High-voltage battery system without a stand-alone pack enclosure

Abstract

An electric vehicle comprises a vehicle body; a cavity in the vehicle body, the cavity being formed by at least one wall of the vehicle body and an opening in the vehicle body; a closing part configured to close the opening; an electric motor for propelling the electric vehicle; and a component including a high-voltage battery system, the component being mounted on the vehicle body within the cavity, the high-voltage battery system including an electrochemical cell for supplying power to the electric motor, the high-voltage battery system being surrounded by the wall of the vehicle body and the closing part and not having a stand-alone pack enclosure.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 367,248, filed on June 29, 2022, entitled "High - Voltage Battery System without a Stand - Alone Pack Enclosure", the disclosure of which is incorporated herein by reference in its entirety.

[0002] This document relates to a high - voltage battery system without a stand - alone pack enclosure.

Background Art

[0003] In recent years, transportation worldwide has been beginning to shift from power trains mainly driven by fossil fuels to more sustainable energy sources. Such increasingly popular power trains include an electric motor powered by an on - board energy storage unit. To make these new transportation modes available to a larger segment of the population, vehicle manufacturers are working to reduce the costs of manufacturing, assembling, and maintaining electric vehicles.

Summary of the Invention

[0004] In a first aspect, an electric vehicle includes a vehicle body; a cavity in the vehicle body, the cavity being formed by at least one wall of the vehicle body and an opening in the vehicle body; a closure configured to close the opening; an electric motor for propulsion of the electric vehicle; and a component including a high - voltage battery system, the component being mounted on the vehicle body within the cavity, the high - voltage battery system including electrochemical cells that supply power to the electric motor, the high - voltage battery system being surrounded by the wall of the vehicle body and the closure and having no stand - alone pack enclosure.

[0005] The implementation may include any or all of the following features. The high-voltage battery system includes a first and a second module of electrochemical cells, and an electrical interconnect that electrically connects the first and second modules to each other. Each of the first and second modules has a high-voltage portion of the high-voltage battery system. The electrical interconnect includes a bus bar that is partially covered by an insulator. Each of the first and second modules includes a circuit that controls the respective electrochemical cells of the first or second module. Each of the first and second modules has a shape composed of straight lines, the main surfaces of the shape composed of straight lines face each other, and the normal direction of each of the main surfaces is substantially parallel to the normal direction of the opening in the vehicle body. The first and second modules are mounted side by side in the cavity, and their main surfaces are substantially aligned with each other. The first and second modules are stacked in the cavity, and their main surfaces face each other substantially. Each of the first and second modules has a shape composed of straight lines, the main surfaces of the shape composed of straight lines face each other, and the normal direction of each of the main surfaces is not substantially parallel to the normal direction of the opening in the vehicle body. The normal direction of each of the main surfaces is substantially perpendicular to the normal direction of the opening in the vehicle body. The first and second modules are stacked in the cavity, and their main surfaces face each other substantially. The cavity is formed by at least five walls of the vehicle body. The five walls include a rear wall facing the opening and four side walls substantially perpendicular to the rear wall. The opening faces the ground on which the electric vehicle is located. The electric vehicle further includes a gap that separates the electrochemical cell from the closed portion.

[0006] In a second aspect, a method of manufacturing an electric vehicle comprises: forming a cavity in a vehicle body by at least one wall of the vehicle body and an opening in the vehicle body; mounting an electric motor on the electric vehicle for propulsion of the electric vehicle; mounting a component including a high voltage battery system in the cavity on the vehicle body, the high voltage battery system including an electrochemical cell for supplying power to the electric motor; and closing the opening with a closure, the high voltage battery system being surrounded by the wall of the vehicle body and the closure and not having a stand-alone pack enclosure.

[0007] The implementation may include the following features. The step of mounting the component in the cavity on the vehicle body includes: mounting first and second modules of the electrochemical cell in the cavity; and installing an electrical interconnect for electrically connecting the first and second modules to each other.

[0008] In a third aspect, a method for servicing an electric vehicle comprises: removing a closure that closes an opening in the vehicle body of the electric vehicle, a cavity in the vehicle body being formed by the opening and at least one wall of the vehicle body, a component including a high voltage battery system being mounted in the cavity on the vehicle body, the high voltage battery system including at least first and second modules of an electrochemical cell, and removing an electrical interconnect for electrically connecting the first and second modules from the high voltage battery system.

[0009] The implementation may include any or all of the following features. The step of removing the electrical interconnect includes pulling while gripping an insulating portion of the electrical interconnect. The method further comprises subsequently installing the electrical interconnect to electrically connect the first and second modules to each other; and subsequently closing the opening with the closure after installing the electrical interconnect. BRIEF DESCRIPTION OF THE DRAWINGS

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[0021] Like reference numerals in the various drawings indicate like elements. **DETAILED DESCRIPTION**

[0022] This document describes examples of systems and techniques for providing an electric vehicle (EV) having a battery system without a stand - alone pack enclosure. Thereby, even by just listing some examples, the mass of the EV can be reduced, or the EV can be enabled to hold more electrochemical cells with the same mass, or the manufacturing process of the stand - alone pack assembly can be reduced. The ability to provide a high - voltage battery system without a stand - alone pack enclosure can be enabled by ensuring that the high - voltage battery system is serviceable without special high - voltage tools or high - voltage training. For example, using a high - voltage battery system can mean ensuring that service personnel only encounter terminals or other conductive elements having a non - lethal potential difference (e.g., at a voltage lower than that of the high - voltage battery system). In some implementations, a high - voltage battery system is provided that is mounted on the vehicle, is structurally and electrically isolated, and does not have a removable stand - alone enclosure. The modules can be structurally integrated into the vehicle body. By being able to directly assemble the electrical interconnects and battery support systems within the vehicle assembly (i.e., without first assembling them into a stand - alone pack enclosure), the vehicle - mounted high - voltage battery energy storage system is completed. The absence of a stand - alone pack enclosure means that the entire battery system cannot be removed from the EV as a single self - contained unit. Rather, the different components of the battery system can be removed separately and independently from the EV for service or replacement.

[0023] Examples herein relate to a battery system for an electric vehicle (EV) that is an assembly of electrochemical cells configured to power an electric motor for propulsion of the EV. Examples herein refer to battery modules. These are individual components configured to hold and manage multiple electrochemical cells during charging, storage, and use. The battery system can include any number of modules. A battery module can be intended as the sole power source for one or more loads (e.g., an electric motor), or more than one battery module of the same or different types can be used. Two or more battery modules can be implemented in a system where the battery system does not have a stand-alone enclosure. For example, the battery system can include two or more battery modules of the same or different types. A battery module can include control circuitry for managing charging, storage, and / or use of electrical energy in the electrochemical cells, or a battery module can be controlled by an external component. For example, a battery management system can be implemented on one or more circuit boards (e.g., printed circuit boards).

[0024] The examples in this specification relate to battery systems having a high voltage, which may be referred to as high voltage battery systems in some cases. Having a high voltage involves an operating voltage or potential difference that is generally considered lethal if a human comes into contact with it. As used herein, high voltage means at least about 250 volts (V). The voltages specified herein are direct current (DC) voltages. In some implementations, the high voltage battery system may have a voltage greater than about 300V. In some implementations, the high voltage battery system may have a voltage greater than about 400V. In some implementations, the high voltage battery system may have a voltage greater than about 500V. In some implementations, the high voltage battery system may have a voltage greater than about 600V. In some implementations, the high voltage battery system may have a voltage greater than about 700V. In some implementations, the high voltage battery system may have a voltage greater than about 800V. In some implementations, the high voltage battery system may have a voltage greater than about 900V. In contrast, battery terminals or other conductive elements that are considered acceptable even for maintenance personnel without special high voltage tools or high voltage training may be said to have a non-lethal voltage. For example, making a high voltage battery system (e.g., one having a voltage greater than about 900V) maintainable without special high voltage tools or high voltage training may involve ensuring that the high voltage terminals are not exposed to maintenance personnel and that only terminals with non-lethal voltages are exposed to maintenance personnel.

[0025] In the examples of this specification, an electrochemical cell is referred to. An electrochemical cell may include an electrolyte and two electrodes to store energy and deliver it when in use. In some implementations, the electrochemical cell can be a rechargeable cell. For example, the electrochemical cell can be a lithium-ion cell. In some implementations, the electrochemical cell can serve as a galvanic cell during discharge and as an electrolytic cell during charging. The electrochemical cell can have at least one terminal for each electrode. The terminal or at least a part of it can be disposed at one end of the electrolytic cell. For example, when the electrochemical cell has a cylindrical shape, one of the terminals can be provided at the center of the end of the cell, and the can forming the cylinder can constitute the other terminal and thus also be present at its end. Other shapes of electrochemical cells including a prismatic shape can be used, but are not limited thereto.

[0026] The examples of this specification mention a bus bar, and a battery module can have at least one bus bar. The bus bar is conductive and is used to conduct electricity to or from the electrochemical cell during charging or discharging. The bus bar is made of a conductive material (e.g., metal) and has appropriate dimensions considering the characteristics and intended use of the electrochemical cell. In some implementations, the bus bar includes aluminum (e.g., an aluminum alloy). The bus bar can be flat (e.g., flat) or have one or more curved portions depending on the shape and intended use of the battery module.

[0027] The examples of this specification refer to up, down, front, or back. These and similar expressions identify things or aspects in a relative manner based on explicit or arbitrary concepts of perspective. That is, these terms are merely illustrative used for the purpose of explanation and do not necessarily indicate the only possible positions, directions, etc.

[0028] FIG. 1 shows an example of an electric vehicle (EV) 100 having a high voltage (HV) battery system 102 without a stand-alone pack enclosure. The EV 100 is shown in an exploded view for purposes of illustration. The EV 100 and / or the HV battery system 102 can be used with one or more other examples described elsewhere in this specification. The EV 100 has one or more electric traction motors (not shown) powered by the HV battery system 102. Some other components of the vehicle 100, including but not limited to the wheels, are omitted from this figure for clarity.

[0029] The EV 100 includes a vehicle body 104. The vehicle body 104 can include various structural components that together form a framework, and a plurality of sections of the EV 100. In some implementations, the EV 100 includes a frame assembled from a plurality of individual sections. In some implementations, the EV 100 includes a chassis 106. For example, the chassis 106 can form a support structure for the vehicle body 104 and can be made using various frame components, rails, rockers, torque boxes, and / or cross members.

[0030] The EV 100 has a cavity 108 in the vehicle body 104. The cavity 108 is here partially defined by an opening 110. The cavity 108 can be formed in any of various sections or parts of the vehicle body 104. In some implementations, the cavity 108 is formed in the chassis 106 of the vehicle body 104. For example, the cavity 108 can be configured such that the ground on which the EV 100 is located faces the opening 110.

[0031] The cavity 108 can have any shape including, but not limited to, a shape composed of straight lines. In some implementations, the cavity is formed by a plurality of walls of the vehicle body 104. For example, the cavity 108 can be at least partially formed by the rear wall 112. As another example, the cavity 108 can be at least partially formed by the side wall 114 (not visible in this figure). As another example, the cavity 108 can be at least partially formed by the side wall 116 (not visible in this figure). As another example, the cavity 108 can be at least partially formed by the side wall 118. As another example, the cavity 108 can be at least partially formed by the side wall 120. The rear wall 112 can face the opening 110 (e.g., be substantially parallel). One or more of the side walls 114 - 120 can be substantially perpendicular to the rear wall 112. The length dimension of the side walls 114 - 120 that extends away from the opening 110 (e.g., the depth of the cavity 108) can have any relationship with the size dimension of the rear wall 112. In some implementations, this length dimension of the side walls 114 - 120 is substantially smaller than the width of the rear wall 112 (e.g., less than 10% of it). For example, the cavity 108 can then be characterized as being relatively shallow. In other implementations, instead, these dimensions can have other ratios such that the cavity 108 can be characterized as being relatively deep instead. Thus, the cavity 108 can be formed by at least five walls of the vehicle body 104 (e.g., the side walls 114 - 120 and the rear wall 112). The cavity 108 can have other shapes.

[0032] The HV battery system 102 may include a plurality of modules of electrochemical cells, which may be referred to as battery cell collectors in some cases, each of which functions to include a plurality of electrochemical cells. Here, the HV battery system 102 includes modules 122A to 122D of electrochemical cells. Modules 122A to 122D are components that include the HV battery system 102. Modules 122A to 122D may be positioned in any configuration within the cavity 108. For example, module 122A is located here closest to the front of the vehicle body 104; module 122B is located here immediately behind module 122A; module 122C is located immediately behind module 122B; and module 122D is located immediately behind module 122C. Each of modules 122A to 122D may be an individual unit that is manufactured separately and installed within the cavity 108. For example, each of modules 122A to 122D may be mounted (e.g., in contact) on the rear wall 112.

[0033] Each of modules 122A to 122D includes a plurality of electrochemical cells. The electrochemical cells may have one or more of a plurality of form factors. In some implementations, the HV battery system 102 may use an electrochemical cell 124 having a cylindrical shape. For example, the electrochemical cell 124 may have a central terminal at one end of the cell and a housing terminal that may be accessible in one or more other areas of the electrochemical cell 124. In some implementations, the HV battery system 102 may use an electrochemical cell 126 having a prismatic shape. For example, the electrochemical cell 126 may have terminals on one or more of its sides (e.g., on a side surface or a main surface). Other form factors may be used.

[0034] The HV battery system 102 may include electrical interconnects for connecting the modules 122A - 122D to each other and / or to other electrical fittings within the cavity 108. Here, the HV battery system 102 includes electrical interconnects 128A - 128C. The electrical interconnects 128A - 128C are components that include the HV battery system 102. The electrical interconnects 128A - 128C can serve one or more of a plurality of purposes. For example, the electrical interconnects 128A - 128C can connect two or more of the modules 122A - 122D to each other, thereby increasing the overall voltage from the module-level voltage (e.g., non-lethal voltage) to the battery system-level voltage (e.g., lethal voltage). As another example, one or more of the electrical interconnects 128A - 128C can be selectively removed (e.g., for maintenance inspection activities) to reduce the overall voltage from the battery system-level voltage to the module-level voltage.

[0035] Each of the electrical interconnects 128A - 128C can include a bus bar that is partially covered by an insulator. For example, electrical interconnect 128A includes a bus bar that provides a conductor 130 and also includes an insulator 132 that partially covers the bus bar. In some implementations, electrical interconnect 128A can electrically connect modules 122A - 122B to each other. In some implementations, electrical interconnect 128B can electrically connect modules 122B - 122C to each other. In some implementations, electrical interconnect 128C can electrically connect modules 122C - 122D to each other.

[0036] The EV100 includes a closure portion 134 configured to close the opening 110 of the cavity 108. The closure portion 134 may include a member of metal and / or composite material. In some implementations, the closure portion 134 may be formed as a single piece of material that functions as a cover for the cavity 108. In some implementations, the closure portion 134 may have a non-planar shape. The closure portion 134 may provide environmental protection and / or structural protection for the HV battery system 102. In some implementations, the closure portion 134 may provide structural reinforcement for the overall structure of the vehicle body 104. For example, the closure portion 134 may provide rigidity thereto by being combined with the entire bottom of the EV100 (e.g., the chassis 106). In some implementations, the closure portion 134 closes and seals the opening 110. For example, the closure portion 134 may include a sealing strip (e.g., of a flexible material) that connects to the opening 110.

[0037] The modules 122A - 122D and the electrical interconnects 128A - 128C may provide features related to the serviceability of the EV100. For example, after removal of the closure portion 134, the high - voltage terminals of the HV battery system 102 are not exposed to the technician while the electrical interconnects 128A - 128C remain installed in their respective locations. Rather, the insulators of the electrical interconnects 128A - 128C cover the high - voltage terminals or other conductors and thereby function to prevent accidental contact therewith. The service technician may then remove one or more of the electrical interconnects 128A - 128C. Any of a plurality of removal methods may be used. In some implementations, the electrical interconnects 128A - 128C may be removed by gripping and pulling on the insulating portions of the respective electrical interconnects 128A - 128C. In some implementations, the electrical interconnects 128A - 128C may be removed by rotating or otherwise moving the components. For example, screws of plastic material may be surrounded by insulators such that removal can be performed using a conventional screwdriver without special tools.

[0038] Removing the electrical interconnect disconnects the electrical connections between corresponding ones of modules 122A - 122D, thereby reducing the voltage from the system voltage level (e.g., lethal voltage) to the module level voltage (e.g., non - lethal voltage). This subject can make the HV battery system 102 “finger - safe” in that it enables the HV battery system 102 to be serviced without special high - voltage tools or high - voltage training. That is, before any of modules 122A - 122D becomes accessible for servicing, the HV battery system 102 is disconnected from the portion of the full battery system voltage. For example, each of modules 122A - 122D has a voltage lower than the voltage of the HV battery system 102.

[0039] FIG. 2 schematically shows an example of an EV200. The EV200 can be used with one or more other examples described elsewhere in this specification. The EV200 includes at least one electric motor 202 for traction. For example, the electric motor 202 can be mounted on the frame of the EV200. The electric motor 202 can be any type of electric motor including, but not limited to, a permanent - magnet motor, an induction motor, a synchronous motor, or a reluctance motor. The EV200 can include a motor control unit 204 that can execute software (e.g., firmware) to control the electric motor 202. In some implementations, the motor control unit 204 can control an inverter 206 that provides electricity to the electric motor 202. For example, the motor control unit 204 can include a microprocessor or a field - programmable logic array.

[0040] The EV200 includes a high - voltage battery system 208 mounted on the vehicle body of the EV200 within a cavity 210. The high - voltage battery system 208 does not have a stand - alone pack enclosure as schematically shown by the cavity 210 indicated using dashed lines.

[0041] The EV200 includes a vehicle body (e.g., vehicle body 104 in FIG. 1); a cavity in the vehicle body (e.g., cavity 210), the cavity being formed by at least one wall of the vehicle body (e.g., one or more of the rear wall 112, side walls 114, 116, 118, or 120 in FIG. 1) and an opening in the vehicle body (e.g., opening 110 in FIG. 1); a closure configured to close the opening (e.g., closure 134 in FIG. 1); an electric motor for propelling the electric vehicle (e.g., electric motor 202); and a component including a high-voltage battery system (e.g., high-voltage battery system 208), the component being mounted on the vehicle body within the cavity, the high-voltage battery system including an electrochemical cell (e.g., electrochemical cell 124 or 126 in FIG. 1) that supplies power to the electric motor, the high-voltage battery system being surrounded by the walls and the closure of the vehicle body and having no stand-alone pack enclosure, and is an example of an EV.

[0042] FIG. 3 shows an example of a module 300 for an electrochemical cell that can be used with a battery system having no stand-alone pack enclosure. Module 300 can be used with one or more other examples described elsewhere in this specification. For example, any of modules 122A - 122D in FIG. 1 can be module 300. As another example, module 300 can be part of a component including an HV battery system.

[0043] Module 300 here includes a housing 302 that includes an electrochemical cell. Housing 302 can be made of a non-conductive material such as a thermoplastic or thermosetting material. For example, a polymer material including, but not limited to, polycarbonate can be used in forming housing 302.

[0044] Module 300 here includes flat bus bar 303, end bus bar 306, and end bus bar 308 at an end of housing 302 opposite to end bus bar 306. End bus bars 306 and 308 are each electrically connected to flat bus bar 303 or a portion thereof. Housing 302 may have an opening 310 therein. In some implementations, one or more connections to the terminals of the electrochemical cell may be formed through at least one of openings 310.

[0045] Flat bus bar 303 and end bus bars 306 and 308 may be made of the same or different conductive materials. For example, aluminum or an aluminum alloy can be used. End bus bar 306 may position at least one electrical terminal 312 adjacent to housing 302. In some implementations, electrical terminal 312 may be accessible from one or more of electrical interconnects 128A - 128D in FIG. 1. In some implementations, any of conductors 130 in FIG. 1 contacts electrical terminal 312 when the corresponding one of electrical interconnects 128A - 128D is installed, thereby connecting electrical terminal 312 to another conductive component (e.g., the corresponding electrical terminal of another module). Electrical terminal 312 may be regarded as a high - voltage terminal of the battery system when the electrical interconnect is installed, and the insulator of the electrical interconnect then prevents maintenance personnel from accidentally contacting the high - voltage terminal. In contrast, when the electrical interconnect is removed from its installed position and as a result conductor 130 is no longer in contact, electrical terminal 312 may instead be a module - level voltage (e.g., non - lethal voltage) terminal of module 300, such as a voltage terminal.

[0046] Module 300 may include a circuit 314 for managing the charging, storage, and / or use of electrical energy in an electrochemical cell. For example, circuit 314 may include a battery management system implemented as an integrated circuit installed on a printed circuit board. In some implementations, module 300 may instead be controlled by an external component (e.g., a circuit common to the entire HV battery system).

[0047] A plurality of examples are described herein to illustrate some of the various possibilities for placing a module within a cavity of a vehicle body.

[0048] FIG. 4A schematically shows an example of a cavity 400 in a vehicle body 402. Vehicle body 402 includes the perimeter of cavity 400 shown by the dashed outline, and the details of vehicle body 402 are not shown. Cavity 400 is here formed by a rear wall 404; side walls 406, 408 (not visible in this figure), 410 (not visible in this figure), and 412 which is substantially perpendicular to rear wall 112; and an opening 414. That is, opening 414 is defined by the respective edges of side walls 406 - 412.

[0049] Opening 414 may be a substantially flat area. The normal direction of opening 414 may be indicated by arrow 416. That is, arrow 416 is perpendicular to opening 414. Several examples are provided below with reference to arrow 416.

[0050] FIG. 4B schematically shows an example of a module 418 of an electrochemical cell. Module 418 may have a shape configured substantially in a straight line. Here, module 418 is surrounded by its surfaces including a rear wall 420 (not visible in this figure), side walls 422, an upper wall 424, side walls 426 (not visible in this figure), a front wall 428, and a bottom wall 430 (not visible in this figure).

[0051] The upper wall 424 and the bottom wall 430 are here opposite to each other (e.g., substantially parallel) and are relatively larger than the other surfaces of the module 418. Thus, the upper wall 424 and the bottom wall 430 may be referred to as the main surfaces of the module 418. The normal direction of the upper wall 424 and / or the bottom wall 430 may be indicated by the arrow 432. That is, the arrow 432 is perpendicular to the upper wall 424 and the bottom wall 430. Here, with reference to the arrow 432, several examples are provided.

[0052] FIG. 4C schematically shows examples of modules 418A and 418B for electrochemical cells located within the cavity 400 in the vehicle body 402. Modules 418A and 418B are two instances of the module 418 in FIG. 4B. Module 418A here has a main surface 434A, and module 418B here has a main surface 434B. The normal direction of the main surface 434A may be indicated by the arrow 436A, and the normal direction of the main surface 434B may be indicated by the arrow 436B. The normal direction of each of the main surfaces 434A - 434B is substantially parallel to the normal direction of the opening 414 in the vehicle body 402, as indicated by the arrow 416. For example, modules 418A and 418B are mounted side by side within the cavity 400, and their main surfaces 434A - 434B are substantially aligned with each other.

[0053] FIG. 4D schematically shows examples of modules 418C and 418D for electrochemical cells located within the cavity 400 in the vehicle body 402. Modules 418C and 418D are two instances of the module 418 in FIG. 4B. Module 418C here has a main surface 434C, and module 418D here has a main surface 434D. The normal direction of the main surface 434C may be indicated by the arrow 436C, and the normal direction of the main surface 434D may be indicated by the arrow 436D. The normal direction of each of the main surfaces 434C - 434D is substantially parallel to the normal direction of the opening 414 in the vehicle body 402, as indicated by the arrow 416. For example, modules 418A and 418B are stacked within the cavity 400, and their main surfaces 434C - 434D are substantially facing each other.

[0054] FIG. 4E schematically shows an example of modules 418C and 418D for an electrochemical cell located within cavity 400 in vehicle body 402. The normal direction of main surface 434C may be indicated by arrow 436C, and the normal direction of main surface 434D may be indicated by arrow 436D. The normal direction of each of main surfaces 434C-434D is not substantially parallel to the normal direction of opening 414 in vehicle body 402, as indicated by arrow 416. For example, the normal direction of each of main surfaces 434C-434D is substantially perpendicular to the normal direction of opening 414 in vehicle body 402 indicated by arrow 416. Modules 418A and 418B are stacked within cavity 400 here, and their main surfaces 434C-434D face substantially towards each other.

[0055] The figures in FIGS. 4A-4E are not necessarily shown in side view, nor are they shown from a common direction. One or more of the figures in FIGS. 4A-4E can be, by way of example only, a side view, a top view, a bottom view, a front view, or a rear view.

[0056] FIG. 5 shows an example of a cross-section 500 of a vehicle body 502, a module 504 of an HV battery system, an electrochemical cell 506, and a closure 508. The cross-section 500 can be used with one or more other examples described elsewhere in this specification. The vehicle body 502, the module 504, and the closure 508 are partially omitted here for the sake of brevity. The module 504 can be attached to the vehicle body 502. In some implementations, this can be done to install any one of the modules 122A - 122D in FIG. 1 within the cavity 108. For example, a portion 504A of the module 504 can here abut against and be fixed to the vehicle body 502. The electrochemical cell 506 is encompassed by the module 504 and held in its fixed position. In some implementations, this can be done using the housing 302 in FIG. 3. For example, another portion 504B of the module 504 can function as another restrictive structure for the electrochemical cell 506 (e.g., for attachment and / or cooling). A gap 510 can exist between the closure 508 and the module 504. For example, the gap 510 can separate the electrochemical cell 506 from the closure 508. In some implementations, the gap 510 can be omitted. For example, the closure 508 can be mechanically coupled to the module 504.

[0057] FIG. 6 shows an example of a method 600. The method 600 can be used with one or more other examples described elsewhere in this specification. More or fewer operations than those shown can be performed. Two or more operations can be performed in a different order unless otherwise indicated. The method 600 is an example of a method of manufacturing an EV.

[0058] Operation 602 can involve forming a cavity within the vehicle body by at least one wall of the vehicle body and an opening in the vehicle body. For example, the cavity 108 in FIG. 1 can be formed by the side walls 114 - 120, the rear wall 112, and the opening 110.

[0059] Operation 604 may involve mounting an electric motor for propelling an electric vehicle on the electric vehicle. For example, the electric motor 202 in FIG. 2 may be mounted on the frame of the EV 100 in FIG. 1.

[0060] Operation 606 may involve mounting a high-voltage battery system on the vehicle body within a cavity. For example, the HV battery system 102 in FIG. 1 may be mounted on the vehicle body 104. The high-voltage battery system includes electrochemical cells (e.g., electrochemical cells 124 or 126) for supplying power to the electric motor.

[0061] Operation 608 may involve closing an opening using a closure, and the high-voltage battery system is surrounded by the vehicle body wall and the closure and does not have a stand-alone pack enclosure. In some implementations, the closure 134 in FIG. 1 may be mounted on the vehicle body 104 to close the opening 110.

[0062] FIG. 7 shows an example of a method 700. The method 700 may be used in conjunction with one or more other examples described elsewhere in this specification. More or fewer operations than those shown may be performed. Two or more operations may be performed in a different order unless otherwise indicated. The method 700 is an example of a method for performing maintenance inspection of an EV.

[0063] Operation 702 may involve removing a closure that closes an opening in the vehicle body of the electric vehicle. For example, the closure 134 in FIG. 1 may be removed from the vehicle body 104 to expose the opening 110. A cavity is formed in the vehicle body by the opening and at least one wall of the vehicle body. For example, the cavity 108 in FIG. 1 may be formed by the side walls 114-120, the rear wall 112, and the opening 110. The high-voltage battery system is mounted on the vehicle body within the cavity. For example, the HV battery system 102 in FIG. 1 may be mounted on the vehicle body 104. The high-voltage battery system includes at least first and second modules of electrochemical cells. For example, the HV battery system 102 in FIG. 1 may include two or more of the modules 122A-122D.

[0064] Operation 704 may involve removing the electrical interconnect that electrically connects the first and second modules from the high-voltage battery system. For example, any one of the electrical interconnects 128A-128C in FIG. 1 may be removed. The electrical interconnect may be removed by pulling while gripping the insulating portion of the electrical interconnect. For example, the maintenance technician may grip the insulator 132 (or another insulating portion) using a hand or tool. The electrical interconnect may be removed by rotating or otherwise moving the component. The high-voltage terminals of the high-voltage battery system are not exposed to the maintenance technician before or after removal of the electrical interconnect. After removal of the electrical interconnect, only the terminals of the high-voltage battery system having portions of the full battery system voltage are exposed to the maintenance technician.

[0065] After the maintenance inspection is complete, the electrical interconnect may then be installed, followed by installation of the closure to close the opening.

[0066] The terms "substantially" and "about" as used throughout this specification are used to account for and consider minor variations, such as those due to variations during processing. For example, they may refer to being less than or equal to ±5%, such as less than or equal to ±2%, such as less than or equal to ±1%, such as less than or equal to ±0.5%, such as less than or equal to ±0.2%, such as less than or equal to ±0.1%, such as less than or equal to ±0.05%. Also, as used herein, indefinite articles such as "a" or "an" mean "at least one".

[0067] It should be understood that all combinations of the above concepts and additional concepts discussed in more detail below are contemplated as being part of the subject matter of the invention disclosed herein, provided that such concepts are not mutually inconsistent. In particular, all combinations of the claimed subject matter that appear at the end of this disclosure are contemplated as being part of the subject matter of the invention disclosed herein.

[0068] A number of implementations have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of this specification.

[0069] In addition, the logical flows shown in the figures do not require the particular order, or sequential order, shown to achieve desirable results. In addition, other processes may be provided, or processes may be eliminated from the flows described, other components may be added to the systems described, or other components may be removed from the systems described. Accordingly, other implementations are within the scope of the following claims.

[0070] Certain features of the described implementations have been shown as described herein, but now many modifications, substitutions, changes, and equivalents will occur to those skilled in the art. Accordingly, it should be understood that the appended claims are intended to cover all such modifications and changes that fall within the scope of these implementations. They are presented by way of example only and not of limitation, and it should be understood that various changes can be made in form and detail. Except for mutually exclusive combinations, any part of the apparatus and / or method described herein can be combined in any combination. The implementations described herein can include various combinations and / or sub-combinations of the functions, components, and / or features of the different implementations described.

Claims

**Claim 1** An electric vehicle, comprising: a vehicle body; a cavity in the vehicle body, the cavity being formed by at least one wall of the vehicle body and an opening in the vehicle body; a closing part configured to close the opening; an electric motor for propelling the electric vehicle; and a component including a high-voltage battery system, the component being mounted on the vehicle body within the cavity, the high-voltage battery system including an electrochemical cell for supplying power to the electric motor, the high-voltage battery system being surrounded by the wall and the closing part of the vehicle body and not having a stand-alone pack enclosure, the electric vehicle being provided with the above components. **Claim 2** The electric vehicle according to claim 1, wherein the high-voltage battery system includes first and second modules of electrochemical cells and includes an electrical interconnect for electrically connecting the first and second modules to each other. **Claim 3** The electric vehicle according to claim 2, wherein each of the first and second modules has a high-voltage portion of the high-voltage battery system. **Claim 4** The electric vehicle according to claim 2, wherein the electrical interconnect includes a bus bar partially covered by an insulator. **Claim 5** The electric vehicle according to claim 2, wherein each of the first and second modules includes a circuit for controlling the respective electrochemical cells of the first or second module. **Claim 6** The electric vehicle according to claim 2, wherein each of the first and second modules has a shape composed of a straight line, the main surfaces of the shape composed of a straight line face each other, and the normal direction of each of the main surfaces is substantially parallel to the normal direction of the opening in the vehicle body. **Claim 7** The electric vehicle according to claim 6, wherein the first and second modules are mounted side by side within the cavity, and their main surfaces are substantially aligned with each other. **Claim 8** The electric vehicle according to claim 6, wherein the first and second modules are stacked within the cavity, and their main surfaces substantially face each other. **Claim 9** The electric vehicle according to claim 2, wherein each of the first and second modules has a shape composed of a straight line, the main surfaces of the shape composed of a straight line face each other, and the normal direction of each of the main surfaces is not substantially parallel to the normal direction of the opening in the vehicle body. **Claim 10** The electric vehicle according to claim 9, wherein a normal direction of each of the main surfaces is substantially perpendicular to a normal direction of the opening in the vehicle body.

11. The electric vehicle according to claim 10, wherein the first and second modules are stacked in the cavity, and their main surfaces substantially face each other.

12. The electric vehicle according to claim 1, wherein the cavity is formed by at least five walls of the vehicle body.

13. The electric vehicle according to claim 12, wherein the five walls include a rear wall facing the opening and four side walls substantially perpendicular to the rear wall.

14. The electric vehicle according to any one of claims 1 to 13, wherein the opening faces the ground on which the electric vehicle is located.

15. The electric vehicle according to any one of claims 1 to 13, further comprising a gap separating the electrochemical cell from the closing portion.

16. A method of manufacturing an electric vehicle, comprising: forming a cavity in a vehicle body by at least one wall of the vehicle body and an opening in the vehicle body; mounting an electric motor on the electric vehicle for propulsion of the electric vehicle; mounting a component including a high-voltage battery system in the cavity on the vehicle body, the high-voltage battery system including an electrochemical cell for supplying power to the electric motor; and closing the opening with a closing portion, the high-voltage battery system being surrounded by the wall and the closing portion of the vehicle body and not having a stand-alone pack enclosure, a method comprising.

17. The step of mounting the component in the cavity on the vehicle body comprises: mounting first and second modules of an electrochemical cell in the cavity; and installing an electrical interconnect for electrically connecting the first and second modules to each other The method according to claim 16, comprising.

18. A method for servicing an electric vehicle, comprising: removing a closing portion closing an opening in the vehicle body of the electric vehicle, the cavity in the vehicle body being formed by the opening and at least one wall of the vehicle body, a component including a high-voltage battery system being mounted in the cavity on the vehicle body, the high-voltage battery system including at least first and second modules of an electrochemical cell; and Removing an electrical interconnect that electrically connects the first and second modules from the high voltage battery system A method comprising.

19. The method according to claim 18, wherein the step of removing the electrical interconnect includes pulling while gripping an insulating portion of the electrical interconnect.

20. Subsequently, installing the electrical interconnect to electrically connect the first and second modules to each other; and After subsequently installing the electrical interconnect, closing the opening at the closing portion The method according to claim 18 or 19, further comprising.

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