Battery modules for modular high-voltage battery systems

Abstract

A battery module for a modular high-voltage battery system comprises: an electrochemical cell; a housing of electrically insulating material, the housing enclosing the electrochemical cell; and a first connector on an exterior surface of the housing, the first connector electrically connected to the electrochemical cell, the first connector having terminals accessible only through an insulating cover and openings in the insulating cover, the first connector configured to mate with a first electrical interconnect having bus bars extending into the openings to contact the terminals.

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 373,914, filed August 30, 2022, entitled "BATTERY MODULE FOR MODULAR HIGH-VOLTAGE BATTERY SYSTEM," the entire disclosure of which is incorporated herein by reference.

[0002] This document relates to a battery module for a modular high voltage battery system. [Background technology]

[0003] In recent years, global transportation has begun to transition away from powertrains primarily powered by fossil fuels and toward more sustainable energy sources. The majority of such increasingly popular powertrains include electric motors powered by on-board energy storage. To make these new modes of transportation accessible to a larger segment of the population, vehicle manufacturers are striving to reduce the costs of manufacturing, assembling, operating, and servicing electric vehicles.

[0004] Some existing battery packs for electric vehicles have modules of cells, where the modules are electrically coupled to each other by bolted joints. This approach is associated with cost and time penalties during manufacturing and service. Also, disassembling the pack (e.g., removing a module) requires service technicians to undergo extensive high-voltage safety training and use specialized high-voltage equipment. Summary of the Invention

[0005] In a first aspect, a battery module for a modular high voltage battery system comprises: an electrochemical cell; a housing of an electrically insulating material, the housing enclosing the electrochemical cell; and a first connector on an exterior surface of the housing, the first connector electrically connected to the electrochemical cell, the first connector having terminals accessible only through an insulating cover and openings in the insulating cover, the first connector configured to mate with a first electrical interconnect having bus bars extending into the openings to contact the terminals.

[0006] The implementation may include any or all of the following features: The battery module is rated for an ingress protection rating of 2 or higher according to International Electrotechnical Commission (IEC) standard IEC 60529 for solid particle protection; The first connector protects against fingers or other objects no greater than approximately 80 mm in length; The first connector protects against fingers or other objects greater than approximately 12 mm in diameter; The opening is substantially flat and rectangular; The opening includes a gap between first and second members, the first and second members being connected to each other at a first end and separated from each other at a second end opposite the first end, and the terminal being disposed between the first and second members at the first end; The gap is substantially U-shaped; The battery module has a substantially linear shape. The linear shape includes first and second major surfaces parallel to each other and four side surfaces perpendicular to the overall first and second major surfaces, each of the side surfaces abutting a respective edge of the first and second major surfaces. The first connector is disposed on at least a first of the side surfaces. The first side surface is smaller than a second of the side surfaces. The battery module further includes a second connector configured to mate with a second electrical interconnect, the second connector disposed on the overall outer surface of the housing at a second of the side surfaces, the second side surface being opposite the first side surface. An opening faces along the first side surface. The battery module is configured to be placed side by side with the other battery modules, with the first side surface of the battery module and the corresponding side surface of the other battery modules facing in a common direction. At least the first major surface covers current collectors coupled to at least some of the electrochemical cells. The first connector is configured to mate with the first electrical interconnect, which is a blade, such that the bus bar extends into the opening.

[0007] In a second aspect, a modular high-voltage battery system includes first and second battery modules, each of the first and second battery modules having an electrochemical cell; a housing of a first electrically insulating material, the housing enclosing the electrochemical cell; and a connector on an exterior surface of the housing, the connector electrically connected to the electrochemical cell, the connector including an insulating cover and terminals accessible only through openings in the insulating cover; and an electrical interconnect connecting the first and second modules to each other, the electrical interconnect having bus bars configured to extend into each of the openings in the connectors of the first and second modules to contact the terminals of the connectors of the first and second modules; and a second insulating material partially covering the bus bars. [Brief explanation of the drawings]

[0008] [Figure 1] 1 illustrates an example of an electric vehicle having a modular high voltage battery system.

[0009] [Figure 2] 1 illustrates an example of a battery module of electrochemical cells for a modular high voltage battery system.

[0010] [Figure 3] 3A, 3B, 3C, and 3D show examples of battery modules.

[0011] [Figure 4] 4A and 4B show another example of a battery module.

[0012] Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION OF THE INVENTION

[0013] This specification describes example systems and techniques for battery modules for holding electrochemical cells in a high-voltage battery system. Such high-voltage battery systems can be used in vehicles and / or stationary power sources. The battery modules can be configured to break down the system's high voltage into smaller chunks, allowing safe inspection of individual modules to be performed at inspection centers without specialized high-voltage equipment or training. Previous connection techniques, such as bolted joints, are eliminated, which can help qualify the battery modules for preferred ingress protection ratings. Providing battery modules with interconnection interfaces according to the present disclosure can provide low contact resistance, facilitate inspection, and eliminate the need for torqueing bolts and the tracking and documentation associated with these operations. In this way, the battery modules can enhance high-voltage safety architectures.

[0014] Examples herein refer to battery systems, which are assemblies of electrochemical cells. Battery systems can be configured to power electric motors for propulsion or to provide stationary power sources, to name just two examples. Examples herein refer to battery modules, which are individual components configured to hold and manage multiple electrochemical cells during charging, storage, and use. Battery systems can include any number of modules. A battery module can be intended as the sole power source for one or more loads (e.g., electric motors) or can employ more than one battery module of the same or different types. A battery system can include two or more battery modules of the same or different types. A battery module can include control circuitry for managing the charging, storage, and / or use of electrical energy in the electrochemical cells, or the 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).

[0015] Examples herein refer to battery systems having high voltages, sometimes referred to as high-voltage battery systems. Having high voltage generally involves an operating voltage or potential difference that is considered lethal to human contact. As used herein, high voltage means at least about 250 volts (V). Voltages specified herein are direct current (DC) voltages. In some implementations, a high-voltage battery system can have a voltage greater than about 300 V. In some implementations, a high-voltage battery system can have a voltage greater than about 400 V. In some implementations, a high-voltage battery system can have a voltage greater than about 500 V. In some implementations, a high-voltage battery system can have a voltage greater than about 600 V. In some implementations, a high-voltage battery system can have a voltage greater than about 700 V. In some implementations, a high-voltage battery system can have a voltage greater than about 800 V. In some implementations, a high-voltage battery system can have a voltage greater than about 900 V. In contrast, battery terminals or other conductive elements that are deemed acceptable to an inspector without special high-voltage tools or high-voltage training may be referred to as having a non-lethal voltage. For example, making a high-voltage battery system (e.g., having a voltage greater than about 900 V) inspectable without special high-voltage tools or high-voltage training may involve ensuring that high-voltage terminals are not exposed to inspectors, and that only terminals with non-lethal voltages are exposed to inspectors.

[0016] Examples herein refer to electrochemical cells. Electrochemical cells can include an electrolyte and two electrodes to store energy and deliver it when used. 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 function as a galvanic cell when discharged and as an electrolytic cell when charged. The electrochemical cell can have at least one terminal for each of the electrodes. The terminals, or at least a portion thereof, can be located at one end of the electrochemical cell. For example, if the electrochemical cell is cylindrical, one of the terminals can be located at the center of the end of the cell, and the can that forms the cylinder can constitute the other terminal and therefore also be at that end. Other shapes of electrochemical cells can be used, including, but not limited to, prismatic shapes.

[0017] Examples described herein may refer to above, below, in front, or behind. These and similar expressions identify things or aspects in a relative manner based on an explicit or arbitrary concept of perspective. That is, these terms are merely examples used for illustrative purposes and do not necessarily represent the only possible positions, orientations, etc.

[0018] 1 illustrates an example of an electric vehicle (EV) 100 with a high-voltage (HV) battery system 102. The EV 100 is shown in an exploded view for illustrative purposes. The EV 100 and / or the HV battery system 102 may be used with one or more other examples described elsewhere herein. The EV 100 has one or more electric traction motors (not shown) powered by the HV battery system 102. Some other components of the EV 100 (including, but not limited to, wheels) are omitted from this illustration for clarity.

[0019] EV 100 includes a body 104. Body 104 may include various structural components that together form the framework and sections of EV 100. In some implementations, EV 100 includes a frame assembled from multiple individual sections. In some implementations, EV 100 includes a chassis 106. For example, chassis 106 may form a support structure for body 104 and may be constructed using various frame components, rails, rockers, torque boxes, and / or cross members.

[0020] The EV 100 includes a cavity 108 in a body 104. The cavity 108 is here partially defined by an opening 110. The cavity 108 may be formed in any of various sections or portions of the body 104. In some implementations, the cavity 108 is formed in a chassis 106 of the body 104. For example, the cavity 108 may be configured such that the opening 110 faces the ground on which the EV 100 is placed.

[0021] The cavity 108 can have any shape, including, but not limited to, a rectilinear shape. In some implementations, the cavity is defined by multiple walls of the vehicle body 104. For example, the cavity 108 can be defined at least in part by the rear wall 112. As another example, the cavity 108 can be defined at least in part by the side wall 114 (shown obscured in this figure). As another example, the cavity 108 can be defined at least in part by the side wall 116 (shown obscured in this figure). As another example, the cavity 108 can be defined at least in part by the side wall 118. As another example, the cavity 108 can be defined at least in part by the side wall 120. The rear wall 112 can be oriented toward (e.g., substantially parallel to) the opening 110. One or more of the side walls 114-120 can be substantially perpendicular to the rear wall 112. The cavity 108 can have other shapes.

[0022] The HV battery system 102 may include multiple modules of electrochemical cells, which may be referred to as battery modules or battery cell collectors because each module functions to contain multiple electrochemical cells. Here, the HV battery system 102 includes modules of electrochemical cells 122A-122D. The modules 122A-122D are components that make up the HV battery system 102. The modules 122A-122D may be arranged in any configuration within the cavity 108. Each of the modules 122A-122D may be an individual unit that can be manufactured separately and installed in the cavity 108. For example, each of the modules 122A-122D may be attached to (e.g., abutting) the rear wall 112. The HV battery system 102 may or may not include a standalone pack enclosure (not shown).

[0023] Each of the modules 122A-122D includes a plurality of electrochemical cells. The electrochemical cells can have one or more of a plurality of form factors. In some implementations, the HV battery system 102 can use electrochemical cells 124 having a cylindrical shape. In some implementations, the HV battery system 102 can use electrochemical cells 126 having a prismatic shape. Other form factors can be used.

[0024] The HV battery system 102 may include electrical interconnects for coupling 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 make up the HV battery system 102. The electrical interconnects 128A-128C may serve one or more of several purposes. For example, the electrical interconnects 128A-128C may connect two or more of the modules 122A-122D to each other, thereby increasing the overall voltage from a module-level voltage (e.g., a non-lethal voltage) to a battery system-level voltage (e.g., a lethal voltage). As another example, one or more of the electrical interconnects 128A-128C can be selectively removed (eg, for a service session) to reduce the overall voltage from a battery system-level voltage to a module-level voltage.

[0025] Each of the electrical interconnects 128A-128C may include a bus bar partially covered by an insulator. For example, the electrical interconnect 128A may include a bus bar providing terminals 130 and may also include an insulator 132 covering the bus bar. The terminals 130 may have any shape. In some implementations, the terminals 130 are blades formed from the bus bar. In some implementations, the electrical interconnect 128A may electrically connect the modules 122A-122B to each other. In some implementations, the electrical interconnect 128B may electrically connect the modules 122B-122C to each other. In some implementations, the electrical interconnect 128C may electrically connect the modules 122C-122D to each other.

[0026] The EV 100 includes a closure 134 configured to close the opening 110 of the cavity 108. The closure 134 may include a metal and / or composite member. In some implementations, the closure 134 is in the form of a sheet of material that acts as a shield for the cavity 108. Other shapes for the closure 134 may be used.

[0027] Having modules 122A-122D selectively connected or disconnected by electrical interconnects 128A-128C can provide advantages regarding serviceability of EV 100. For example, after removal of closure 134, electrical interconnects 128A-128C remain in their respective locations, and the high-voltage terminals of HV battery system 102 are not exposed to a technician. That is, the high-voltage terminals of modules 122A-122D may now be covered (e.g., by the insulating material of electrical interconnects 128A-128C) to make each individual module 122A-122D, and HV battery system 102 as a whole, finger-safe. For example, the insulators of electrical interconnects 128A-128C function to cover the high-voltage terminals or other conductors, thereby preventing inadvertent contact therewith. The inspector may then remove one or more of the electrical interconnects 128A-128C. Any of several removal methods may be used. In some implementations, the electrical interconnects 128A-128C may be removed by grasping and pulling on an insulated portion of each electrical interconnect 128A-128C.

[0028] Removal of the electrical interconnect severs the electrical connection between corresponding ones of the modules 122A-122D, thereby reducing the voltage from a system voltage level (e.g., a lethal voltage) to a module-level voltage (e.g., a non-lethal voltage). The present subject matter can make the HV battery system 102 finger-safe in that it allows the HV battery system 102 to be serviced without special high-voltage tools or high-voltage training. That is, the HV battery system 102 is disconnected to a fraction of the full battery system voltage before any of the modules 122A-122D can be accessed for service. For example, each of the modules 122A-122D has a voltage lower than the voltage of the HV battery system 102.

[0029] FIG. 2 illustrates an example of a battery module 200 of electrochemical cells for a modular high-voltage battery system. The battery module 200 can be used with one or more other examples described elsewhere herein. Any number of battery modules can be included. Here, battery modules 200-1, 200-2, 200-3, ..., 200-N are shown, where N is any integer. The battery modules 200 can be arranged in any configuration relative to one another. For example, here, the battery modules 200 are arranged in a row, with each battery module 200 adjacent to one or two other battery modules 200. Each battery module 200 encloses multiple electrochemical cells (not shown). For example, each battery module 200 can include the same number of electrochemical cells. Other approaches can be used.

[0030] Each of the battery modules 200 may have a substantially rectilinear shape. For example, any respective surface of the battery module 200 may be substantially flat and rectangular. In some implementations, each of the battery modules 200 has a major surface 202A, as shown here with battery module 200-1. Battery module 200-1 may have a major surface 202B (illustrated here in a fuzzy fashion) parallel to major surface 202A. Battery module 200-1 may have a side surface 202C. Battery module 200-1 may have a side surface 202D (illustrated here in a fuzzy fashion) parallel to side surface 202C. Battery module 200-1 may have a side surface 202E. Battery module 200-1 may have a side surface 202F (illustrated here in a fuzzy fashion) parallel to side surface 202E. That is, the battery module 200-1 can have four side surfaces, ie, side surfaces 202C to 202F, that are perpendicular to the main surfaces 202A to 202B and abut against the edges of the main surfaces 202A to 202B, respectively.

[0031] Each of the battery modules 200 may include a housing of an electrically insulating material. In some implementations, the battery modules 200 may be molded. For example, molding may be performed using a polymer material, such as a thermoplastic or thermoset. Prior to molding, one or more other materials may be added to the polymer material to change one or more of its properties. In some implementations, a polycarbonate material may have one or more additives. For example, strands of glass and / or another material may be added.

[0032] Each of the battery modules 200 can have at least one connector 204 on its exterior, as shown here with battery module 200-1. The connector 204 can provide a high-voltage connection to the battery module 200-1 and can also allow the modular high-voltage battery system to be disassembled into lower-voltage units for inspection or maintenance. The connector 204 is electrically connected to the electrochemical cells of the battery module 200-1. For example, the connector 204 is connected to one or more bus bars (not shown) inside the battery module 200-1 and thereby to the electrochemical cells of the battery module 200-1. The connector 204 is configured to mate with an electrical interconnect (e.g., any of the electrical interconnects 128A-128C in FIG. 1). The connector 204 has an insulating cover 204′ and terminals that are accessible only through openings in the insulating cover 204′. Thus, the connector 204 can provide an advantageous ingress protection rating to the battery module 200-1, such as to make it finger-safe.

[0033] One or more instances of connector 204 can be located on any or all of the exterior surfaces of battery module 200. In some implementations, connector 204 is located on side 202E and / or 202F. For example, connector 204 can be located on one of sides 202C-202F that is smaller than the other of sides 202C-202F. The connector can be located anywhere on any of the exterior surfaces. In some implementations, connector 204 is located in a central or off-center position on the surface. For example, connector 204 can be located closer to a corner of battery module 200, where the corner is closer to the location of a corresponding connector on an adjacent battery module (e.g., as shown with modules 200-2 and 200-3). In some implementations, battery module 200-1 has connector 205 located on side 202F. That is, connector 205 can be configured to mate with another electrical interconnect (e.g., the same electrical interconnect as for connector 204), and connector 205 is located on the outer surface of housing side 202F, opposite side 202E.

[0034] The battery modules 200 can be configured to be installed side by side. In some implementations, one of the side surfaces 202C to 202F of the battery module 200-1 can face an adjacent side surface of the battery modules 200. For example, the side surface 202D of the battery module 200-1 can face directly toward the corresponding side surface of the battery module 200-2. Thus, for example, the side surfaces 202E of the battery modules 200 can face a common direction.

[0035] Each of the battery modules 200 can have a current collector 206 (here fuzzy and shown generally as a rectangle) coupled to at least some of the electrochemical cells. The current collector 206 can include a bus bar or any other conductive substrate coupled to at least some of the electrochemical cells. In some implementations, the major surfaces 202A and / or 202B cover the current collector 206.

[0036] In a method of manufacturing a modular high-voltage battery system, battery modules 200-2 and 200-3 can be placed adjacent to one another (e.g., in EV 100 of FIG. 1). An electrical interconnect (e.g., any of electrical interconnects 128A-128C in FIG. 1) can be attached to battery modules 200-2 and 200-3. For example, this can involve relative sliding between a safety interconnect, on the one hand, and battery modules 200-2 and 200-3, on the other hand.

[0037] In a method for inspecting a modular high-voltage battery system, a service technician may access equipment in the modular high-voltage battery system (e.g., in EV 100 of FIG. 1 ). The service technician may remove (e.g., by pulling or pushing) the safety interconnects attached to battery modules 200-2 and 200-3. This reduces the voltage of the battery system to a non-lethal level. Once the inspection is complete, the service technician may then install the safety interconnects back onto the battery modules. Removal of the safety interconnects may occur any time the modular high-voltage battery system is inspected.

[0038] 3A-3D show an example of a battery module 300. The battery module 300 can be part of a modular high-voltage battery system and can be used with one or more other examples described elsewhere herein. The battery module 300 includes a housing made of an insulating material and enclosing electrochemical cells. A main surface 302 and a side surface 304 are shown. The battery module 300 has a connector 306 on the side surface 304. The connector 306 is electrically connected to the electrochemical cells. The connector 306 includes an insulating cover 308 that includes one or more insulated portions 310. For example, the insulating cover 308 can be made from the same material as the housing of the battery module 300. The connector 306 includes terminals 312 ( FIG. 3C ) that are accessible only through openings 314 in the insulating cover. The terminals 312 provide electrical connections to the electrochemical cells of the battery module 300. For example, blades of an electrical interconnect can extend through the openings 314 to contact the terminals 312. Here, the opening 314 is a substantially flat rectangle defined by the insulating cover 308. For example, the opening 314 faces along the side surface 304.

[0039] The connector 306 can provide advantages in manufacturing, maintenance, and / or service of the modular high-voltage battery system. In some implementations, the connector 306 ensures that the battery module 300 meets a preferred ingress protection (IP) rating according to the International Electrotechnical Commission (IEC) standard IEC 60529 for solid particle protection. The battery module 300 can have an IP rating of 2 or higher for solid particle protection. For example, the battery module 300 can have an IP rating of 3 or 4. In some implementations, the smallest size of the opening 314 can ensure that a human finger cannot contact the terminal 312. For example, the connector 306 can protect against fingers or other objects no greater than approximately 80 mm in length. As another example, the connector 306 can protect against fingers or other objects greater than approximately 12 mm in diameter. Other approaches can be used.

[0040] 4A-4B show another example of a battery module 400. The battery module 400 can be part of a modular high-voltage battery system and can be used with one or more other examples described elsewhere herein. The battery module 400 includes a housing made of an insulating material and enclosing electrochemical cells. Here, a main surface 402 and a side surface 404 are shown. The battery module 400 has a connector 406 on the side surface 404. The connector 406 is electrically connected to the electrochemical cells. The connector 406 includes an insulating cover 408 that includes one or more insulated portions 410. For example, the insulating cover 408 can be made from the same material as the housing of the battery module 400. The connector 406 includes terminals 412 that are accessible only through openings 414 in the insulating cover. The terminals 412 provide electrical connection to the electrochemical cells of the battery module 400. For example, blades of an electrical interconnect can extend through the openings 414 to contact the terminals 412. Insulating cover 408 includes members 409A and 409B. Members 409A-409B are connected to each other at ends near terminals 412. Members 409A-409B are separated from each other at their respective free ends opposite (distal to) the connected ends. That is, terminals 412 are disposed between members 409A-409B at the connected ends. Here, opening 414 includes a gap between members 409A-409B. Opening 414 is substantially U-shaped (terminals 412 are disposed substantially at the open end of the U) and is defined by members 409A-409B.

[0041] The connector 406 can provide advantages in manufacturing, maintenance, and / or service of the modular high-voltage battery system. In some implementations, the connector 406 ensures that the battery module 400 meets a preferred IP rating according to standard IEC 60529 for solid particle protection. The battery module 400 can have an IP rating of 2 or higher for solid particle protection. For example, the battery module 400 can have an IP rating of 3 or 4. In some implementations, the smallest size of the opening 414 can ensure that a person's finger cannot contact the terminal 412. For example, the connector 406 can protect against fingers or other objects no larger than approximately 80 mm in length. As another example, the connector 406 can protect against fingers or other objects larger than approximately 12 mm in diameter. Other approaches can be used.

[0042] As used throughout this specification, the terms "substantially" and "about" are used to describe and take into account small variations, such as those due to processing variations. For example, they can refer to 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."

[0043] It should be understood that all combinations of the above concepts, and additional concepts discussed in more detail below, (provided that such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

[0044] Although several implementations have been described, it will nevertheless be understood that various modifications may be made without departing from the spirit and scope of the specification.

[0045] Additionally, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Additionally, other processes may be provided or processes may be eliminated from the described flows, and other components may be added to or removed from the described systems. Accordingly, other implementations are within the scope of the following claims.

[0046] While certain features of the described implementations have been illustrated as described herein, many modifications, substitutions, changes, and equivalents will now occur to those skilled in the art. It should therefore be understood that the appended claims are intended to cover all such modifications and variations that fall within the scope of these implementations. They have been presented by way of example only, and not limitation, and it should be understood that various changes in form and detail may be made. Except for mutually exclusive combinations, any portion of the apparatus and / or methods described herein may be combined in any combination. The implementations described herein may include various combinations and / or subcombinations of the functions, components, and / or features of the different implementations described.

Claims

1. 1. A battery module for a modular high voltage battery system, the battery module comprising: electrochemical cells; a housing of electrically insulating material, said housing enclosing said electrochemical cell; and a first connector on an exterior surface of the housing, the first connector electrically connected to the electrochemical cell, the first connector having terminals accessible only through an insulating cover and an opening in the insulating cover, the first connector configured to mate with a first electrical interconnect having a bus bar extending into the opening to contact the terminals; A battery module comprising:

2. 10. The battery module of claim 1, wherein the battery module is compliant with an ingress protection rating of 2 or higher according to International Electrotechnical Commission (IEC) standard IEC 60529 for solid particle protection.

3. 10. The battery module of claim 1, wherein the first connector protects against fingers or other objects no greater than about 80 mm in length.

4. 10. The battery module of claim 1, wherein the first connector protects against fingers or other objects greater than about 12 mm in diameter.

5. The battery module of claim 1 , wherein the opening is a substantially flat rectangle.

6. 2. The battery module of claim 1, wherein the opening includes a gap between a first member and a second member, the first member and the second member being connected to each other at a first end and separated from each other at a second end opposite the first end, and the terminal being disposed between the first member and the second member at the first end.

7. The battery module of claim 6 , wherein the gap is substantially U-shaped.

8. The battery module of claim 1 , wherein the battery module is substantially rectilinear in shape.

9. 9. The battery module according to claim 8, wherein the linear shape includes a first main surface and a second main surface that are parallel to each other, and four side surfaces that are perpendicular to the first main surface and the second main surface, and each of the side surfaces abuts an edge portion of each of the first main surface and the second main surface.

10. The battery module according to claim 9 , wherein the first connector is disposed on at least a first one of the side surfaces.

11. The battery module according to claim 10 , wherein the first side is smaller than a second one of the side surfaces.

12. 11. The battery module of claim 10, further comprising a second connector configured to mate with a second electrical interconnect, the second connector being disposed on the exterior surface of the housing on a second one of the sides, the second side being opposite the first side.

13. The battery module of claim 10 , wherein the opening faces along the first side.

14. 11. The battery module of claim 10, wherein the battery module is configured to be installed side by side with the other battery modules, with the first side of the battery module and the corresponding side of the other battery modules facing in a common direction.

15. 10. The battery module of claim 9, wherein at least the first major surface covers current collectors coupled to at least some of the electrochemical cells.

16. 16. The battery module of claim 1, wherein the first connector is configured to mate with the first electrical interconnect, the first electrical interconnect being a blade, such that the bus bar extends into the opening.

17. a first battery module and a second battery module, each of the first battery module and the second battery module comprising: electrochemical cells; a housing of a first electrically insulating material, said housing enclosing said electrochemical cell; and a connector on an exterior surface of the housing, the connector being electrically connected to the electrochemical cell, the connector including an insulating cover and terminals accessible only through openings in the insulating cover; a first battery module and a second battery module having an electrical interconnect connecting the first battery module and the second battery module to each other, the electrical interconnect comprising: bus bars configured to extend into each of the openings of the connectors of the first battery module and the second battery module and to contact the terminals of the connectors of the first battery module and the second battery module; and a second insulating material partially covering the bus bar; Electrical interconnect having A modular high voltage battery system comprising:

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