig. Figure 38 illustrates a flowchart showing an example of a Process 900 that can be carried out to form a battery module according to one or more implementations of the present disclosure. For explanatory purposes, Process 900 is described herein mainly with reference to components that are described in the Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18, Fig. 19, Fig. 20, Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25, Fig. 26, Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32, Fig. 33, Fig. 34, Fig. 35, Fig. 36 to Fig. 37 are illustrated. However, the 900 process is not limited to those shown in the Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18, Fig. 19, Fig. 20, Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25, Fig. 26, Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32, Fig. 33, Fig. 34, Fig. 35, Fig. 36 to Fig. The components illustrated in Figure 37 are limited, and one or more blocks (or operations) of Process 900 may be performed by one or more other components of other suitable movable equipment, devices, or systems. Furthermore, for illustrative purposes, some of the blocks of Process 900 are described herein as being performed serially or linearly. However, several blocks of Process 900 may be performed in parallel. Additionally, the blocks of Process 900 need not be performed in the sequence shown, and / or one or more blocks of Process 900 need not be performed and / or may be replaced by other operations.

[0133] Block 902 provides a base. The base can be configured and arranged to support one or more battery cells, including one or more such battery cells.

[0134] Block 904 provides one or more battery cells and / or sets of battery cells. For example, the base may be provided with battery cells and / or sets of battery cells. Sets of battery cells may be arranged so that they contact a cooling element (e.g., an intercellular cooling tube). For example, the battery cells may be separated from each other by the cooling element. The arrangement of cells in contact with a cooling element (e.g., an intercellular cooling tube) may be referred to as a vine or vine arrangement.

[0135] Block 906 provides one or more frames. For example, the one or more frames may be provided in such a way that they extend over one or more battery cells and / or such battery cells.

[0136] In block 908, a current collector assembly is connected to each of the one or more battery cells. For example, the current collector assembly can be provided on one or more frames, and parts of the current collector assembly can extend through the frame to connect to the terminals of the battery cells.

[0137] Block 910 can accommodate one or more encapsulation materials. For example, each encapsulation material can cover part of the frame, part of a battery cell (e.g., terminals), and part of the current collector assembly (e.g., connecting sections).

[0138] In block 912, a busbar is connected to one or more battery cells and / or sets of battery cells. For example, the busbar may be provided on a section of one or more frames. As another example, the busbar may connect a first set of battery cells on the first side of a cooling element to a second set of battery cells on the second side of the cooling element.

[0139] Block 914 provides a cover. For example, the cover may be provided on at least part of the one or more frames, the current collector assembly, and / or the encapsulation materials.

[0140] Block 916 provides one or more potting dams. For example, a potting dam can be provided at each end of a section of the battery module.

[0141] Block 918 provides a potting compound. For example, the potting compound can be provided in such a way that it penetrates into and / or between one or more components of the battery module. The one or more potting dams can retain the potting compound in a specific area of ​​the battery module.

[0142] According to one or more implementations of the present disclosure, a process for assembling a battery module is provided. According to one or more implementations of the present disclosure, a facility is provided in which a battery module is assembled. Fig. Figure 39 illustrates a flowchart showing an example of a process that can be carried out to assemble a battery module according to one or more implementations of the present disclosure. For explanatory purposes, the process is described here mainly with reference to components that are included in the Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18, Fig. 19, Fig. 20, Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25, Fig. 26, Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32, Fig. 33, Fig. 34, Fig. 35, Fig. 36 to Fig. 37 are illustrated. However, process 1000 is not limited to those in the Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18, Fig. 19, Fig. 20, Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25, Fig. 26, Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32, Fig. 33, Fig. 34, Fig. 35, Fig. 36 to Fig. The components illustrated in Figure 37 are limited, and one or more blocks (or operations) of the process may be performed by one or more other components of other suitable movable equipment, devices, or systems. Furthermore, for illustrative purposes, some of the process blocks are described herein as being performed serially or linearly. However, several process blocks may be performed in parallel. Additionally, the process blocks need not be performed in the sequence shown, and / or one or more process blocks need not be performed, and / or may be replaced by other operations.

[0143] In a first phase 1010 (e.g., a phase for assembling a battery cell set) and in block 1012, a set of battery cells can be arranged in a predetermined configuration and / or pattern (e.g., a "vine") that includes one or more rows and / or columns, for example, to contact a thermal management element or component, such as a cooling element or component. In block 1014, battery cells (e.g., on a cooling tube positioned between the cells) can be loaded into a device (and / or next to a cooling element). In block 1014, the device can be rotated (e.g., in a first direction) to facilitate the alignment of the battery cells, for example, by means of one or more datums and / or by means of gravity (with the battery cells on a first side of the cooling element). In blocks 1016 and 1018, a first (e.g., starboard) side of the arrangement of battery cells can be moistened (e.g.,The cells are attached to a cooling tube (e.g., with adhesive or another material) and cured. In block 1020, the device can be rotated (e.g., in a second direction) to facilitate the alignment of the battery cells, for example, using one or more dates and / or gravity (with the battery cells on a second side of the cooling element). In blocks 1022 and 1024, a second (e.g., terminal) side of the battery cell arrangement can be moistened (e.g., with adhesive or another material) and cured.

[0144] In a second phase 1030 (e.g., a phase for checking the battery cell set), a set of battery cells can be inspected. In blocks 1032, 1034, and 1036, such an inspection can include rotating the device (and / or the arrangement of the battery cells), taking a measurement (e.g., using one or more metrics), and / or performing a high-voltage test to assess the dielectric strength of the battery cell insulation.

[0145] In a third phase 1040 (e.g. a discharge phase for battery cell sets) the arrangement of the battery cells on a pallet, which has been prepared with a barrier and arranged with regard to the arrangement of the battery cells, can be provided in blocks 1042, 1044 and 1046.

[0146] In a fourth phase 1050 (e.g., a frame assembly phase), the set of battery cells can be provided to a base as described herein, and in block 1052, a first or more frames (e.g., a rear frame and / or a front frame) can be provided together with a voltage and temperature compensation module (VTC). In block 1054, another frame (e.g., a mid-frame) can be provided together with one or more busbars.

[0147] In a fifth phase 1060 (e.g., a phase of thermal contact riveting and CCA installation) and in block 1062, one or more frames can be pressed into place. This can be achieved, for example, by using an adhesive to facilitate adhesion. In block 1062, one or more busbars can be thermally riveted to establish an electrical and mechanical connection with the battery cells. In block 1064, a current collector assembly can be installed and pressed onto one or more frames and aligned with the battery cells.

[0148] In a sixth phase 1070 (e.g., a connection and testing phase) and in block 1072, the connection sections of the current collector assembly can be electrically and mechanically connected to the battery cells, for example, by welding. In block 1074, the welds can be optically scanned or otherwise (e.g., non-contact) inspected for connection quality. In block 1076, the welds can be mechanically (e.g., by contact) inspected for connection quality. If, starting from block 1076, one or more welds are unsatisfactory, the connection can be repeated or corrected (e.g., by welding).

[0149] In a seventh phase 1080 (e.g., an end-of-line (“EOL”) encapsulation and cover installation phase), one or more components can be connected to the BVT module. The components installed in block 1082 can include, for example, a thermistor, a voltage sensor, and / or a communication device. In block 1084, one or more seals can be installed and a verification performed. In block 1086, one or more tests can be performed on the battery module. In block 1088, one or more encapsulation materials can be applied to one or more corresponding connectors and / or battery cells, as described herein. In block 1088, a cover can be provided over the encapsulation materials and pressed down.

[0150] In a subsequent step, the battery module can be rotated and / or turned over to prepare it for placement in a support frame and potting in it.

[0151] Fig. Figure 40 illustrates a perspective view of a device for assembling a battery module according to one or more implementations of the present disclosure. The device can provide stations for carrying out the operations described herein. For example, as shown on the right side of Figure 40, the device can provide stations for carrying out the operations described herein. For example ... Fig. As shown in Figure 40, one or more stations can be provided to assemble a battery module as described herein. Furthermore, for example, as shown on the left side of Figure 40, one or more stations can be provided to assemble a battery module as described herein. Fig. As shown in Figure 40, one or more stations are provided to assemble each battery module into a battery pack, as described herein.

[0152] In some embodiments, one or more assembly phases can be performed at a first station 1110 (e.g., a cell processing station) and / or a second station 1120 (e.g., an assembly station for battery cell sets), as described with reference to Fig. 39 described how the first phase 1010 (e.g. an assembly phase for battery cell sets), the second phase 1030 (e.g. a verification phase for battery cell sets) and / or the third phase 1040 (e.g. a discharge phase for battery cell sets) of the process described in Fig. 39 illustrated processes 1000.

[0153] In some embodiments, one or more assembly phases can be performed at a third station 1130 (e.g., a module assembly station) as described above. Fig. 39 described, such as the fourth phase 1050 (e.g. a frame assembly phase) and / or the fifth phase 1060 (e.g. a heat contact riveting and CCA installation phase) of process 1000 as described in Fig. 39 illustrated.

[0154] In some embodiments, one or more phases of assembly can be performed at a fourth station 1140 (e.g., a laser welding station) as with reference to Fig. 39 described how to carry out, such as the sixth phase 1070 (e.g., a connection and testing phase) of process 1000 as in Fig. 39 illustrated.

[0155] In some embodiments, one or more assembly phases can be performed at a fifth station 1150 (e.g., an assembly station for high-voltage distribution boxes) as described with reference to Fig. 39, such as at least part of the seventh phase 1080 (e.g., an end-of-line (“EOL”), encapsulation, and cover installation phase). For example, a high-voltage distribution box (“HVDB”) can be installed. An HVDB is a component in electric vehicles that manages high-voltage energy from the battery and distributes it to various systems and components in the vehicle. It can ensure safe and efficient power distribution and often incorporates safety features such as fuses and relays to protect the vehicle's electrical system. Furthermore, an energy management module (“EMM”) can be installed. An energy management module is a system or device that can optimize the use and distribution of energy in electric vehicles.It can monitor energy consumption, manage power distribution, and ensure efficient operation by controlling various components to reduce energy waste and improve overall performance.

[0156] In some embodiments, one or more assembly phases can be performed at a sixth station 1160 (e.g., a pack end-of-line test station) as described above. Fig. 39 described, such as at least part of the seventh phase 1080 (e.g. an end-of-line (“EOL”), encapsulation and cover installation phase) of process 1000 as in Fig. Figure 39 illustrates this. An end-of-line (“EOL” test) is a quality control process that can be performed in the final stage of manufacturing to ensure that a product meets all specified requirements and functions properly before it is shipped to customers. In the context of automotive manufacturing, EOL tests can include verifying various aspects of a vehicle’s performance, safety features, and system functions to ensure it works as intended. This process helps identify any defects or problems that need to be addressed before the product is shipped.

[0157] In some embodiments, one or more phases of assembly can be performed at a seventh station 1170 (e.g., a potting and sealing station) as described above. Fig. 39. In some embodiments, the battery module can be charged into a vehicle at an eighth station 1180 (e.g., a module charging station).

[0158] Fig. Figure 41 illustrates a top view of a device for assembling a battery module according to one or more implementations of the present disclosure. The device can provide stations for carrying out the operations described herein. For example, one or more stations can be provided for assembling a battery module as described herein. The Fig. The 41 illustrated facility can accommodate at least some of the features described in Fig. Include 40 illustrated stations.

[0159] In some embodiments, one or more assembly phases can be performed at the first station 1110 (e.g., a cell processing station) as described above. Fig. 39 described, such as one or more operations corresponding to block 1012 of process 1000, as in Fig. Figure 39 illustrates this. For example, at position 1202, one or more battery cells can be charged, tested and / or forwarded.

[0160] In some embodiments, at the second station 1120 (e.g., an assembly station for a set of battery cells), one or more phases of assembly can be carried out as with reference to Fig. 39 described, such as one or more operations corresponding to blocks 1014, 1016, 1018, 1020, 1022, 1024, 1032, 1034, 1036, 1052 and / or 1054 of process 1000, as described in Fig. Figure 39 illustrates this. For example, at position 1204, the battery cells and / or a cooling element can be charged. Furthermore, at position 1206, for example, the cooling element and / or the set of battery cells can be tested for electrical insulation (e.g., by HIPOT testing). Furthermore, at position 1208, for example, the sub-assembly can be moistened, rotated, and / or cured as described herein. At location 1210, for example, the set of battery cells can be charged and conveyed further.

[0161] For example, a base can be provided at position 1212 and the set of battery cells can be mounted on it. For example, the set of battery cells can be fitted with one or more frames at position 1214.

[0162] In some embodiments, one or more assembly phases can be performed at the third station 1130 (e.g., a module assembly station) as described with reference to Fig. 39 are carried out, wherein one or more operations correspond to blocks 1062 and / or 1064 of process 1000, as described in Fig. Figure 39 illustrates this. For example, a current collector arrangement can be provided and pressed onto one or more frames at position 1216.

[0163] In some embodiments, one or more assembly phases can be performed at the fourth station 1140 (e.g., a laser welding station) as described above. Fig. 39 described, such as one or more operations corresponding to blocks 1072, 1074, 1076, 1082, 1084, 1086 and / or 1088 of process 1000, as described in Fig. Figure 39 illustrates this. For example, at position 1216, a current collector assembly can be provided on the one or more frames and pressed onto them. Furthermore, at position 1218, for example, one or more connecting sections can be connected (e.g., welded) to the one or more battery cells. Furthermore, at position 1220, for example, the welds can be inspected and / or tested, the thermistor installed, and / or the voltage sensing harness connected to the BVT module. Furthermore, at position 1222, for example, one or more encapsulation materials can be dispensed, as described herein. Furthermore, at position 1224, for example, the battery module can be unloaded for a packaging operation.

[0164] According to one or more implementations of the present disclosure, a process for packaging a battery module is provided. According to one or more implementations of the present disclosure, a facility is provided in which a battery module is assembled. Fig. Figure 42 illustrates a flowchart showing an example of a process that can be performed to package a battery module according to one or more implementations of the present disclosure. For explanatory purposes, the process is described here mainly with reference to components that are included in the Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18, Fig. 19, Fig. 20, Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25, Fig. 26, Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32, Fig. 33, Fig. 34, Fig. 35, Fig. 36 to Fig. 37 are illustrated. However, process 1300 is not based on the one in the Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18, Fig. 19, Fig. 20, Fig. 21, Fig. 22, Fig. 23, Fig. 24, Fig. 25, Fig. 26, Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig. 32, Fig. 33, Fig. 34, Fig. 35, Fig. 36 to Fig. The components illustrated in Figure 37 are limited, and one or more blocks (or operations) of the process may be performed by one or more other components of other suitable movable equipment, devices, or systems. Furthermore, for illustrative purposes, some of the process blocks are described herein as being performed serially or linearly. However, several process blocks may be performed in parallel. Additionally, the process blocks need not be performed in the sequence shown, and / or one or more process blocks need not be performed, and / or may be replaced by other operations.

[0165] In a first phase 1310 (e.g., a phase for discharging a battery module) and in block 1312, a set of battery cells from a previous phase and / or operation can be charged. For example, block 1312 can follow the operations at position 1224 of Fig. 41 corresponds.

[0166] In a second phase 1320 (e.g., a pack preparation phase), a battery module can be prepared for packaging. In block 1322, the battery module can be prepared, for example, by providing one or more battery modules to a support frame. In block 1324, the battery module can be further prepared, for example, by providing potting dams and / or by testing for any leaks. In block 1326, potting material can be dispensed and the resulting profile tested. Release and testing can be carried out in stages, so that testing can also be performed after partial dispensing. In block 1328, the battery module can be tested for leaks.

[0167] In a third phase 1330 (e.g., a pack configuration and discharge phase), a battery module can be prepared for packaging. In block 1332, the battery module can be flipped and / or otherwise oriented as required. A high-voltage distribution box and / or an energy management module can be prepared for installation, for example, as shown here with reference to the fifth station 1150 of Fig. 40. In block 1334, the high-voltage distribution box and / or the energy management module can be installed on the battery module. In block 1336, the battery module can be prepared for end-of-line testing. In block 1338, end-of-line testing can be performed, for example, as described here with reference to the sixth station 1160 of Fig.40 describes this process. For example, one or more tests can be performed, including checking the functionality of the battery module. From block 1338, the battery module can return to the second stage 1320, for example, to block 1328, where the battery module can be checked again for any leaks. From block 1328 onwards, the battery module can be charged into a vehicle.

[0168] Aspects of this technology can contribute to extending the lifespan of a battery in a vehicle. This can help facilitate the use and / or widespread adoption of batteries, which can positively impact the climate by reducing greenhouse gas emissions.

[0169] As used herein, the phrase "at least one of" before a list of elements with the term "and" or "or" to separate any one of the elements modifies the list as a whole, rather than each element of the list (i.e., each element). The phrase "at least one of" does not require the selection of at least one of each of the listed elements; rather, the phrase allows for a meaning that includes at least one of any one of the elements and / or at least one of any combination of the elements and / or at least one of each of the elements. For example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" refer, respectively, to only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0170] When an element is described herein as "connected" or "coupled" to another element, it is understood that the elements may be directly connected to the other element or have intermediate elements that exist between the elements. Conversely, when an element is described as "directly connected" or "directly coupled" to another element, it is understood that no intermediate elements exist in the "direct" connection between the elements. However, the existence of a direct connection does not preclude other connections in which intermediate elements may exist.

[0171] The predicate words "configured for," "operational for," and "programmed for" do not imply any particular tangible or intangible modification of an object, but are instead used interchangeably. In some embodiments, a processor configured to monitor and control an operation or component may also mean that the processor is programmed to monitor and control the operation, or that the processor is operational to monitor and control the operation. Likewise, a processor configured to execute code may be understood as a processor programmed to execute code or operational to execute code.

[0172] Terms such as a viewpoint, the viewpoint, another viewpoint, some viewpoints, one or more viewpoints, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the technology in question, the disclosure, the present disclosure, other variations thereof, and the like are used for simplification purposes and do not imply that a disclosure referring to such a term (or such terms) is essential to the technology in question, or that such disclosure applies to all configurations of the technology in question.A revelation relating to such a term (or terms) may apply to all configurations or to one or more configurations. A revelation relating to such a term (or terms) may provide one or more examples. A term, such as a viewpoint or some viewpoints, may refer to one or more viewpoints and vice versa, and this applies similarly to other foregoing terms.

[0173] The word "exemplary" is used herein to mean "serving as an example, case, or illustration." Any embodiment described herein as "exemplary" or as an "example" is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, to the extent that the term "include," "feature," or the like is used in the description or the claims, such term shall be understood in a manner similar to the term "comprise" as "comprise" is interpreted when used as a transitional word in a claim.

[0174] All structural and functional equivalents to the elements of the various aspects described in this disclosure, which are known or may subsequently become known to persons skilled in the art, are expressly incorporated herein by reference and are intended to be encompassed by the claims. Furthermore, nothing disclosed herein is intended to be made available to the public, regardless of whether such disclosure is expressly mentioned in the claims. No claim element is to be understood within the meaning of 35 USC § 112(6) unless the element is expressly identified using the term "means for" or, in the case of a process claim, the element is identified using the term "step for".

[0175] The preceding description is provided to enable all those skilled in the art to practice the various aspects described herein. Various modifications of these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other aspects. Thus, the claims are not intended to be limited to the aspects shown herein, but are intended to correspond to the full scope of protection consistent with the linguistic claims, where reference to a singular element is not meant to mean "one and only one," unless expressly stated otherwise, but rather "one or more." Unless expressly stated otherwise, the expression "some" refers to one or more. Masculine pronouns (e.g., his / her) include the feminine and neuter genders (e.g., her / her and his / her) and vice versa.Headings and subheadings, if any, are used for simplification only and do not limit the disclosure contained herein.

[0176] According to the present invention, a battery sub-arrangement is provided comprising: one or more battery cells, each enclosing a central section defining a first connection, and an outer edge defining a second connection; and a current collector arrangement comprising: one or more first connection sections, each welded to a respective central section of each of the one or more battery cells; and one or more second connection sections, each welded to a respective outer edge of each of the one or more battery cells, wherein each of the one or more second connection sections terminates in a respective concave edge extending along a concave shape of the respective outer edge of each of the one or more battery cells.

[0177] According to one embodiment, the respective concave edge of each of the one or more second connecting sections is positioned such that several sections along the respective concave edge have a common distance from the respective central section of the respective one or more battery cells.

[0178] According to one embodiment, each of the one or more first connection sections is welded to the respective central section of each of the one or more battery cells by several first welding areas; and each of the one or more second connection sections is welded to the respective outer edge of each of the one or more battery cells by several second welding areas.

[0179] According to one embodiment, the current collector arrangement further includes: a first conductor terminating next to each of the one or more first connection sections; and a second conductor overlapping the first conductor and defining at least one section of each of the one or more first connection sections, the first conductor being welded to the second conductor at one or more third weld areas.

[0180] According to one embodiment, each of the one or more third welding areas has a spiral shape.

[0181] According to one embodiment, each of the one or more third welding areas defines a continuous series of multiple loops extending along a length of the first conductor.

[0182] According to one embodiment, the one or more third welding areas extend in one or more rows along one or more sections of the first conductor, each of the one or more first connection sections originating from a respective one or more sections of the first conductor.

[0183] According to the present invention, a current collector arrangement is provided comprising: one or more connection sections, each intended for welding to a corresponding section of one or more battery cells; and a first conductor with ends each terminating adjacent to one or more of the connection sections; and a second conductor overlapping the first conductor and defining at least one section of each of the connection sections, wherein the first conductor is welded to the second conductor at one or more welding points.

[0184] According to one embodiment, each of the one or more welding areas has a spiral shape.

[0185] According to one embodiment, each of the one or more welding areas defines a continuous series of multiple loops extending along a length of the first conductor.

[0186] According to one embodiment, each of the one or more welding areas has a wave-like shape extending along a length of the first conductor.

[0187] According to one embodiment, the one or more welding areas extend in one or more rows along one or more sections of the first conductor, with each of the one or more connecting sections originating from a respective one or more sections of the first conductor.

[0188] According to one embodiment, each of the one or more welding areas defines a concentric shape.

[0189] According to one embodiment, the one or more connection sections are one or more first connection sections, the one or more welding areas are one or more first welding areas, and the current collector arrangement further comprises: one or more second connection sections, each of which is intended for welding to a respective section of each of several battery cells, each of the one or more first connection sections and each of the one or more second connection sections extending into a respective opening extending through the current collector arrangement; and a third conductor with ends each terminating adjacent to a respective one of the one or more second connection sections;and a fourth conductor overlapping the third conductor and defining at least one section of each of the one or more second connection sections, the third conductor being welded to the fourth conductor at one or more second weld areas.

[0190] According to one embodiment, each of the one or more first connection sections is configured to be welded to a respective middle section of a respective group of several battery cells; and each of the one or more second connection sections is welded to a respective outer edge of a respective group of several battery cells.

[0191] According to the present invention, a method for assembling a battery arrangement includes: forming a current collector arrangement by: welding a first conductor to a second conductor, wherein the second conductor overlaps the first conductor and forms at least one section of each of the multiple first connection sections, the first conductor having ends that each terminate adjacent to a respective one of the multiple first connection sections; and welding a third conductor to a fourth conductor, wherein the fourth conductor overlaps the third conductor and defines at least one section of each of the multiple second connection sections, the third conductor having ends that each terminate adjacent to a respective one of the multiple second connection sections; welding each of the multiple first connection sections to a respective middle section of a respective one of the multiple battery cells;and welding each of the several second connection sections to a respective outer edge of one of the several battery cells.

[0192] In one aspect of the invention, the method includes: providing a frame on the multiple battery cells; and attaching the current collector arrangement to the frame on one side of the frame opposite the multiple battery cells.

[0193] In one aspect of the invention, each of the several first connecting sections and each of the several second connecting sections extends into a respective opening that extends through the current collector arrangement.

[0194] According to one aspect of the invention, welding the first conductor to the second conductor and welding the third conductor to the fourth conductor each involve forming weld areas that define a spiral shape.

[0195] According to one aspect of the invention, welding the first conductor to the second conductor and welding the third conductor to the fourth conductor each involve forming weld areas that define a continuous series of multiple loops.

[0196] According to the present invention, a series busbar is provided comprising: a first terminal; a second terminal; and several locking elements connecting the first terminal and the second terminal in parallel, wherein the several locking elements have different cross-sectional dimensions.

[0197] According to one embodiment, a first fuse element of the multiple fuse elements on a first side of the series busbar, which is configured to face a current collector arrangement, has a first cross-sectional dimension; and a second fuse element of the multiple fuse elements on a second side of the series busbar opposite the first side, which is configured to point away from the current collector arrangement, has a second cross-sectional dimension that is larger than the first cross-sectional dimension.

[0198] According to one embodiment, the first terminal, the second terminal and the multiple locking elements form a monolithic structure.

[0199] According to one embodiment, the invention is further characterized by a non-conductive container that surrounds the multiple safety elements.

[0200] According to one embodiment, parts of the non-conductive container are inserted between each adjacent pair of the multiple securing elements.

[0201] According to one embodiment, the multiple locking elements include at least three locking elements.

[0202] According to the present invention, a battery arrangement is provided comprising: a first set of battery cells; a second set of battery cells; a current collector arrangement; and a series busbar for electrical connection to the first set of battery cells via the current collector arrangement and to the second set of battery cells via the current collector arrangement, wherein the series busbar occupies a plane occupied by the current collector arrangement.

[0203] According to one embodiment, the invention is further characterized by: a frame for bearing against the outer edges of the first set of battery cells and the second set of battery cells, wherein the current collector arrangement extends over the frame, wherein connecting sections of the current collector arrangement extend through openings in the frame to the first set of battery cells and the second set of battery cells; and a cover extending over the current collector arrangement and the busbar.

[0204] According to one embodiment, the busbar includes: a first terminal; a second terminal; and several fuse elements connecting the first terminal and the second terminal in parallel, the several fuse elements having different cross-sectional dimensions.

[0205] According to one embodiment, a first fuse element of the multiple fuse elements is located on a first side of the busbar facing the current collector arrangement and has a first cross-sectional dimension; and a second fuse element of the multiple fuse elements is located on a second side of the busbar opposite the first side and facing away from the current collector arrangement, and has a second cross-sectional dimension that is larger than the first cross-sectional dimension.

[0206] According to one embodiment, the first terminal, the second terminal and the multiple locking elements form a monolithic structure.

[0207] According to one embodiment, the invention is further characterized by a non-conductive container that surrounds the multiple safety elements.

[0208] According to one embodiment, parts of the non-conductive container are inserted between each adjacent pair of the multiple securing elements.

[0209] According to one embodiment, the multiple locking elements include at least three locking elements.

[0210] According to the present invention, a method for assembling a battery sub-assembly includes: providing a first set of battery cells and a second set of battery cells; connecting a current collector assembly to each of the battery cells of the first set of battery cells and the second set of battery cells; and connecting a series busbar, including several fuse elements, via the current collector assembly to each of the first and second sets of battery cells.

[0211] In one aspect of the invention, the method includes providing a cover over the current collector arrangement and the series busbar.

[0212] In one aspect of the invention, the method includes providing one or more frames that abut an outer edge of each of the battery cells of the first set of battery cells and the second set of battery cells, wherein the current collector arrangement is connected to each of the battery cells of the first set of battery cells and the second set of battery cells through openings in the one or more frames.

[0213] In one aspect of the invention, the method includes: providing a base to support the first set of battery cells and the second set of battery cells; providing one or more potting dams, each extending along a respective end of the one or more frames to the base; and providing potting material between the cover and the base.

[0214] In one aspect of the invention, connecting the series busbar to each of the first set of battery cells and the second set of battery cells includes: connecting a first terminal of the series busbar to the first set of battery cells via the current collector arrangement; and connecting a second terminal of the series busbar to the second set of battery cells via the current collector arrangement, wherein the multiple fuse elements connect the first terminal and the second terminal in parallel, the multiple fuse elements having different cross-sectional dimensions.

[0215] In one aspect of the invention, the method includes aligning the busbar in order to occupy a plane occupied by the current collector arrangement.

[0216] According to the present invention, a frame for a battery arrangement is provided, comprising: a structure for abutting an outer edge of each of the multiple battery cells, wherein the frame defines openings, the frame being configured to support a current collector arrangement extending over the frame and including connecting sections extending through the openings of the frame to the multiple battery cells; one or more first engagement elements configured to form a first datum with the multiple battery cells; one or more second engagement elements configured to form a second datum with the multiple battery cells; and one or more third engagement elements configured to form a third datum with the current collector arrangement.

[0217] According to one embodiment, the one or more first engagement elements are configured to surround one or more of the multiple battery cells; and the one or more second engagement elements are configured to extend between an adjacent pair of the multiple battery cells.

[0218] According to one embodiment, the first date is a 4-way date; and the second date is a 2-way date.

[0219] According to one embodiment, the one or more third engagement elements are configured to extend into one or more CCA openings of the current collector arrangement.

[0220] According to one embodiment, the third date is a 4-way date.

[0221] According to one embodiment, the frame is further configured to support a cover extending over the current collector arrangement, the frame further including one or more fourth engagement elements to form a fourth datum with the cover.

[0222] According to one embodiment, the one or more fourth engagement elements are configured to extend into one or more cover openings of the cover.

[0223] According to one embodiment, the fourth date is a 4-way date.

[0224] According to one embodiment, the frame is a first frame, wherein the battery cells are first battery cells, and wherein the structure is a first structure, a second frame comprising: a second structure for abutting an outer edge of each of the multiple second battery cells; one or more fifth engagement elements configured to form a fifth datum with the multiple second battery cells; one or more sixth engagement elements configured to form a sixth datum with the multiple second battery cells; and one or more seventh engagement elements configured to form a seventh datum with the current collector arrangement.

[0225] According to one embodiment, the first frame and the second frame are further configured to support a cover extending over the current collector arrangement; the first frame further includes one or more fourth engagement elements for forming a fourth datum with the cover; and the second frame further includes one or more eighth engagement elements for forming an eighth datum with the cover.

[0226] According to the present invention, a method for assembling a battery arrangement includes: providing several battery cells; aligning a frame with the several battery cells by means of one or more first and one or more second engagement elements of the frame, wherein the one or more first engagement elements form a first datum with the several battery cells and the one or more second engagement elements form a second datum with the several battery cells; and aligning a current collector arrangement with the frame by means of one or more third engagement elements of the frame, wherein the one or more third engagement elements form a third datum with the current collector arrangement.

[0227] In one aspect of the invention, the first date is a 4-way date; and the second date is a 2-way date.

[0228] In one aspect of the invention, the third date is a 4-way date.

[0229] In one aspect of the invention, the method includes aligning a cover with the frame using one or more fourth engagement elements of the frame, wherein the one or more fourth engagement elements form a fourth datum with the cover.

[0230] In one aspect of the invention, the fourth date is a 4-way date.

[0231] In one aspect of the invention, the method includes: aligning the frame to the multiple battery cells includes bearing an outer edge of each of the multiple battery cells against a structure of the frame; and connecting connecting sections of the current collector arrangement to each of the multiple battery cells through appropriate openings in the frame.

[0232] According to the present invention, a battery sub-assembly for a vehicle is provided, comprising: a cover defining a cover opening extending through the cover and forming a shape of a first size; a current collector assembly under the cover, including connection sections for electrical connection to terminals of one or more battery cells, wherein the current collector assembly defines a CCA opening extending through the current collector assembly and forming a shape of a second size smaller than the first size; and a frame defining a frame opening extending through the frame and forming a shape of a third size smaller than the second size, wherein the cover opening, the CCA opening, and the frame opening are concentrically aligned.

[0233] According to one embodiment, the current collector arrangement is connected to the one or more battery cells through additional frame openings in the frame.

[0234] According to one embodiment, the invention is further characterized by: a base; a potting dam extending along one end of the frame to the base; and potting material between the cover and the base.

[0235] According to one embodiment, the cover further defines an additional cover opening extending through the cover and forming the shape of the first size; the current collector assembly further defines an additional CCA opening extending through the current collector assembly and forming the shape of the second size; and the frame further defines an additional frame opening extending through the frame and forming the shape of the third size, wherein the additional cover opening, the additional CCA opening, and the additional frame opening are concentrically aligned. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 684,233

[0001] US 63 / 807,457

[0001]

Claims

[1] Battery sub-assembly comprising: several battery cells, each forming a middle section and an outer edge; a frame that rests against the outer edge of each of the battery cells; a current collector arrangement extending over the frame and connected to the central section of each of the multiple battery cells and the outer edges of each of the multiple battery cells; and a cover extending over the current collector arrangement, wherein the cover is configured to redirect forces acting upon it away from the central section of each of the multiple battery cells and towards the outer edges of each of the multiple battery cells. [2] Battery sub-arrangement according to claim 1, wherein the current collector arrangement includes: first connecting sections, each connected to a respective middle section of each of the several battery cells; and second connecting sections, each of which is connected to a respective outer edge of one of the multiple battery cells. [3] Battery sub-arrangement according to claim 2, wherein the frame defines openings which each (i) expose the central section of each of the multiple battery cells for connection with each of the first connection sections and (ii) expose a section of the outer edge of each of the multiple battery cells for connection with each of the second connection sections. [4] Battery sub-arrangement according to claim 1, wherein the cover forms an inner surface defining a concave shape facing the central section of each of the multiple battery cells. [5] Battery sub-arrangement according to claim 1, wherein: the multiple battery cells are a first set of battery cells; the frame is a first frame that covers the first set of battery cells; and wherein the battery sub-assembly further comprises a second frame for covering a second set of battery cells. [6] Battery arrangement comprising: several battery cells, each forming a middle section and an outer edge; a frame to be attached to the outer edge of each of the multiple battery cells; and a current collector arrangement extending over the frame, the current collector arrangement including the following: first connecting sections, each connected to a respective middle section of each of the several battery cells; and second connecting sections, each connected to a respective outer edge of one of the multiple battery cells; and several encapsulation materials, each enclosing a respective middle section and an respective outer edge of each of the several battery cells and one of the first connection sections and one of the second connection sections. [7] Battery arrangement according to claim 6, wherein the frame defines openings which each (i) expose the central section of each of the multiple battery cells for connection with each of the first connection sections and (ii) expose a section of the outer edge of each of the multiple battery cells for connection with each of the second connection sections. [8] Battery arrangement according to claim 7, wherein each of the multiple encapsulation materials extends to an edge of a respective opening of the frame. [9] Battery arrangement according to claim 6, wherein: the multiple battery cells are a first set of battery cells; the frame is a first frame that covers the first set of battery cells; and wherein the battery assembly further comprises a second frame for covering a second set of battery cells. [10] Battery arrangement according to claim 6, further comprising a cover configured to redirect forces acting upon it away from an encapsulation material between the cover and a central section of each of the multiple battery cells and onto the outer edge of each of the multiple battery cells. [11] Battery arrangement according to claim 10, wherein the cover forms an inner surface defining concave shapes which are each facing one of the several encapsulation materials and one of the central sections of one of the several battery cells. [12] Battery arrangement according to claim 10, wherein the multiple encapsulation materials have a modulus of elasticity that is lower than the modulus of elasticity of the cover and the modulus of elasticity of the frame. [13] Battery arrangement according to claim 10, further comprising a foam layer on a side of the cover opposite the frame. [14] Battery arrangement according to claim 10, further comprising: a base; a grout dam extending along one end of the frame to the base; and Potting compound between cover and base. [15] Method for assembling a battery assembly, the method comprising: Providing a first set of battery cells and a second set of battery cells, wherein each of the battery cells of the first set of battery cells and of the second set of battery cells defines a middle section including a first terminal and an outer edge including a second terminal; Providing one or more frames that are located at the outer edge of the first set of battery cells and the second set of battery cells, respectively; Connecting a current collector arrangement to the first terminal and the second terminal of each of the first set of battery cells and the second set of battery cells; Providing encapsulation materials over a respective middle section of the first set of battery cells and the second set of battery cells; and Providing a cover over the current collector assembly and each of the encapsulation materials. [16] Method according to claim 15, wherein providing the cover over the current collector arrangement and over each of the encapsulation materials includes aligning each of the multiple concave shapes along an inner surface of the cover with a respective encapsulation material. [17] Method according to claim 15, further comprising providing a base to support the first set of battery cells and the second set of battery cells, wherein providing the first set of battery cells and the second set of battery cells includes applying the first set of battery cells and the second set of battery cells to an adhesive strip of the base. [18] The method of claim 17, further comprising: Providing one or more grouting dams, each extending along a respective end of the one or more frames to the base; and Providing potting compound between the cover and the base. [19] Method according to claim 15, further comprising connecting a series busbar to the first set of battery cells and the second set of battery cells, wherein the cover extends over the series busbar. [20] Method according to claim 15, further comprising providing a foam layer on one side of the cover opposite the one or more frames.

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