Battery module system, assembly, and manufacturing method

Abstract

The battery module may include a housing and a plurality of cells disposed within the housing. The housing may be designed and configured to prevent the propagation of thermal runaway to adjacent battery modules of a battery system including the plurality of battery modules. In other words, the battery module may be hermetically sealed from the external environment except for a vent port that directs gases or debris generated by a thermal runaway event away from the battery module. In other words, the housing may form an airtight enclosure surrounding the plurality of cells disposed therein.

Description

[Technical Field]

[0001] Inventor: JOSEPH JAMES MICHAEL ARMSTRONG Assignee: ELECTRIC POWER SYSTEMS, INC. The present disclosure generally relates to apparatus, systems, and methods for providing interconnected battery modules. [Background technology]

[0002] The inventions described in the Background Art section should not be considered prior art merely because they are mentioned in the Background Art section. Similarly, the problems mentioned in the Background Art section or problems related to the inventions described in the Background Art section should not be considered previously recognized in the prior art. The inventions described in the Background Art section simply demonstrate different approaches and may be inventions in their own right.

[0003] Battery modules, for purposes of this disclosure, include a plurality of electrically connected cell brick assemblies. These cell brick assemblies may further include collections of electrochemical or electrostatic cells (hereinafter collectively referred to as "cells") configured in parallel, series, or a combination of both. The cells may be electrically charged to provide a static potential for power supply or a releasable charge when needed. When the cells are assembled into a battery module, they are often connected together via metal strips, straps, wires, bus bars, etc. These connecting members are welded, soldered, or otherwise secured to the cells to connect them together in the desired configuration.

[0004] A cell may be composed of at least one positive electrode and at least one negative electrode. One common form of such a cell is the well-known secondary battery, enclosed in a cylindrical metal can or prismatic case. Examples of chemistries used in such secondary batteries include lithium cobalt oxide, lithium manganese, lithium iron phosphate, nickel cadmium, nickel zinc, and nickel metal hydride. Such cells are being mass-produced due to the expanding consumer market demand for low-cost rechargeable energy for portable electronic devices.

[0005] Custom battery solutions may be more costly for the customer. Custom battery solutions may have longer lead times due to the customization desired by the customer. Custom battery solutions may require a higher engineering workload to meet the characteristics desired by the customer.

[0006] The inventive subject matter of the present disclosure is particularly pointed out and distinctly claimed at the end of this specification. However, a more complete understanding of the present disclosure may best be obtained by reference to the detailed description and claims set forth in connection with the following drawings, which illustrate various embodiments utilizing the principles described herein, but which do not limit the scope of the claims. Summary of the Invention [Means for solving the problem]

[0007] The battery system disclosed herein can be configured to supply power to electric vehicles (e.g., electric aircraft, electric ships, electric submarines, and the like). The battery system includes a plurality of battery modules coupled to each other to form an energy storage device. Each of the plurality of battery modules is configured to be electrically coupled to an adjacent battery module via an electrical connector to form an electrical path between the modules. Similarly, each of the plurality of battery modules is configured to form a communication path via a communication connector. In this regard, each of the plurality of battery modules is designed and configured with ease of assembly in mind. In other words, by having a connector interface and a communication interface that can be formed in response to sliding a first electrical connector (e.g., a male connector) and a communication connector (e.g., a male connector) of a first battery module toward and into an electrical connector (e.g., a female connector) and a communication connector (e.g., a female connector) of a second battery module, assembly of the battery system can be performed more quickly and efficiently than with typical battery systems for electric vehicles.

[0008] In various embodiments, the battery modules disclosed herein include a housing with multiple cells disposed therein. In various embodiments, the housing is configured to prevent propagation of a thermal runaway event from the battery module to adjacent battery modules in a battery system. In other words, while a thermal runaway event can propagate within a battery module disclosed herein, the housing of the battery module is configured to contain the event within a single battery module in a battery system. In various embodiments, the housing includes a vent port. In various embodiments, the interior space of the battery module defined by the housing, except for the vent port, is hermetically sealed from the external environment. In other words, in various embodiments, the housing disclosed herein forms an airtight enclosure surrounding the multiple cells disposed therein. In various embodiments, gases and / or ejecta generated by a thermal runaway event are vented via the vent port to a vent system (e.g., an exhaust duct, an exhaust pipe, or the like). In other words, because the enclosure is hermetically sealed except for the vent port, there is no path through which gases generated by a thermal runaway event can escape, and therefore the gases are directed exclusively through the vent port. [Brief explanation of the drawings]

[0009] [Figure 1] 1 shows a schematic diagram of an electric aircraft, according to various embodiments.

[0010] [Figure 2] 2 illustrates an exploded view of a battery module used in the battery system of the electric aircraft of FIG. 1, according to various embodiments.

[0011] [Figure 3] 3A-3C illustrate various views of the battery module of FIG. 2 during assembly thereof, according to various embodiments.

[0012] [Figure 4]1 illustrates a cross-sectional view of a vent port connection of a battery system, according to various embodiments.

[0013] [Figure 5] 1 illustrates a cross-sectional view of an electrical connector, according to various embodiments.

[0014] [Figure 6] 1 illustrates a cross-sectional view of an electrical connector, according to various embodiments.

[0015] [Figure 7] 6 illustrates an exploded view of the electrical connector of FIG. 5, according to various embodiments.

[0016] [Figure 8] 7 illustrates an exploded view of the electrical connector of FIG. 6, according to various embodiments.

[0017] [Figure 9] 1 illustrates a cross-sectional view of a communication connector, according to various embodiments.

[0018] [Figure 10] 1 illustrates a cross-sectional view of a communication connector, according to various embodiments.

[0019] [Figure 11] 10 illustrates an exploded view of the communication connector of FIG. 9, according to various embodiments.

[0020] [Figure 12] 11 illustrates an exploded view of the communication connector of FIG. 10, according to various embodiments.

[0021] [Figure 13] FIG. 1 illustrates a side view of a connector shield of a battery module, according to various embodiments.

[0022] [Figure 14] FIG. 1 illustrates a side view of a connector shield of a battery module, according to various embodiments.

[0023] [Figure 15] 1 illustrates a perspective view of a portion of a battery system, according to various embodiments.

[0024] [Figure 16] 1 illustrates electrical connections between electrical connectors of adjacent battery modules, according to various embodiments.

[0025] [Figure 17] 1 illustrates electrical connections between adjacent communication connectors of adjacent battery modules, according to various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0026] The following detailed description of various embodiments herein refers to the accompanying drawings, which illustrate various embodiments by way of illustration. The various embodiments described herein have been described in sufficient detail to enable those skilled in the art to practice the present disclosure, but it should be understood that other embodiments may be realized and changes may be made without departing from the scope of the present disclosure. Accordingly, the detailed description set forth herein is provided for illustrative purposes only and is not intended to be limiting. Furthermore, references to the singular encompass multiple embodiments, and references to multiple components or steps may encompass a single embodiment or step. Furthermore, references to "attached," "fixed," "connected," and the like may encompass permanent, detachable, temporary, partial, full, or any other form of attachment. Furthermore, references to "non-contact" or similar expressions may encompass reduced or minimal contact. Additionally, unless otherwise expressly stated, references to the singular (such as "a," "an," or "the") are to be construed as either singular or plural and should be understood to encompass the plural of the item in question. Furthermore, all numerical ranges are inclusive, and all range and ratio limits disclosed herein are mutually combinable.

[0027] Referring now to FIG. 1 , a schematic diagram of an aircraft 100 with an electric propulsion system 101 is shown, according to various embodiments. In various embodiments, the electric propulsion system 101 includes a propulsion unit 110 and a propulsion unit 120. In various embodiments, the propulsion units 110 and 120 each include an electric motor and a propeller. For example, the propulsion unit 110 includes an electric motor 111 and a propeller 112, and the propulsion unit 120 includes an electric motor 121 and a propeller 122. The electric motor 111 is configured to drive the propeller 112, and the electric motor 121 is configured to drive the propeller 122. The propulsion unit 120 is disposed on a wing 103 of the aircraft 100, and the propulsion unit 110 is disposed on a wing 104 of the aircraft 100. In various embodiments, the propellers 112 and 122 may be variable-pitch or fixed-pitch propellers, although the disclosure is not limited in this respect. Although the present specification describes an aircraft having one propulsion unit per wing, in various other embodiments, any number of propulsion units may be provided on each wing, and the propulsion units may be located in the nose of the aircraft 100, and other configurations are within the scope of this disclosure.

[0028] In various embodiments, electric propulsion system 101 further includes an electrical system 140. Electrical system 140 includes a battery system 150 and a battery system 160. Battery system 150 is configured to provide power to electric motor 121, and battery system 160 is configured to provide power to electric motor 111. In various embodiments, battery system 150 and battery system 160 may be independent battery systems. In various embodiments, battery system 150 is disposed aft of propulsion unit 120, and battery system 160 is disposed aft of propulsion unit 130. Battery system 150 may be disposed in a nacelle of wing 103, and battery system 160 may be disposed in a nacelle of wing 104.

[0029] Although described herein with respect to aircraft 100, the present disclosure is not limited thereto. For example, battery module 200 and battery systems 150, 160 may be utilized in other electric vehicle applications, such as land vehicles (e.g., trucks, automobiles, etc.), marine vehicles (e.g., boats, underwater survey craft, submarines, etc.), or airborne vehicles (e.g., aircraft 100), and these applications are within the scope of the present disclosure.

[0030] 2, a perspective exploded view of a battery module 200 is shown, according to various embodiments. The battery module 200 includes a housing 210 and a cell brick assembly 220 disposed within the housing 210. In various embodiments, the cell brick assembly 220 includes a plurality of cells 222 (e.g., prismatic cells, pouch cells, cylindrical cells, and the like) disposed within the housing 210.

[0031] In various embodiments, the housing 210 (e.g., enclosure assembly) includes a plurality of side walls 290, which form a generally rectangular parallelepiped shape in an assembled state (e.g., as shown in FIG. 3 and described further below). The plurality of side walls 290 may include lateral side walls (e.g., side walls 291 and 292), wide side walls (e.g., side walls 293 and 294), an upper side wall (e.g., lid 295), and a lower side wall (e.g., bottom panel 296). The side wall 291 is disposed opposite the side wall 292. In other words, the side wall 291 is disposed spaced apart from the side wall 292 in the longitudinal direction (i.e., the Z direction), with the side wall 291 defining a first longitudinal side of the housing 210 and the side wall 292 defining a second longitudinal side of the housing 210. Similarly, the side wall 293 is disposed opposite the side wall 294. In other words, side wall 293 is spaced apart from side wall 294 in the lateral direction (i.e., X direction), with side wall 293 defining a first lateral side of housing 210 and side wall 294 defining a second lateral side of housing 210. Similarly, bottom panel 296 is disposed opposite lid portion 295. In other words, lid portion 295 is spaced apart from bottom panel 296 in the vertical direction (i.e., Y direction), with lid portion 295 defining a first vertical side (e.g., upper side) of housing 210 and bottom panel 296 defining a second vertical side (e.g., lower side) of housing 210.

[0032] In various embodiments, briefly referring to FIG. 3 , where like numbers indicate like or similar elements, the generally rectangular parallelepiped shape 310 of the housing 210 includes a plurality of seams 301 (e.g., seams 311, 312, 313, 321, 322, 323, 331, 341, 351, 352, 353, 354). Each of the plurality of seams may at least partially define an edge of the housing 210. In various embodiments, all edges of the housing 210 are defined by a corresponding seam. In this regard, in various embodiments, each edge of the generally rectangular parallelepiped shape 310 may be hermetically sealed by fusion-bonding a first of the plurality of sidewalls to a second of the plurality of sidewalls. In various embodiments, each of the plurality of seams is formed by fusion-bonding a first of the plurality of sidewalls to a second of the plurality of sidewalls. In other words, a joint, such as a weld joint, braze joint, or the like, is formed between each pair of adjacent side walls. For example, side wall 293 may be welded (e.g., laser welded) to side wall 291 to form seam 311. In this regard, seam 311 formed by melt-joining adjacent side walls (e.g., side wall 291 and side wall 293) together may form a hermetic seal (i.e., an airtight seal) along seam 311. In various embodiments, each of the plurality of seams 301 shown in FIG. 3 may be formed as described herein. For the sake of brevity, a detailed description of each seam is omitted, but it should be understood that each seam may be formed as described for seam 311.

[0033] In various embodiments, each of the plurality of side walls 290 may include a flat plate (e.g., a metal plate). For example, in various embodiments, each of the plurality of side walls 290 may be a metal plate made of commercially pure titanium (e.g., a composition having a titanium content of 99% or more, 99.5% or more, or 99.9% or more) or a metal plate made of a titanium alloy.

[0034] Typically, battery module housing materials used in aviation applications are constructed from aluminum or non-metallic materials such as carbon fiber composites and thermoplastics. Key design factors in aviation applications include weight and cost. Accordingly, aluminum, carbon fiber, and thermoplastics are lighter than pure titanium or titanium alloys. However, using pure titanium or titanium alloys for the housing 210 can significantly improve the strength-to-weight ratio of the housing 210 compared to aluminum, thereby enabling the housing to accommodate heavier battery modules. In various embodiments, using titanium for the housing 210 can significantly improve the thermal properties of the housing 210 compared to aluminum. For example, using pure titanium for the housing 210 can reduce the thermal conductivity of the housing 210 by approximately 10 times compared to an aluminum housing. In this regard, while aluminum housings 210 can be designed so that heat generated during a thermal runaway event will rapidly and significantly heat the aluminum frame through the housing, titanium housings 210 can be designed to conduct the heat more gradually through the frame.

[0035] In various embodiments, the use of a flat plate for each of the plurality of side walls 290 can simplify joining adjacent side walls of the plurality of side walls 290. For example, each side wall can include a flat plate having the same nominal thickness (i.e., a flat plate formed from the same sheet metal material). In this regard, welding flat plates having similar thicknesses can promote a strong bond, thereby facilitating a hermetic seal along each seam.

[0036] In various embodiments, using flat plates for each of the side walls 290 simplifies the construction of the side walls 290, reducing costs and manufacturing time. Although the housing 210 is described herein as being formed by welding adjacent side walls to form the seams 301, the present disclosure is not limited thereto. For example, it is within the scope of the present disclosure to form the housing 210 by forming most of the housing 210 (e.g., side walls 291, 292, 293, 294 and bottom panel 296) using a deep draw process, with the lid 295 being welded to the edges of the side walls 291, 292, 293, 294.

[0037] 2, the housing 210 has an interior space 212 located inside a plurality of side walls 290. As previously mentioned, a plurality of cells of the cell brick assembly 220 are disposed within the interior space 212 of the housing 210.

[0038] In various embodiments, the housing 210 further includes a vent port 230. In various embodiments, the vent port 230 is disposed through one of the side walls (e.g., the lid 295). The vent port 230 is in fluid communication with the interior space 212 and facilitates the evacuation of hot gases and debris during a thermal runaway event. In this regard, the vent port 230 may be configured to couple to a vent, such as a vent tube, vent duct, or the like, to direct hot gases and debris away from the battery module 200 during a thermal runaway event.

[0039] In various embodiments, the vent port 230 comprises a generally cylindrical body extending from the vent port edge 231 into the interior space 212. As used herein, when the word "generally" is followed by a shape description, it is understood to include slight variations in the shape from the standard contour of the shape. In other words, a shape that is not strictly considered cylindrical can be considered "generally cylindrical" if it fits within plus or minus one inch (2.54 cm) of the contour of a standard cylindrical shape.

[0040] In various embodiments, the vent port 230 is configured to couple to tubing or a coupling for a vent system. In this regard, and with brief reference to FIG. 4 , the inner diameter surface 232 of the vent port 230 can include a threaded surface. While described herein as including a threaded surface, the present disclosure is not limited thereto. For example, the vent port 230 may have a flat wall and be configured to mate with a piloted O-ring connection, and still be within the scope of the present disclosure. In various embodiments, the vent port 230 has a threaded surface configured to mate with a male threaded surface of a vent coupling 410 made of a different material (e.g., aluminum), thereby enabling the vent port interface 401 between the components (e.g., between the vent port 230 and the vent coupling 410) to be self-sealing during a thermal runaway event. In other words, in various embodiments, the mating material of vent coupling 410 is configured to expand more upon heating than vent port 230, such that the mating material of vent coupling 410 expands radially outward against inner diameter surface 232 of vent port 230, sealing that portion of the vent system from the external environment during a thermal runaway event, thereby protecting various components within the structure of aircraft 100 shown in Figure 1. In other words, vent coupling 410 may have a higher coefficient of thermal expansion than vent port 230.

[0041] 2, according to various embodiments, a lip 231 of the vent port 230 is fusion-bonded (e.g., by welding, brazing, or other similar bonding method) to a plate 299 of the lid 295. In various embodiments, by fusion-bonding the lip 231 of the vent port 230 to the lid 295, the joint between the vent port 230 and the lid 295 can be hermetically sealed.

[0042] 2 , in various embodiments, the housing 210 further includes at least one cold plate 241. In various embodiments, each of the wide side walls (e.g., side wall 293 and side wall 294) includes a cold plate 241 coupled thereto. For example, the battery module 200 may include a first cold plate (e.g., cold plate 241 located on a first side of the housing 210) and a second cold plate (e.g., cold plate 241 located on a second side of the housing 210). The first cold plate includes a first wide side wall (e.g., side wall 293) of the plurality of side walls 290 and a first vane plate (e.g., vane plate 242) coupled thereto, and the second cold plate includes a second wide side wall (e.g., side wall 294) of the plurality of side walls 290 and a second vane plate (e.g., vane plate 242) coupled thereto. Although sidewall 294 is described in further detail herein, according to various embodiments, sidewall 293 may have similar features as sidewall 294. In other words, in various embodiments, both sidewall 293 and sidewall 294 include cold plate 241, which is described in further detail below. In this regard, heating and / or cooling of battery module 200 while battery module 200 is being charged may occur more uniformly compared to when cold plate 241 is provided on only one side of battery module 200.

[0043] In various embodiments, sidewall 294 may include a flat plate 299 and a vane plate 242 coupled thereto to form cold plate 241. In other words, flat plate 299 and vane plate 242 may define a flow path therein (e.g., a serpentine flow path or the like). While shown as a serpentine flow path, the present disclosure is not limited thereto. For example, the flow path may include parallel channels extending longitudinally (i.e., in the Z direction) or the like, and is within the scope of the present disclosure. In various embodiments, providing a flow path that flows in a serpentine manner from the top side of housing 210 to the bottom side and back to the top side may allow for more efficient purging of cold plate 241 after charging a battery system disclosed herein (e.g., battery system 150 and / or battery system 160 of FIG. 1 ).

[0044] In various embodiments, vane plate 242 may be coupled to flat plate 299 in a manner similar to the methods for joining adjacent side walls described above. For example, vane plate 242 may be fusion-bonded (e.g., by welding, brazing, or the like) to flat plate 299 (e.g., along the periphery of vane plate 242 or between adjacent flow passages, e.g., between flow passage 243 and flow passage 244, between flow passage 244 and flow passage 245, etc.), which is also within the scope of the present disclosure. In other words, in various embodiments, vane plate 242 is fusion-bonded to flat plate 299 of each wide side wall (e.g., side wall 293 or side wall 294) of multiple side walls 290, thereby forming each wide side wall (e.g., side wall 293 or side wall 294). Furthermore, any suitable method for connecting vane plate 242 to flat plate 299 is contemplated.

[0045] For example, in various embodiments, for battery systems 150, 160 of FIG. 1 , fluid may flow through cold plate 241 (e.g., to cool or heat cell brick assembly 220) during charging of each battery system 150, and this is within the scope of the present disclosure. However, when battery systems 150, 160 are in operation (i.e., when aircraft 100 of FIG. 1 is in flight), cold plate 241 may not be used, which is configured to reduce the onboard weight of aircraft 100. In other words, battery systems 150, 160 shown in FIG. 1 may not use active cooling while aircraft 100 is in operation, thereby eliminating the need for a cooling medium (e.g., liquid) that would otherwise be required onboard. Therefore, it may be desirable to purge any fluid remaining within battery systems 150, 160 shown in FIG. 1 after charging. In various embodiments, the serpentine shape of the flow channels of the cold plate 241 may facilitate purging of fluid in a range of about 70% to 100%, or about 80% to 100%, or about 85% to 99%.

[0046] In various embodiments, battery module 200 further includes a mounting structure 250. In various embodiments, mounting structure 250 includes a plurality of brackets 251. Each of the plurality of brackets 251 is coupled to housing 210. In this regard, each of the plurality of brackets 251 is configured to enable battery module 200 to be mounted to a respective support structure (e.g., a support structure within aircraft 100 shown in FIG. 1 , or the like). In various embodiments, by including multiple brackets 251 for engaging with each support structure, battery module 200 can maintain the same configuration in various usage configurations; only the plurality of brackets 251 and their mounting positions may need to be changed.

[0047] In various embodiments, each of the plurality of brackets 251 may have an opening (e.g., opening 259 corresponding to a first bracket 252 of the plurality of brackets 251) corresponding to an opening in one of the plurality of side walls 290 (e.g., opening 298 extending through lid 295). In this regard, in various embodiments, each of the plurality of brackets 251 may be fusion-bonded to the housing 210 (e.g., by welding, brazing, or a similar bonding method), and the fusion bond may hermetically seal the respective bonding locations of the plurality of brackets 251.

[0048] In various embodiments, the first bracket 252 of the plurality of brackets 251 may be spaced apart from the second bracket 253 of the plurality of brackets 251 in the longitudinal direction (i.e., the Z direction). The first bracket 252 and the second bracket 253 of the plurality of brackets 251 may be coupled to the housing 210. While the first bracket 252 and the second bracket 253 of the plurality of brackets are shown as being coupled to the lid 295, the present disclosure is not limited thereto. For example, the first bracket 252 of the plurality of brackets 251 may be coupled to the side wall 291, the side wall 293, or the side wall 294 and still be within the scope of the present disclosure. Similarly, the second bracket 253 of the plurality of brackets 251 may be coupled to the side wall 292, the side wall 293, and / or the side wall 294 and still be within the scope of the present disclosure.

[0049] In various embodiments, the third bracket 254 of the plurality of brackets 251 may be spaced apart from the fourth bracket 255 of the plurality of brackets 251 in the longitudinal direction (i.e., Z direction). The third bracket 254 and the fourth bracket 255 of the plurality of brackets 251 may be coupled to the housing 210. While the third bracket 254 and the fourth bracket 255 of the plurality of brackets are shown as being coupled to the side wall 291 and the side wall 292, respectively, the present disclosure is not limited thereto. For example, the third bracket 254 of the plurality of brackets 251 may be coupled to the side wall 293, the side wall 294, and / or the bottom panel 296 and still be within the scope of the present disclosure. Similarly, the fourth bracket 255 of the plurality of brackets 251 may be coupled to the side wall 293, the side wall 294, and / or the bottom panel 296 and still be within the scope of the present disclosure.

[0050] In various embodiments, third bracket 254 of multiple brackets 251 may be disposed vertically spaced apart from first bracket 252 of multiple brackets 251. Similarly, fourth bracket 255 of multiple brackets 251 may be disposed vertically spaced apart from second bracket 253 of multiple brackets 251. In this regard, mounting structure 250 may include a first mounting side (e.g., a first side portion of housing 210) and a second mounting side (e.g., a second side portion of housing 210). Furthermore, in various embodiments, mounting structure 250 may include a third mounting side (e.g., an upper surface of housing 210) and / or a fourth mounting side (e.g., a lower surface of housing 210). In this regard, in various embodiments, mounting structure 250 may enable multiple possible interface configurations depending on each application.

[0051] In various embodiments, each of the plurality of brackets 251 may include at least two nuts 258 coupled to the bracket. In various embodiments, the nuts 258 may be coupled to a corresponding flange of each bracket by any method known to those skilled in the art (e.g., welding, riveting, brazing, or similar joining method). In various embodiments, the nuts may be configured to receive fasteners (e.g., bolts) to couple a corresponding support structure to a corresponding bracket.

[0052] In various embodiments, each of the plurality of brackets 251 may include a main body (e.g., a main body 261 associated with a second bracket 253 of the plurality of brackets 251), a first flange extending outward from a first edge of the main body (e.g., a first flange 262 associated with a second bracket 253 of the plurality of brackets 251), and a second flange extending outward from a second edge of the main body (e.g., a second flange 263 associated with a second bracket 253 of the plurality of brackets 251).

[0053] In various embodiments, to facilitate electrical connection between a first battery module 200 and a second battery module 200, a first electrical connector 281 (e.g., having a positive terminal, as described in more detail below) may be coupled to a sidewall 291 located on a first longitudinal side of the housing 210, and a second electrical connector 282 (e.g., having a negative terminal, as described in more detail below) may be coupled to a sidewall 292 located on a second longitudinal side of the housing 210 opposite the sidewall 291. Similarly, a first communication connector 271 (e.g., having a plurality of pins to facilitate connection of communication lines of the battery system) may be coupled to the sidewall 291 located on the first longitudinal side of the housing 210, and a second communication connector 272 (e.g., having a plurality of receptacles configured to receive a corresponding one of the plurality of pins) may be coupled to a sidewall 292 located on a second longitudinal side of the housing 210 opposite the sidewall 291. Therefore, as described in detail below, a battery connection step in the assembly steps of a battery system (e.g., battery system 150 or battery system 160 shown in FIG. 1 ) may include a step of sliding a first side wall 292 of the battery module 200 toward a second side wall 291 of the battery module 200 (i.e., in the longitudinal direction / Z direction). In response to the battery connection step being performed, the first second electrical connector 282 of the battery module 200 may be coupled to the second first electrical connector 281 of the battery module 200, and the first second communication connector 272 of the battery module 200 may be coupled to the second first communication connector 271 of the battery module 200.

[0054] In various embodiments, this specification describes the first electrical connector 281 and the first communication connector 271 as both male connectors and the second electrical connector 282 and the second communication connector 272 as both female connectors, but the present disclosure is not limited in this respect. For example, even if the first electrical connector 281 is a male connector and the first communication connector 271 is a female connector, this is within the scope of the present disclosure as long as the second electrical connector 282 is a female connector and the second communication connector 272 is a male connector. In other words, as long as one of the first electrical connector 281 and the second electrical connector 282 is a male connector and the other is a female connector, an electrical interface between adjacent battery modules 200 in the battery system 150 or the battery system 160 shown in FIG. 1 can be realized. Similarly, as long as one of the first communication connector 271 and the second communication connector 272 is a male connector and the other is a female connector, a communication interface between adjacent battery modules 200 in the battery system 150 or battery system 160 shown in Figure 1 can be realized.

[0055] 5, 6, 7, and 8, there are shown a cross-sectional view of electrical connector 500, which is a female electrical connector (FIG. 5), a cross-sectional view of electrical connector 600, which is a male electrical connector (FIG. 6), an exploded view of electrical connector 500 (FIG. 7), and an exploded view of electrical connector 600 (FIG. 8), according to various embodiments. With collective reference to FIGS. 2, 5, 6, 7, and 8, if first electrical connector 281 is electrical connector 500, then second electrical connector 282 is electrical connector 600. Similarly, if first electrical connector 281 is electrical connector 600, then second electrical connector 282 is electrical connector 500. In other words, the battery module 200 is provided with a male electrical connector (e.g., electrical connector 600) and a female electrical connector (e.g., electrical connector 500) to facilitate electrical coupling between adjacent battery modules in a battery system having multiple battery modules 200 (e.g., battery system 150 or battery system 160 shown in FIG. 1).

[0056] In various embodiments, the electrical connector 500 may be configured as a positive or negative terminal of the battery module 200. Similarly, the electrical connector 600 may be configured as a positive or negative terminal of the battery module 200. The disclosure is not limited in this respect. In various embodiments, if the electrical connector 500 is configured as a positive terminal of the battery module 200, the electrical connector 600 may be configured as a negative terminal of the battery module 200. Similarly, if the electrical connector 500 is configured as a negative terminal of the battery module 200, the electrical connector 600 may be configured as a positive terminal of the battery module 200. In other words, the battery modules 200 described herein may be configured to facilitate direct series connection with adjacent battery modules 200, according to various embodiments. Although described herein as facilitating series connection, the disclosure is not limited in this respect. For example, it would still be within the scope of the disclosure if the battery module 200 were configured to facilitate parallel electrical connection with adjacent battery modules 200.

[0057] In various embodiments, electrical connectors 500 and 600 described herein are high voltage connectors. As used herein, "high voltage" is intended to include voltages greater than 600 volts or voltages ranging from 601 volts to 5,000 volts. While described herein as high voltage, electrical connectors 500 and 600 are not limited in this respect.

[0058] In various embodiments, the electrical connectors 500 and 600 described herein have a significantly lower profile (i.e., occupy a smaller volume) than typical high-voltage connectors. In various embodiments, the electrical connector 500 and electrical connector assembly, respectively, have a simplified structure compared to typical high-voltage connectors. In various embodiments, the manufacturing costs of the electrical connectors 500 and 600, respectively, may be reduced by approximately 75% compared to typical high-voltage connectors.

[0059] In various embodiments, the electrical connector 500 and the electrical connector 600 each include a connector housing 510, 610, a seal 520, 620, and an electrode 530, 630. In various embodiments, the connector housing 510, 610 is configured to be coupled to the housing 210 of the battery module 200 shown in FIG. 2 . For example, the connector housing 510 may be configured to be coupled to one flat plate 299 of the side walls 290 (e.g., the side wall 291 corresponding to the first electrical connector 281 or the side wall 292 corresponding to the second electrical connector 282). In various embodiments, the seals 520, 620 are directly coupled to the connector housing 510, 610 and the electrode 530, 630. In this regard, the seals 520, 620 may include a non-conductive material (e.g., a thermoplastic material such as polyetheretherketone (PEEK) or other thermoplastic resins or electrical insulators known in the art).

[0060] In various embodiments, the first longitudinal ends 531, 631 of the electrical connectors 500 and 600 are configured to be coupled to a bus bar. In this regard, the first longitudinal ends 531, 631 of each of the electrical connectors 500 and 600 may include axial surfaces configured to be welded, fastened, or similarly connected to the bus bar. The disclosure is not limited in this respect. Thus, according to various embodiments, the first longitudinal ends 531, 631 are disposed within the interior space 212 of the housing 210 of the battery module 200 shown in FIG. 2 and are electrically coupled to the cell brick assembly 220 (e.g., via a bus bar).

[0061] In various embodiments, the seal 520, 620 may provide dual functionality to the electrical connector 500, 600. For example, the seal 520, 620 may be configured to seal the interior space 212 of the housing 210 from the external environment via the electrical connector 500, 600. In this regard, the seal 520, 620 may prevent a leak path through the electrical connector 500, 600. For example, in response to a thermal runaway event within the battery module 200 shown in FIG. 2 , the interior space 212 of the housing 210 may heat up significantly. This temperature increase may similarly heat the electrical connector 500, 600. In various embodiments, the seal 520, 620 may be configured to expand radially more relative to the components it engages (i.e., the connector housing 510, 610 and the electrodes 530, 630). Thus, the seals 520, 620 may expand radially outward and radially inward and press against the electrodes 530, 630 and connector housings 510, 610 to form a seal therebetween, preventing hot gases or ejecta resulting from a thermal runaway event from leaking into adjacent modules of the battery system 150, 160 of Figure 1, as previously described. In other words, the seals 520, 620 may have a higher coefficient of thermal expansion than the connector housings 510, 610 and electrodes 530, 630.

[0062] In various embodiments, the seals 520, 620 may be further configured to electrically insulate the electrodes 530, 630 from the connector housings 510, 610 and the housing 210. In this regard, because the housing 210 and the connector housings 510, 610 are both constructed of metal (e.g., pure titanium, titanium alloys, and the like), the electrodes 530, 630 are configured to be insulated from the connector housings 510, 610 and the housing 210 to prevent short circuits during operation of the battery module 200 of FIG.

[0063] In various embodiments, the seal 520, 620 includes a body 525, 625 extending from a first longitudinal end 521, 621 along a longitudinal axis defined by the seal body 525, 625 to a second longitudinal end 529, 629. In various embodiments, the body 525 includes an inner diameter surface 522, 622 and an outer diameter surface 528, 628. At least a portion of the inner diameter surface 522, 622 and at least a portion of the outer diameter surface 528, 628 are threaded. In this regard, at least a portion of the outer diameter surface 532, 632 of each engaging electrode (e.g., electrode 530, 630) is threaded in a manner complementary to the threads of the inner diameter surface 522, 622 of the seal 520, 620. Similarly, at least a portion of the outer diameter surface 518, 618 of each mating connector housing (e.g., connector housing 510, 610) is threaded to complement the threads on the outer diameter surface 528, 628 of the seal 520, 620. In this regard, the connector housing 510, 610 may be secured to the seal 520, 620 via a threaded connection, and the electrodes 530, 630 may be secured to the seal 520, 620 via a threaded connection. Although described herein as being coupled via a threaded connection, the present disclosure is not limited in this respect. For example, the coupling between the components of the electrical connectors 500, 600 may be achieved via press fit, adhesive, bonding, or other similar alternative coupling means. The present disclosure is not limited in this respect. However, as mentioned above, the threaded connection, combined with the use of seals 520, 620 having a material with a different thermal expansion coefficient than the mating components (e.g., connector housings 510, 610 and electrodes 530, 630), can promote a sealing effect during a thermal runaway event that occurs within the internal space 212 of the housing 210 of the battery module 200 shown in FIG. 2.

[0064] In various embodiments, electrode 530 further includes a main body 533 and a generally cylindrical body 534 extending along a longitudinal axis defined by electrical connector 530. Generally cylindrical body 534 may at least partially define a receptacle 536 configured to receive a counter electrode (e.g., electrode 630). An inner diameter surface 535 of electrode 530 may be configured to mate with a counter electrode (e.g., electrode 630 of electrical connector 600) via a radial connection, as described below. In various embodiments, seal 520 may further include a generally cylindrical body 526 disposed radially outward from generally cylindrical body 534 of electrode 530. In this regard, electrode 530 may be further protected by seal 520 (e.g., during transportation), according to various embodiments.

[0065] For example, electrode 630 may include a main body 635 extending along a longitudinal axis defined by main body 635 from a first longitudinal end 631 to a second longitudinal end 639, and one or more conductive elements 641 may be coupled to main body 635. In this regard, an outer diameter surface 632 of main body 635 may define at least one radial groove 633 longitudinally spaced from a threaded surface configured to engage seal 620. Radial groove 633 may be configured to receive one of the one or more conductive elements 641 therein. In various embodiments, conductive element 641 may be configured to be radially compressed (e.g., due to being inserted within generally cylindrical body 534 of electrode 530). In this regard, the conductive element 641 may include a conductive coil, a hollow conductive ring, or other annular structure configured to be radially compressed due to partial contact with a radially inner mating surface (e.g., inner diameter surface 535 of electrode 530). While the one or more conductive elements 641 are illustrated as including two conductive elements disposed in corresponding radial grooves 633, the present disclosure is not limited in this regard. For example, electrode 630 may include one conductive element 641 disposed in one of the radial grooves 633, or multiple conductive elements 641 disposed in respective grooves, or similar configurations, all of which remain within the scope of the present disclosure. In various embodiments, including multiple (e.g., two or more) conductive elements 641 may provide redundant electrical connections and improve the robustness of the electrical connections.

[0066] In various embodiments, the electrodes 530, 630 of the electrical connectors 500, 600 may protrude beyond the outer surface of the housing 210. In this regard, the connection between the electrodes can be visually confirmed and ensured during the battery connection step, which will be described in more detail below.

[0067] In various embodiments, the connector housing 510, 610 of the electrical connector 500, 600 may be welded, brazed, or otherwise fusion bonded to the housing 210. In this regard, the connector housing 510, 610 may comprise the same material as the housing 210 described above, or may facilitate a metal-to-metal bond (e.g., welded, brazed, or otherwise). In this regard, the interior space 212 of the housing 210 may be further sealed from the external environment via the bond between the connector housing 510, 610 and the housing 210.

[0068] In various embodiments, electrical connector 500 and electrical connector 600 may each include a protective member (e.g., plug 540 that prevents a user's fingers from entering receptacle 536 of electrode 530 and electrode cap 640 that is coupled to second longitudinal end 639 of electrode 630). In this regard, the protective members (e.g., plug 540 and electrode cap 640) may include a non-conductive material (e.g., a thermoplastic material or other non-conductive material known in the art).

[0069] 9, 10, 11, and 12, there are shown a cross-sectional view of communication connector 900, which is a female communication connector (FIG. 9), a cross-sectional view of communication connector 1000, which is a male communication connector (FIG. 10), an exploded view of communication connector 900 (FIG. 11), and an exploded view of communication connector 1000 (FIG. 12), according to various embodiments. Referring together to FIGS. 2, 9, 10, 11, and 12, if first communication connector 271 is communication connector 900, then second communication connector 272 is communication connector 1000. Similarly, if first communication connector 271 is communication connector 1000, then second communication connector 272 is communication connector 900. In other words, battery module 200 includes a male communication connector (e.g., communication connector 1000) and a female communication connector (e.g., communication connector 900) configured to facilitate communication coupling between adjacent battery modules in a battery system having multiple battery modules 200, such as battery system 150 or battery system 160 shown in FIG. 1. In various embodiments, the male communication connector (e.g., communication connector 1000) may be located on the same side of housing 210 as the male electrical connector (e.g., electrical connector 600 of FIG. 6), or may be located on a different side of housing 210 from the male electrical connector. The disclosure is not limited in this respect.

[0070] In various embodiments, the communication connector 900 and the communication connector 1000 may each include a shield 910, 1010, a communication board 920, 1020 (e.g., a target board 922 for the communication connector 900 and a pin board 1022 for the communication connector 1000), a seal 930, 1030, and a gasket 940, 1040. In various embodiments, the shield 910, 1010 and the seal 930, 1030 may be configured to prevent gas and / or ejecta resulting from a thermal runaway event occurring within the battery module 200 shown in FIG. 2 from leaking out of the enclosure at the location of the communication connector 900, 1000. In other words, in various embodiments, the shield 910, 1010 and the seal 930, 1030 may be incorporated into an assembly for the communication connector 900, 1000 and may provide reinforcement for the location of the communication connector 900, 1000.

[0071] In various embodiments, the communication connectors 900 and 1000 disclosed herein may have a significantly lower profile (i.e., occupy a smaller volume) than communication connectors for typical high-voltage battery module applications. In various embodiments, the manufacturing costs of the communication connectors 900 and 1000, respectively, may be significantly reduced compared to typical communication connectors for high-voltage applications. In various embodiments, the communication connectors 900 and 1000 may prevent the propagation of thermal runaway from one battery module 200 to an adjacent battery module 200, as shown in FIG. 2 .

[0072] 11 and 12, in various embodiments, the housing 210 (e.g., one of the side walls 290 in FIG. 2) may include a plurality of studs 991, 1091 coupled to the housing 210 and extending into the interior space 212 of the housing 210. In various embodiments, the plurality of studs 991, 1091 may each be fusion-bonded to the housing 210 (e.g., by welding, brazing, or other similar bonding method) to prevent potential leak paths.

[0073] In various embodiments, the laminate comprising the communication connector 900, 1000 may be coupled to the housing 210 by coupling each of the multiple studs 991, 1091 to a corresponding fastener 993, 1093 (e.g., a nut or other clamping or fastening hardware known to those skilled in the art).

[0074] In various embodiments, the housings 210 corresponding to the communication connectors 900 and 1000, respectively, may include openings 992, 1092 therethrough that are configured to receive the axial projections 932, 1032 of the seals 930, 1030 therethrough.

[0075] In various embodiments, a plurality of pins 1025 disposed on the pin substrate 1022 of the communication substrate 1020 may be configured to mate with and be electrically coupled to a plurality of pin receptacles 925 on the target substrate 922 of the communication substrate 920. In this regard, in response to execution of a battery connection step described below, the first communication connector 900 provided on the battery module 200 is configured to be electrically coupled to the second communication connector 1000 provided on the battery module 200, thereby enabling communication between the battery modules in each battery system (e.g., battery system 150 or battery system 160 of FIG. 1 ) in a daisy chain connection.

[0076] In various embodiments, similar to electrical connectors 500, 600, seal member 930 and shield 910 of communication connectors 900, 1000 may comprise an electrically insulating material (e.g., a thermoplastic resin, etc.). In various embodiments, seal member 930 and shield 910 may each comprise a high-strength thermoplastic material, such as PEEK, or other high-strength, electrically insulating material known to those skilled in the art. The disclosure is not limited in this respect.

[0077] In various embodiments, gasket 940 may include a flexible material such as silicone, natural rubber, or the like. In this regard, according to various embodiments, gasket 940 may be configured to form a seal between interior space 212 within housing 210 of FIG. 2 and the external environment.

[0078] 13 and 14 , side views of battery module 200 (e.g., facing side wall 291 in FIG. 13 and side wall 292 in FIG. 14 ) are illustrated according to various embodiments, with like numbers indicating like elements. In various embodiments, battery module 200 further includes a connector shield 1310 and a connector shield 1410. In various embodiments, as described below, a first connector shield 1310 of battery module 200 may be configured to couple to a second connector shield 1410 of battery module 200 in response to the first battery module 200 being coupled to the second battery module 200. In this regard, the connection between first connector shield 1310 of battery module 200 and second connector shield 1410 of battery module 200 may be configured to protect the electrical connection between the first and second battery modules 200 from the external environment.

[0079] In various embodiments, each electrical connection (e.g., the electrical connection between first electrical connector 281 and second electrical connector 282 or the communication connection between first communication connector 271 and second communication connector 272) may be a corresponding adapter connection. For example, connector shield 1310 may include adapter 1312 and adapter 1314, and connector shield 1410 may include adapter 1412 and adapter 1414. Adapter 1312 may be coupled to and configured to mate with adapter 1412, and adapter 1314 may be coupled to and configured to mate with adapter 1414. In this regard, adapters 1312, 1412 and adapters 1314, 1414 may be separate and independent components, or they may be formed as an integrated adapter / fitting as shown. The disclosure is not limited in this respect. However, in various embodiments, adapter 1312 and adapter 1314 may be formed as a unitary member, thereby reducing the number of parts in the assembly and enabling a reduction in the number of mounting positions on housing 210.

[0080] In various embodiments, the connector shields 1310, 1410 are coupled to the sidewall 291 of the housing 210. The connector shield 1310 can be coupled to the housing 210 via fasteners or the like. In various embodiments, a plurality of blind nuts 1322, 1422 are fusion-bonded to the housing 210 by welding, brazing, or the like and can be configured to receive corresponding fasteners (e.g., studs, bolts, etc.) for attaching the connector shields 1310, 1410 to the housing 210. In this regard, by welding each of the plurality of blind nuts 1322, 1422 to the housing 210, the interior space 212 of the housing 210 can be hermetically sealed from the external environment via each weld.

[0081] Referring now to FIG. 15 , a perspective view of a portion of a battery system 1500 corresponding to portions of battery system 150 and / or battery system 160 shown in FIG. 1 is shown, with like numbers indicating like elements, according to various embodiments. Battery system 1500 includes a first battery module 200 (1510) coupled to a second battery module 200 (1520). In various embodiments, first battery module 200 (1510) may be coupled in series to second battery module 200 (1520) via electrical connections 1600, as described below. Similarly, the communication system of battery system 1500 includes various communication lines extending from first battery module 200 (1510) to second battery module 200 (1520) via electrical connections 1600, as described below. While described herein as being connected in series, the present disclosure is not limited thereto, and two or more battery modules 200 may be connected in parallel using similar principles described herein and remain within the scope of the present disclosure. In various embodiments, battery module 200 may include various electronic components therein (e.g., sensors, one or more processors, or any other electronic components known in the art). In this regard, according to various embodiments, the communication systems and communication connections formed between battery modules described herein enable each component located within each battery module to communicate with a battery management system of a battery system (e.g., battery system 150 and / or battery system 160 shown in FIG. 1).

[0082] In various embodiments, a fluid path between a first (1510) cold plate 241 of a battery module 200 and a second (1520) cold plate 241 of a battery module 200 may be fluidly coupled via a fluid conduit 1530 (e.g., a tube assembly, a fitting assembly, etc.). In this regard, according to various embodiments, the thermal management system of the battery system 1500 may include a fluid path passing through multiple battery modules 200 in series.

[0083] In various embodiments, to facilitate forming the electrical connection 1600 between the first battery module 200 (1510) and the second battery module 200 (1520), the first battery module 200 (1510) and the second battery module 200 (1520) may be pressed together in the longitudinal direction (i.e., Z direction). In this regard, referring to FIGS. 2 and 13 together, the side wall 292 of the first battery module 200 (1510) is pressed toward the side wall 291 of the second battery module 200 (1520). By pressing the first battery module 200 (1510) and the second battery module 200 (1520) together, the electrical connection 1600 between the first battery module 200 (1510) and the second battery module 200 (1520) may be formed without the use of an assembly jig or additional external connections. In other words, an electrical connection consisting of an electrical connection between cells and an electrical connection between communications may be simply formed by pressing the first (1510) of the battery module 200 and the second (1520) of the battery module 200 together.

[0084] 16 and 17, various embodiments illustrate cross-sectional views of an electrical connection 1600 formed between a first (1510) of the battery module 200 and a second (1520) of the battery module 200. The electrical connection 1600 may include a first connection 1601 between the electrical connector 500 and the electrical connector 600, and a second connection 1602 between the communication connector 900 and the communication connector 1000, as previously described.

[0085] In various embodiments, upon forming the electrical connection 1600, an additional seal may be provided between the first connection portion 1601 and the second connection portion 1602 to protect the electrical connection from the external environment. For example, the connector shield 1310 may include a generally cylindrical body 1714 that protrudes from a flange 1712 of the connector shield 1310, and the generally cylindrical body 1714 may have a groove 1716 formed in its radially outer circumferential surface. Disposed within the groove 1716 is an O-ring 1718 (e.g., made from silicone, natural rubber, or a similar flexible material). The O-ring 1718 may be configured to engage and form a seal with a radially inner circumferential surface of a generally cylindrical body 1626 that extends outward from the flange 1622 of the connector shield 1410. In this regard, a portion of the connector shield 1310 and a portion of the connector shield 1410 may be coupled to one another and configured to form a seal around the electrical connection formed between the electrical connector 500 and the electrical connector 600. In this regard, a guided O-ring connection 1730 provided between the connector shield 1310 coupled to the first 1510 of the battery module 200 and the second 1520 of the battery module 200 may be able to protect the electrical connection from the external environment.

[0086] In this regard, similarly, according to various embodiments, the connector shield 1310 and the connector shield 1410 may form a guided O-ring connection 1730 around the electrical connection between the communication connector 900 of the first 1510 of the battery module 200 and the second 1520 of the battery module 200.

[0087] Benefits, other advantages, and solutions to problems have been described herein with reference to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may contribute to the occurrence or realization of the benefits, advantages, or solutions of the present invention should not be construed as key features, required elements, or essential components of the specification. Accordingly, the scope of the present disclosure is to be limited only by the appended claims, and references to elements in the singular are not intended to mean "one and only one" unless expressly stated as such, but rather "one or more." Furthermore, when a phrase similar to "at least any of A, B, or C" is used in a claim, this phrase is intended to mean that only A may be included in an embodiment, only B may be included, or only C may be included, or any combination of A, B, and C (e.g., A and B, A and C, B and C, or A, B, and C) may be included in an embodiment. In the drawings, different hatching is used to distinguish components, but these do not necessarily indicate different or identical materials.

[0088] Systems, methods, and devices are provided herein. In the detailed description herein, references to "one embodiment," "an embodiment," "various embodiments," etc., mean that the described embodiment may include a particular feature, structure, or characteristic, but indicate that not all embodiments necessarily include that feature, structure, or characteristic. Moreover, such phrases may not necessarily refer to the same embodiment. Furthermore, even if a particular feature, structure, or characteristic is described in connection with an embodiment, it should be understood that it is obvious to one skilled in the art that the feature, structure, or characteristic can also be applied to other embodiments not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the present disclosure in alternative embodiments.

[0089] Furthermore, no element, component, or method step described herein is intended to be available to the public, whether or not expressly recited in a claim. No claim element herein is to be construed under 35 U.S.C. §112(f) unless the element is expressly recited using the phrase "means for." As used herein, the terms "comprises," "comprising," and variations thereof are intended to imply a non-exclusive inclusion, i.e., a process, method, article, or apparatus that includes a list of elements is to be construed as including not only the recited elements, but may also include other elements not expressly recited and elements inherent in the process, method, article, or apparatus.

[0090] Finally, any of the above concepts can be used alone or in combination with any or all of the other above concepts. While various embodiments have been disclosed and described, those of ordinary skill in the art will appreciate that various modifications are possible that fall within the scope of the present disclosure. Accordingly, this description is not intended to be an exhaustive description of the principles described or illustrated herein or to limit them to any particular form. Many modifications and variations are possible in light of the above teachings.

Claims

1. A battery module, a housing including a first side wall disposed opposite a second side wall of the housing; a plurality of cells disposed within the housing; a first electrical connector coupled to the first sidewall of the housing; a second electrical connector coupled to the second sidewall of the housing; a first communication connector coupled to the first sidewall of the housing; and and a second communication connector coupled to the second side wall of the housing, wherein the first second electrical connector of the battery module is coupled to the second first electrical connector of the battery module, and the first second communication connector of the battery module is coupled to the second first communication connector of the battery module, in response to a battery connection step that includes sliding the first second side wall of the battery module onto the second first side wall of the battery module.

2. 2. The battery module of claim 1, wherein the first second electrical connector of the battery module is configured to apply a clamping force to secure the second first electrical connector of the battery module in response to sliding the first second side wall of the battery module over the second second side wall of the battery module.

3. The first electrical connector comprises: a connector housing coupled to the housing; a seal coupled to the connector housing, the seal comprising an insulating material; and The battery module of claim 1 , further comprising: a first electrode coupled to the seal.

4. The battery module of claim 3 , wherein the seal is configured to electrically insulate the first electrode from the connector housing.

5. The battery module according to claim 3 , wherein the first electrode protrudes laterally outward from the outer surface of the housing.

6. the first electrode having a radially outer surface and a radial groove disposed in the radially outer surface; a conductive coil disposed at least partially within the radial groove and extending radially outward beyond the radially outer surface.

7. the second electrical connector includes a second electrode; the second electrode includes a radially inner surface; 7. The battery module of claim 6, wherein the first radially inner surface of the battery module is configured to engage and compress the second conductive coil of the battery module in response to the battery connecting step.

8. a first adapter coupled to the first sidewall of the housing and positioned radially outward of the first electrical connector; a second adapter coupled to the first sidewall of the housing and positioned radially outward of the first communication connector; a third adapter coupled to the second sidewall of the housing and positioned radially outward of the second electrical connector; and The battery module according to claim 1 , further comprising: a fourth adapter coupled to the second side wall of the housing and disposed radially outward of the second communication connector.

9. a first O-ring coupled to either the first adapter or the third adapter; and The battery module of claim 8 , further comprising: a second O-ring coupled to either the second adapter or the fourth adapter.

10. In response to the battery connection step, The first third adapter of the battery module is fixed to the second first adapter of the battery module, and The battery module of claim 8 , wherein the first fourth adapter of the battery module is fixed to the second second adapter of the battery module.

11. In response to the battery connection step, a first seal is formed by coupling the first third adapter of the battery module with the second third adapter of the battery module, the first seal being located between an external environment and an electrical connection formed between the first second electrical connector of the battery module and the second first electrical connector of the battery module; and 11. The battery module of claim 10, wherein a second seal is formed by coupling the first fourth adapter of the battery module with the second second adapter of the battery module, and the second seal is located between an external environment and a communication connection formed between the first second communication connector of the battery module and the second first communication connector of the battery module.

12. a first connector shield including the first adapter and the second adapter; and 9. The battery module of claim 8, further comprising: a second connector shield including the third adapter and the fourth adapter.

13. the first connector shield is a first unitary component; and The battery module of claim 12 , wherein the second connector shield is a second unitary component.

14. each of the first side wall and the second side wall extending from a first lateral side of the housing to a second lateral side of the housing; The housing includes: a third side wall extending longitudinally from the first side wall to the second side wall on the first lateral side of the housing; and The battery module according to claim 1 , further comprising: a fourth side wall extending longitudinally from the first side wall to the second side wall on the second lateral side of the housing.

15. The battery module of claim 14 , wherein each of the third sidewall and the fourth sidewall includes a fluid pathway disposed therethrough.

16. The battery module of claim 15 , wherein the fluid path comprises a serpentine shape.

17. 15. The battery module of claim 14, wherein each of the third side wall and the fourth side wall includes a fluid inlet port disposed proximate to the first side wall, a fluid outlet port disposed proximate to the second side wall, and a fluid pathway extending from the fluid inlet port to the fluid outlet port.

18. A battery module, an enclosure including a plurality of side walls forming a generally rectangular parallelepiped shape, the generally rectangular parallelepiped shape at least partially including a plurality of seams formed between adjacent side walls in the plurality of side walls, each of the plurality of seams including a first of the plurality of side walls fusion-bonded to a second of the plurality of side walls, the enclosure having an interior space disposed within the plurality of side walls; a vent port coupled to one of the side walls; and the battery module comprising: a plurality of cells disposed within the interior space of the housing.

19. The battery module of claim 18 , wherein each of the plurality of side walls comprises a flat plate.

20. 20. The battery module of claim 19, further comprising a first cold plate and a second cold plate, the first cold plate including a first wide sidewall of the plurality of sidewalls and a first vane plate coupled thereto, and the second cold plate including a second wide sidewall of the plurality of sidewalls and a second vane plate coupled thereto.

21. the first vane plate is fusion-bonded to the flat plate of the first wide side wall of the plurality of side walls to form the first wide side wall; and 21. The battery module of claim 20, wherein the second vane plate is fusion bonded to the flat plate of the second wide side wall of the plurality of side walls.

22. the first cold plate at least partially defining a first flow path therethrough; and 21. The battery module of claim 20, wherein the second cold plates at least partially define a second flow path therethrough.

23. 20. The battery module of claim 18, wherein each of the plurality of seams is formed by either welding or brazing.

24. 20. The battery module of claim 18, wherein each of the plurality of side walls is made from titanium or a titanium alloy.

25. The battery module of claim 24 , wherein each of the plurality of side walls comprises a metal plate.

26. 20. The battery module of claim 18, wherein the plurality of side walls include a lid disposed on a top surface of the housing, the lid including the vent port coupled thereto.

27. 27. The battery module of claim 26, wherein an edge of the vent port is fusion bonded to an edge of an opening disposed through the lid.

28. 28. The battery module of claim 27, wherein the vent port includes a generally cylindrical body extending from the edge of the vent port into the interior space.

29. 30. The battery module of claim 28, wherein an inner diameter surface of the vent port includes a threaded surface.

30. a first mounting bracket coupled to the housing; and 20. The battery module of claim 18, further comprising: a second mounting bracket coupled to the housing and spaced longitudinally from the first mounting bracket.

31. a third mounting bracket coupled to the housing and vertically spaced apart from the first mounting bracket; and 31. The battery module of claim 30, further comprising: a fourth mounting bracket coupled to the housing and spaced longitudinally from the third mounting bracket and spaced vertically from the second mounting bracket.

32. 32. The battery module of claim 31, wherein each of the first mounting bracket, the second mounting bracket, the third mounting bracket, and the fourth mounting bracket is at least partially fusion bonded to the housing.

33. 32. The battery module of claim 31, wherein each of the first mounting bracket, the second mounting bracket, the third mounting bracket, and the fourth mounting bracket includes one or more nuts coupled thereto.

34. Each of the first mounting bracket and the second mounting bracket comprises: The main body and a first flange extending outwardly from a first edge of the main body; and 31. The battery module of claim 30, further comprising: a second flange extending outwardly from a second edge of the main body.

35. 35. The battery module of claim 34, wherein the first flange of each of the first mounting bracket and the second mounting bracket is spaced apart from a first wide sidewall of the plurality of sidewalls, and the second flange of each of the first mounting bracket and the second mounting bracket is spaced apart from a second wide sidewall of the plurality of sidewalls.

36. A battery system including a plurality of battery modules according to claim 1, wherein the plurality of battery modules are a first of the battery modules; a second of the battery modules coupled to the first of the battery modules; and and a third battery module coupled to the second battery module, wherein the first battery module, the second battery module, and the third battery module define an electrical path therethrough.

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