Battery module having stacked busbar assembly

Abstract

A battery module is provided that includes first and second cylindrical battery cells. The module includes a stacked busbar assembly having a bottom isolation layer, a busbar layer, and a top isolation layer. A first opening in the bottom isolation layer receives a positive electrode of the first battery cell through the first opening and exposes a portion of the negative electrode of the first battery cell. A second opening in the bottom isolation layer receives a positive electrode of the second battery cell through the second opening and exposes a portion of the negative electrode of the second battery cell. The busbar layer has a first layer portion in contact with the negative electrode of the first battery cell and the negative electrode of the second battery cell, and a second layer portion in contact with the positive electrode of the first battery cell and the positive electrode of the second battery cell.

Description

[Technical Field]

[0001] The present inventors herein have recognized a need for an improved battery module that utilizes a stacked busbar assembly that has a relatively low height profile design and provides both series and parallel electrical configurations of cylindrical battery cells without requiring modifications to the battery cell packaging. [Background technology]

[0002] Miniature battery modules are often manufactured using a wire bonding process with aluminum bus bars to create multiple series and parallel configurations of cylindrical battery cells. Summary of the Invention [Problem to be solved by the invention]

[0003] However, achieving the desired series or parallel electrical configuration often requires modification of the packaging of the cylindrical battery cells within the battery module, and the battery modules often have a relatively high height profile. [Means for solving the problem]

[0004] A battery module according to an exemplary embodiment is provided. The battery module includes a first cylindrical battery cell having a positive electrode and a negative electrode. The battery module further includes a second cylindrical battery cell having a positive electrode and a negative electrode. The battery module further includes a stacked busbar assembly having a bottom isolation layer, a busbar layer, and an upper isolation layer. The busbar layer is coupled between the bottom isolation layer and the upper isolation layer. The bottom isolation layer contacts the first cylindrical battery cell and the second cylindrical battery cell. The bottom isolation layer has a first opening and a second opening extending therethrough. The first opening in the bottom isolation layer is sized and shaped to receive the positive electrode of the first cylindrical battery cell through the first opening and to expose a portion of the negative electrode of the first cylindrical battery cell. The second opening in the bottom isolation layer is sized and shaped to receive the positive electrode of the second cylindrical battery cell through the second opening and to expose a portion of the negative electrode of the second cylindrical battery cell. The busbar layer has a first layer portion and a second layer portion. The second layer portion is spaced apart from the first layer portion. The first layer portion is disposed opposite the negative electrodes of the first cylindrical battery cell and the second cylindrical battery cell, and is in electrical contact with the negative electrodes of the first cylindrical battery cell and the second cylindrical battery cell. The second layer portion is disposed opposite the positive electrodes of the first cylindrical battery cell and the second cylindrical battery cell, and is in electrical contact with the positive electrodes of the first cylindrical battery cell and the second cylindrical battery cell, so that the first cylindrical battery cell and the second cylindrical battery cell are electrically coupled in parallel to each other.

[0005] A battery module according to another exemplary embodiment is provided. The battery module includes a first cylindrical battery cell having a positive electrode and a negative electrode. The battery module further includes a second cylindrical battery cell having a positive electrode and a negative electrode. The battery module further includes a stacked busbar assembly having a bottom isolation layer, a busbar layer, and an upper isolation layer. The busbar layer is coupled between the bottom isolation layer and the upper isolation layer. The bottom isolation layer contacts the first cylindrical battery cell and the second cylindrical battery cell. The bottom layer has a first opening and a second opening extending therethrough. The first opening is sized and shaped to receive the positive electrode of the first cylindrical battery cell through the first opening and to expose a portion of the negative electrode of the first cylindrical battery cell. The second opening is sized and shaped to receive the positive electrode of the second cylindrical battery cell through the second opening and to expose a portion of the negative electrode of the second cylindrical battery cell. The busbar layer has first, second, and third layer portions spaced apart from one another. The first layer portion is disposed opposite the negative electrode of the first cylindrical battery cell and is in electrical contact with the negative electrode of the first cylindrical battery cell, the second layer portion is disposed opposite the positive electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell and is in electrical contact with the positive electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell, and the third layer portion is disposed opposite the positive electrode of the second cylindrical battery cell and is in electrical contact with the positive electrode of the second cylindrical battery cell, so that the first cylindrical battery cell and the second cylindrical battery cell are electrically coupled to each other in series. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a schematic diagram of a battery module according to an exemplary embodiment of the present invention. [Figure 2] FIG. 2 is an isometric view of the battery module of FIG. 1. [Figure 3] FIG. 2 is an exploded view of the battery module of FIG. [Figure 4] 4 is a cross-sectional view of the battery module of FIG. 3 taken along line 4-4 of FIG. 1. [Figure 5] FIG. 2 is an isometric view of a battery cell retention frame utilized in the battery module of FIG. 1. [Figure 6]FIG. 2 is an isometric view of a first retention housing utilized in the battery module of FIG. 1, the first retention housing holding a plurality of cylindrical battery cells, first and second retaining plates, and a stacked bus bar assembly therein. [Figure 7] FIG. 7 is another isometric view of the first retention housing, the plurality of cylindrical battery cells, and the first and second retaining plates of FIG. 6. [Figure 8] FIG. 7 is a partial exploded view of the first retention housing, the plurality of cylindrical battery cells, the first and second retaining plates, and the stacked bus bar assembly of FIG. 6. [Figure 9] FIG. 7 is a plan view of the first retention housing and stacked bus bar assembly of FIG. 6. [Figure 10] FIG. 7 is a bottom view of the first retention housing, the plurality of cylindrical battery cells, and the first and second retaining plates of FIG. 6. [Figure 11] FIG. 7 is an isometric view of the first retention housing of FIG. 6. [Figure 12] FIG. 12 is a plan view of the first retention housing of FIG. 11. [Figure 13] FIG. 7 is an isometric view of the plurality of cylindrical battery cells of FIG. 6. [Figure 14] FIG. 14 is a plan view of the plurality of cylindrical battery cells of FIG. 13. [Figure 15] FIG. 14 is an isometric view of one of the battery cells within the plurality of cylindrical battery cells of FIG. 13. [Figure 16] FIG. 8 is an isometric view of the first and second retaining plates of FIG. 7. [Figure 17] FIG. 7 is a plan view of the first retention housing of FIG. 6 having a plurality of cylindrical battery cells therein. [Figure 18] FIG. 7 is an isometric view of the laminated busbar assembly of FIG. [Figure 19] FIG. 19 is another isometric view of the laminated busbar assembly of FIG. [Figure 20] FIG. 19 is a plan view of the laminated busbar assembly of FIG. [Figure 21]FIG. 19 is an exploded view of the laminated busbar assembly of FIG. [Figure 22] FIG. 19 is a plan view of a bottom isolation layer utilized in the laminated busbar assembly of FIG. 18. [Figure 23] FIG. 19 is an isometric view of a busbar layer utilized in the laminated busbar assembly of FIG. [Figure 24] FIG. 24 is a plan view of the busbar layer of FIG. 23. [Figure 25] FIG. 19 is a plan view of an upper separation layer utilized in the laminated bus bar assembly of FIG. 18. [Figure 26] FIG. 19 is a plan view of a sensor layer utilized in the laminated busbar assembly of FIG. [Figure 27] 23 is an enlarged portion of the bottom separation layer of FIG. 22. [Figure 28] 26 is an enlarged portion of the upper separation layer of FIG. 25. [Figure 29] 25 is an enlarged portion of the busbar layer of FIG. 24. [Figure 30] 1. FIG. 2 is an isometric view of a second retention housing utilized in the battery module of FIG. 1, the second retention housing holding a plurality of cylindrical battery cells, first and second retaining plates, and a stacked bus bar assembly therein. [Figure 31] FIG. 31 is another isometric view of the second retention housing, the plurality of cylindrical battery cells, and the first and second retaining plates of FIG. 30. [Figure 32] FIG. 32 is an isometric view of a plurality of cylindrical battery cells of FIG. 31. DETAILED DESCRIPTION OF THE INVENTION

[0007] 1-15, a battery module 32 according to an exemplary embodiment is provided. With reference to FIGS. 3 and 4, the battery module 32 includes a battery cell retention frame 50, a first retention housing 54, a plurality of cylindrical battery cells 56, retaining plates 60, 62 (illustrated in FIG. 8), a stacked bus bar assembly 68, a second retention housing 154, a plurality of cylindrical battery cells 156, retaining plates 160, 162 (illustrated in FIG. 31), a stacked bus bar assembly 168, a first outer plate 190, bolts 191, 192, 193, 194, 195, 196, 197, 198, 199, a second outer plate 220, bolts 221, 222, 223, 224, 225, 226, 227, 228, 229, a circuit board 240, an electrical bus bar 242, and a cover plate 246.

[0008] [Battery cell retention frame]

[0009] 4 and 5 , the battery cell retention frame 50 is installed to hold and cool the plurality of cylindrical battery cells 56 and the plurality of cylindrical battery cells 156 thereon. The battery cell retention frame 50 includes a central cooling section 280, a first outer plate 281, and a second outer plate 282. The frame 50 supports and protects the battery cells 56 and 156 with the first and second outer plates 281 and 282, and holds and cools the plurality of cylindrical battery cells 56 and 156 on opposite sides of the central cooling section 280. In particular, the central cooling section 280 contains a cooling fluid that cools the plurality of cylindrical battery cells 56 and the plurality of cylindrical battery cells 156 thereon. In an exemplary embodiment, the first outer plate 281 and the second outer plate 282 are constructed of a metal, such as aluminum. In the exemplary embodiment, the central cooling section 280 includes an aluminum housing with first and second thermally conductive upper portions constructed of a thermally conductive material that is not electrically conductive and that contacts the battery cells 56, 156.

[0010] [region]

[0011] The first and second outer plates 281, 282 and the central cooling portion 280 form a first region 291 for accommodating a plurality of cylindrical battery cells 56 therein. The first and second outer plates 281, 282 and the central cooling portion 280 also form a second region 292 for accommodating a plurality of cylindrical battery cells 156 therein.

[0012] [First retention housing]

[0013] 4, 11, 12, and 17, the first retention housing 54 holds a plurality of cylindrical battery cells 56 therein above and facing a central cooling section 280 (shown in FIG. 5), such that the battery cells 56 are in thermal communication with the central cooling section 280. The first retention housing 54 also holds a stacked bus bar assembly 68 (shown in FIG. 6) thereon. The first retention housing 54 is disposed within a first region 291 (shown in FIG. 5) formed by the central cooling section 280 and first and second outer plates 281, 282. Referring to FIG. 12, the first retention housing 54 has an end wall 350, a first side wall 351, a second side wall 352, a third side wall 353, and a fourth side wall 354. The first and second side walls 351, 352 extend substantially parallel to one another. Additionally, the third and fourth side walls 353, 354 extend substantially parallel to one another and perpendicular to the first and second side walls 351, 352. In the exemplary embodiment, the end wall 350 and the first, second, third and fourth side walls 351, 352, 353, 354 are constructed from plastic.

[0014] 7 and 12, end wall 350 couples to first, second, third, and fourth side walls 351, 352, 353, 354 to form an interior region 460 (shown in FIG. 7) and an open end 462. Referring to FIG. 12, end wall 350 includes a plurality of openings 470 extending therethrough. Each opening of the plurality of openings 470 is associated with a cylindrical battery cell of the plurality of cylindrical battery cells 56. The plurality of openings 470 includes a first row of openings 471, a second row of openings 472, a third row of openings 473, a fourth row of openings 474, a fifth row of openings 475, a sixth row of openings 476, and a seventh row of openings 477. Additionally, each row of openings in the end wall 350 aligns with a respective row of cylindrical battery cells in the plurality of cylindrical battery cells 56, such that each opening in the end wall 350 aligns and thereby receives the upper ends of the cylindrical battery cells.

[0015] The first side wall 351 is connected to the end wall 350 and the third and fourth side walls 353, 354 and extends in a first direction perpendicular to the end wall 350. The second side wall 352 is connected to the end wall 350 and the third and fourth side walls 353, 354 and extends in the first direction perpendicular to the end wall 350. The third side wall 353 is connected to the end wall 350 and the first and second side walls 351, 352 and extends in the first direction perpendicular to the end wall 350. The fourth side wall 354 is connected to the end wall 350 and the first and second side walls 351, 352 and extends in the first direction perpendicular to the end wall 350.

[0016] [First plurality of cylindrical battery cells]

[0017] 4, 7, 13, and 14, a plurality of cylindrical battery cells 56 are held in a first retention housing 54 facing the battery cell retention frame 50. Referring to FIG. 4, the plurality of cylindrical battery cells 56 includes a first row of battery cells 501, a second row of battery cells 502, a third row of battery cells 503, a fourth row of battery cells 504, a fifth row of battery cells 505, a sixth row of battery cells 506, and a seventh row of battery cells 507.

[0018] For simplicity, only two cylindrical battery cells in each row of cylindrical battery cells in the plurality of cylindrical battery cells 56 will be described in more detail below. In particular, the first row of cylindrical battery cells 501 includes cylindrical battery cells 530 and 532. The second row of cylindrical battery cells 502 includes cylindrical battery cells 550 and 552. The third row of cylindrical battery cells 503 includes cylindrical battery cells 570 and 572. The fourth row of cylindrical battery cells 504 includes cylindrical battery cells 590 and 592. The fifth row of cylindrical battery cells 505 includes cylindrical battery cells 610 and 612. The sixth row of cylindrical battery cells 506 includes cylindrical battery cells 630 and 632. The seventh row of cylindrical battery cells 507 includes cylindrical battery cells 650 and 652.

[0019] 15 , each cylindrical battery cell in the plurality of cylindrical battery cells 56 has the same structure, so for simplicity, only the structure of the cylindrical battery cell 530 will be described in more detail. The cylindrical battery cell 530 includes an outer surface 682, a bottom surface 684, a positive electrode 686, and a negative electrode 688. The positive electrode 686 is surrounded by the negative electrode 688. The bottom surface 684 also contacts the central cooling section 280 (shown in FIG. 5 ) of the battery cell retention frame 50 so that thermal energy from the cylindrical battery cell 530 is transferred to the central cooling section 280.

[0020] [First and second retaining plates]

[0021] 7, 12, and 16, the first and second retaining plates 60, 62 couple to the first, second, third, and fourth side walls 351, 352, 353, 354 (shown in FIG. 12) of the first retention housing 54 to retain the first plurality of cylindrical battery cells 56 within an interior region 460 (shown in FIG. 7) of the first retention housing 54. In the exemplary embodiment, the first and second retaining plates 60, 62 are constructed of plastic.

[0022] 16, the retaining plate 60 includes a plurality of openings 730 extending therethrough. The plurality of openings 730 includes a first row of openings 731, a second row of openings 732, a third row of openings 733, a fourth row of openings 734, a fifth row of openings 735, a sixth row of openings 736, and a seventh row of openings 737. Each opening in the first plurality of openings 730 is sized to retain a cylindrical battery cell within the interior region 460 (shown in FIG. 7) of the first retention housing 54 and to allow the bottom surface of each cylindrical battery cell to contact the central cooling section 280 (shown in FIG. 4).

[0023] The retaining plate 62 includes a plurality of openings 760 extending therethrough. The plurality of openings 760 includes a first row of openings 761, a second row of openings 762, a third row of openings 763, a fourth row of openings 764, a fifth row of openings 765, a sixth row of openings 766, and a seventh row of openings 767 that align with the first row of openings 731, the second row of openings 732, the third row of openings 733, the fourth row of openings 734, the fifth row of openings 735, the sixth row of openings 736, and the seventh row of openings 737, respectively. Each opening of the plurality of openings 760 is sized to hold a cylindrical battery cell within the interior region 460 of the first retention housing 54 and to allow the bottom surface of each cylindrical battery cell to contact the central cooling section 280 (shown in FIG. 4 ).

[0024] 14 and 16 , the first row of openings 731 in retaining plate 60 and the first row of openings 761 in retaining plate 62 are aligned with the first row of battery cells 501. The second row of openings 732 in retaining plate 60 and the second row of openings 762 in retaining plate 62 are aligned with the second row of battery cells 502. The third row of openings 733 in retaining plate 60 and the third row of openings 763 in retaining plate 62 are aligned with the third row of battery cells 503. The fourth row of openings 734 in retaining plate 60 and the fourth row of openings 764 in retaining plate 62 are aligned with the fourth row of battery cells 504. The fifth row of openings 735 in retaining plate 60 and the fifth row of openings 765 in retaining plate 62 are aligned with the fifth row of battery cells 505. Additionally, the sixth row of openings 736 in retaining plate 60 and the sixth row of openings 766 in retaining plate 62 are aligned with the sixth row of battery cells 506. Additionally, the seventh row of openings 737 in retaining plate 60 and the seventh row of openings 767 in retaining plate 62 are aligned with the seventh row of battery cells 507.

[0025] [Laminated busbar assembly]

[0026] 6, 14, and 18-26, stacked bus bar assembly 68 is positioned to electrically couple first plurality of cylindrical battery cells 56 in a desired electrical configuration. Referring to FIG. 12, stacked bus bar assembly 68 includes bottom isolation layer 800, bus bar layer 802, top isolation layer 804, sensor layer 806, bus bar 811, and bus bar 812. In an exemplary embodiment, bottom isolation layer 800, bus bar layer 802, top isolation layer 804, and sensor layer 806 are bonded together utilizing adhesive disposed on their edges.

[0027] The busbar layer 802 is bonded between the bottom isolation layer 800 and the top isolation layer 804. In particular, the busbar layer 802 contacts the bottom isolation layer 800 and the top isolation layer 804. The top isolation layer 804 is also bonded between the busbar layer 802 and the sensor layer 806. In particular, the top isolation layer 804 contacts the busbar layer 802 and the sensor layer 806.

[0028] [Bottom separation layer]

[0029] 4, 14, 21, and 22, a bottom isolation layer 800 is disposed opposite and in contact with the first plurality of cylindrical battery cells 56. In an exemplary embodiment, the bottom isolation layer 800 is composed of an electrically insulating material. With reference to FIG. 22, the bottom isolation layer 800 includes a plurality of openings 840 extending therethrough. In particular, the plurality of openings 840 includes a first row of openings 841, a second row of openings 842, a third row of openings 843, a fourth row of openings 844, a fifth row of openings 845, a sixth row of openings 846, and a seventh row of openings 847.

[0030] For simplicity, only two apertures in each row of apertures of the plurality of apertures 840 will be discussed below. In particular, the first row of apertures 841 includes apertures 930 and 932. The second row of apertures 842 includes apertures 950 and 952. The third row of apertures 843 includes apertures 970 and 972. The fourth row of apertures 844 includes apertures 990 and 992. The fifth row of apertures 845 includes apertures 1010 and 1012. The sixth row of apertures 846 includes apertures 1030 and 1032. The seventh row of apertures 847 includes apertures 1050 and 1052.

[0031] 27 , because the shape of each opening in the plurality of openings 840 is the same, only the shape of opening 930 will be discussed in more detail below. In particular, opening 930 has a circular opening 1060 and a skirt-shaped opening 1062 that communicates with the circular opening 1060. As will be discussed in more detail below, the circular opening 1060 communicates with the positive electrode of the cylindrical battery cell 530, and the skirt-shaped portion communicates with a portion of the negative electrode of the cylindrical battery cell 530 that is exposed through the skirt-shaped opening 1062.

[0032] 14, 15 and 22, for simplicity, a brief description will be given of how some of the cylindrical battery cells 56 in each row of cylindrical battery cells contact and communicate with the lower separation layer 800.

[0033] The opening 930 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 530 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 530 .

[0034] The opening 932 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 532 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 532 .

[0035] The opening 950 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 550 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 550 .

[0036] The opening 952 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 552 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 552 .

[0037] The opening 970 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 570 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 570 .

[0038] The opening 972 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 572 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 572 .

[0039] The opening 990 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 590 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 590 .

[0040] The opening 992 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 592 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 592 .

[0041] The opening 1010 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 610 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 610 .

[0042] The opening 1012 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 612 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 612 .

[0043] The opening 1030 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 630 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 630 .

[0044] The opening 1032 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 632 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 632 .

[0045] The opening 1050 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 650 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 650 .

[0046] The opening 1052 in the bottom separator layer 800 is sized and shaped to receive the positive terminal of the cylindrical battery cell 652 therethrough and to expose a portion of the negative terminal of the cylindrical battery cell 652 .

[0047] [Busbar layer]

[0048] 21 , 23 and 24 , the busbar layer 802 is disposed opposite and in contact with the bottom layer 800. The busbar layer 802 includes a first layer portion 1081, a second layer portion 1082, a third layer portion 1083, a fourth layer portion 1084, a fifth layer portion 1085, a sixth layer portion 1086, a seventh layer portion 1087, an eighth layer portion 1088, an outer wall 1091, and an outer wall 1092. The first, second, third, fourth, fifth, sixth, seventh and eighth layer portions 1081, 1082, 1083, 1084, 1085, 1086, 1087, 1088 extend spaced apart from one another and substantially parallel to one another. 21 , an outer wall 1091 is connected to the first layer 1081 and extends perpendicular thereto. An outer wall 1092 is connected to the eighth layer 1088 and extends perpendicular thereto. The outer walls 1091 and 1092 are made of an electrically conductive metal.

[0049] 24, first layer 1081 has a plurality of arcuate slots 1111 extending from a first edge of first layer 1081 into first layer 1081. Each arcuate slot of the plurality of arcuate slots 1011 is spaced apart from one another. The plurality of arcuate slots 1011 includes arcuate slots 1130 and 1132.

[0050] The second layer 1082 includes a plurality of tabs 1222 and a plurality of arcuate slots 1242 disposed on opposing edges of the second layer 1082. The tabs 1222 are spaced apart from one another. The tabs 1222 in the second layer 1082 include tabs 1230, 1232 that align with and extend toward the arcuate slots 1130, 1132 in the first layer 1081. The arcuate slots 1242 are spaced apart from one another. The arcuate slots 1242 include arcuate slots 1250, 1252.

[0051] The third layer 1083 includes a plurality of tabs 1343 and a plurality of arcuate slots 1363 disposed on opposing edges of the third layer 1083. The tabs of the plurality of tabs 1343 are spaced apart from one another. The plurality of tabs 1343 in the third layer 1083 include tabs 1350, 1352 that align with and extend toward the arcuate slots 1250, 1252 in the second layer 1082. Additionally, the arcuate slots of the plurality of arcuate slots 1363 are spaced apart from one another. The plurality of arcuate slots 1363 include arcuate slots 1370, 1372.

[0052] Fourth layer 1084 includes a plurality of tabs 1464 and a plurality of arcuate slots 1484 disposed on opposing edges of fourth layer 1084. Each of the plurality of tabs 1464 is spaced apart from one another. Each of the plurality of tabs 1464 in fourth layer 1084 includes tabs 1470, 1472 that align with and extend toward arcuate slots 1370, 1372 in third layer 1083. Each of the plurality of arcuate slots 1484 is spaced apart from one another. Each of the plurality of arcuate slots 1484 includes arcuate slots 1490, 1492.

[0053] Fifth layer 1085 includes a plurality of tabs 1585 and a plurality of arcuate slots 1605 disposed on opposing edges of fifth layer 1085. Each of the plurality of tabs 1585 is spaced apart from one another. Each of the plurality of tabs 1585 in fifth layer 1085 includes tabs 1590, 1592 that align with and extend toward arcuate slots 1490, 1492 in fourth layer 1084. Each of the plurality of arcuate slots 1605 is spaced apart from one another. Each of the plurality of arcuate slots 1605 includes arcuate slots 1610, 1612.

[0054] Sixth layer 1086 includes a plurality of tabs 1706 and a plurality of arcuate slots 1726 disposed on opposing edges of sixth layer 1086. Each of the plurality of tabs 1706 is spaced apart from one another. Each of the plurality of tabs 1706 in sixth layer 1086 includes tabs 1710, 1712 that align with and extend toward arcuate slots 1610, 1612 in fifth layer 1085. Each of the plurality of arcuate slots 1726 is spaced apart from one another. Each of the plurality of arcuate slots 1726 includes arcuate slots 1730, 1732.

[0055] Seventh layer 1087 includes a plurality of tabs 1827 and a plurality of arcuate slots 1847 disposed on opposing edges of seventh layer 1087. Each of the plurality of tabs 1827 is spaced apart from one another. Each of the plurality of tabs 1827 in seventh layer 1087 includes tabs 1830, 1832 that align with and extend toward arcuate slots 1730, 1732 in sixth layer 1086. Each of the plurality of arcuate slots 1847 is spaced apart from one another. Each of the plurality of arcuate slots 1847 includes arcuate slots 1850, 1852.

[0056] Eighth layer 1088 includes a plurality of tabs 1948. Each tab in the plurality of tabs 1948 is spaced apart from one another. Each of the plurality of tabs 1948 in eighth layer 1088 includes tabs 1950, 1952 that align with and extend toward arcuate slots 1850, 1852 in seventh layer 1087, respectively.

[0057] 14, 24, and 29, for simplicity, a brief description will be given of how some of the plurality of cylindrical battery cells 56 in each row of cylindrical battery cells contact and communicate with the bus bar layer 802.

[0058] The first layer portion 1081 is disposed opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the first row of battery cells 501. In particular, the negative terminals of the cylindrical battery cells 530 contact the first layer portion 1081 in region 1133 of FIG. 29 adjacent to the arcuate slot 1130. In an exemplary embodiment, region 1133 of the first layer portion 1081 can be recessed toward the negative terminal of the cylindrical battery cell 530 using a welding tool (not shown) to weld / bond region 1133 to the negative terminal of the cylindrical battery cell 530. Similarly, the negative terminal of the cylindrical battery cell 532 contacts and is welded to the first layer portion 1081 adjacent to the arcuate slot 1032.

[0059] The second layer portion 1082 is disposed opposite to and in electrical contact with the positive electrodes of the cylindrical battery cells in the first row of battery cells 501. In particular, the positive electrode of cylindrical battery cell 530 contacts tab 1230. In addition, the positive electrode of cylindrical battery cell 532 contacts tab 1232, so that the cylindrical battery cells 530 and 532 are electrically coupled in parallel with each other.

[0060] Additionally, the second layer portion 1082 is positioned opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the second row of battery cells 502. In particular, the negative terminal of cylindrical battery cell 550 contacts the second layer portion 1082 adjacent to the arcuate slot 1250. Additionally, the negative terminal of cylindrical battery cell 552 contacts the second layer portion 1082 adjacent to the arcuate slot 1252.

[0061] The third layer portion 1083 is disposed opposite and in electrical contact with the positive electrodes of the cylindrical battery cells in the second row of battery cells 502. In particular, the positive electrode of cylindrical battery cell 550 contacts tab 1350. Also, the positive electrode of cylindrical battery cell 552 contacts tab 1352, such that cylindrical battery cells 550, 552 are electrically coupled in parallel with each other and in series with the parallel combination of cylindrical battery cells 530, 532.

[0062] Additionally, the third layer portion 1083 is positioned opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the third row of battery cells 503. In particular, the negative terminal of cylindrical battery cell 570 contacts the third layer portion 1083 adjacent to the arcuate slot 1370. Additionally, the negative terminal of cylindrical battery cell 572 contacts the third layer portion 1083 adjacent to the arcuate slot 1372.

[0063] The fourth layer portion 1084 is disposed opposite and in electrical contact with the positive electrodes of the cylindrical battery cells in the third row of battery cells 503. In particular, the positive electrode of cylindrical battery cell 570 contacts tab 1470. Also, the positive electrode of cylindrical battery cell 572 contacts tab 1472, such that cylindrical battery cells 570, 572 are electrically coupled in parallel with each other and in series with the parallel combination of cylindrical battery cells 550, 552.

[0064] Additionally, the fourth layer portion 1084 is positioned opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the second row of battery cells 504. In particular, the negative terminal of cylindrical battery cell 590 contacts the fourth layer portion 1084 adjacent to the arcuate slot 1490. Additionally, the negative terminal of cylindrical battery cell 592 contacts the fourth layer portion 1084 adjacent to the arcuate slot 1492.

[0065] The fifth layer portion 1085 is positioned opposite and in electrical contact with the positive terminals of the cylindrical battery cells in the fourth row of battery cells 504. In particular, the positive terminal of cylindrical battery cell 590 contacts tab 1590. Also, the positive terminal of cylindrical battery cell 592 contacts tab 1592, such that cylindrical battery cells 590, 592 are electrically coupled in parallel with each other and in series with the parallel combination of cylindrical battery cells 570, 572.

[0066] Additionally, the fifth layer portion 1085 is positioned opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the fifth row of battery cells 505. In particular, the negative terminal of the cylindrical battery cell 610 contacts the fifth layer portion 1085 adjacent to the arcuate slot 1610. Additionally, the negative terminal of the cylindrical battery cell 612 contacts the fifth layer portion 1085 adjacent to the arcuate slot 1612.

[0067] The sixth layer portion 1086 is disposed opposite and in electrical contact with the positive terminals of the cylindrical battery cells in the fifth row of battery cells 505. In particular, the positive terminal of cylindrical battery cell 610 contacts tab 1710. Also, the positive terminal of cylindrical battery cell 612 contacts tab 1712, such that the cylindrical battery cells 610, 612 are electrically coupled in parallel with each other and in series with the parallel combination of cylindrical battery cells 590, 592.

[0068] Additionally, the sixth layer portion 1086 is positioned opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the sixth row of battery cells 506. In particular, the negative terminal of the cylindrical battery cell 610 contacts the sixth layer portion 1086 adjacent to the arcuate slot 1730. Additionally, the negative terminal of the cylindrical battery cell 612 contacts the sixth layer portion 1086 adjacent to the arcuate slot 1732.

[0069] The seventh layer portion 1087 is disposed opposite and in electrical contact with the positive terminals of the cylindrical battery cells in the sixth row of battery cells 506. In particular, the positive terminal of cylindrical battery cell 630 contacts tab 1830. Also, the positive terminal of cylindrical battery cell 632 contacts tab 1832, such that the cylindrical battery cells 630, 632 are electrically coupled in parallel with each other and in series with the parallel combination of cylindrical battery cells 610, 612.

[0070] Additionally, the seventh layer portion 1087 is positioned opposite and in electrical contact with the negative terminals of the cylindrical battery cells in the seventh row of battery cells 507. In particular, the negative terminal of cylindrical battery cell 650 contacts the seventh layer portion 1087 adjacent to the arcuate slot 1850. Additionally, the negative terminal of cylindrical battery cell 652 contacts the seventh layer portion 1087 adjacent to the arcuate slot 1852.

[0071] The eighth layer portion 1088 is disposed opposite and in electrical contact with the positive terminals of the cylindrical battery cells in the seventh row of battery cells 507. In particular, the positive terminal of cylindrical battery cell 650 contacts tab 1950. Also, the positive terminal of cylindrical battery cell 652 contacts tab 1952, electrically coupling cylindrical battery cells 650, 652 in parallel with each other and in series with the parallel combination of cylindrical battery cells 630, 632.

[0072] 21 and 24, first and second bus bars 811, 812 are coupled to outer walls 1091, 1092, respectively, of bus bar layer 802.

[0073] [Top separation layer]

[0074] 21 and 25 , upper isolation layer 804 is disposed opposite and in contact with bus bar layer 802. In the exemplary embodiment, upper isolation layer 804 is composed of an electrically insulating material. Upper isolation layer 804 includes a plurality of apertures 2840 extending therethrough. In particular, plurality of apertures 2840 includes a first row of apertures 2841, a second row of apertures 2842, a third row of apertures 2843, a fourth row of apertures 2844, a fifth row of apertures 2845, a sixth row of apertures 2846, and a seventh row of apertures 2847.

[0075] For simplicity, only two apertures in each row of apertures of the plurality of apertures 2840 will be discussed below. In particular, the first row of apertures 2841 includes apertures 2930 and 2932. The second row of apertures 2842 includes apertures 2950 and 2952. The third row of apertures 2843 includes apertures 2970 and 2972. The fourth row of apertures 2844 includes apertures 2990 and 2992. The fifth row of apertures 2845 includes apertures 3010 and 3012. The sixth row of apertures 2846 includes apertures 3030 and 3032. The seventh row of apertures 2847 includes apertures 3050 and 3052.

[0076] 25 and 28, because the shape of each opening in the plurality of openings 2840 is the same, only the shape of opening 2930 will be discussed in more detail below. In particular, opening 2930 has a circular opening 3060 and a skirt-shaped opening 3062 in communication with circular opening 3060.

[0077] 14, 24, and 25, to aid in understanding, a simplified description is provided of how the openings in the upper separation layer 804 align and expose the tabs in the busbar layer 802 that contact the positive electrodes of the plurality of cylindrical battery cells 56, and also align and expose the portions of the busbar layer 802 that contact the negative electrodes of the plurality of cylindrical battery cells 56.

[0078] The openings 2930 are sized and shaped to expose the tabs 1230 of the busbar layer 802 that contact the positive terminals of the cylindrical battery cells 530 and to expose the portions of the busbar layer 802 that contact the negative terminals of the cylindrical battery cells 530. In particular, the circular openings 3060 (shown in FIG. 28) expose the tabs 1230 of the busbar layer 802 that contact the positive terminals of the cylindrical battery cells 530, and the skirt-shaped openings 3062 (shown in FIG. 28) expose the portions of the busbar layer 802 that contact the negative terminals of the cylindrical battery cells 530.

[0079] The opening 2932 is sized and shaped to expose the tab 1232 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 532 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 532.

[0080] The opening 2950 is sized and shaped to expose the tab 1350 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 550 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 550.

[0081] The opening 2952 is sized and shaped to expose the tab 1352 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 552 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 552.

[0082] The opening 2970 is sized and shaped to expose the tab 1470 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 570 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 570.

[0083] The opening 2972 ​​is sized and shaped to expose the tab 1472 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 572 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 572.

[0084] The opening 2990 is sized and shaped to expose the tab 1590 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 590 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 590.

[0085] The opening 2992 is sized and shaped to expose the tab 1592 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 592 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 592.

[0086] The opening 3010 is sized and shaped to expose the tab 1710 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 610 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 610.

[0087] The opening 3012 is sized and shaped to expose the tab 1712 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 612 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 612.

[0088] The opening 3030 is sized and shaped to expose the tab 1830 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 630 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 630.

[0089] The opening 3032 is sized and shaped to expose the tab 1832 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 632 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 632.

[0090] The opening 3050 is sized and shaped to expose the tab 1950 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 650 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 650.

[0091] The opening 3052 is sized and shaped to expose the tab 1952 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 652 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 652.

[0092] [Sensor layer]

[0093] 21 and 26, the sensor layer 806 is disposed opposite and in contact with the upper isolation layer 804. In an exemplary embodiment, the sensor layer 806 includes an electrically insulating substrate 3800, an electrical connector 3802, and an electrical trace 3804. The electrical connector 3802 is coupled to the electrically insulating substrate 3800. The electrical trace 3804 is electrically coupled to and between the electrical connector 3802 and the positive terminal of at least one cylindrical battery cell of the plurality of cylindrical battery cells 56.

[0094] The sensor layer 806 includes a plurality of apertures 3840 that extend through the substrate 3800. In particular, the plurality of apertures 3840 includes a first row of apertures 3841, a second row of apertures 3842, a third row of apertures 3843, a fourth row of apertures 3844, a fifth row of apertures 3845, a sixth row of apertures 3846, and a seventh row of apertures 3847.

[0095] For simplicity, only two apertures in each row of apertures of the plurality of apertures 3840 will be discussed below. In particular, first row of apertures 3841 includes apertures 3930 and 3932. Second row of apertures 3842 includes apertures 3950 and 3952. Third row of apertures 3843 includes apertures 3970 and 3972. Fourth row of apertures 3844 includes apertures 3990 and 3992. Fifth row of apertures 3845 includes apertures 4010 and 4012. Sixth row of apertures 3846 includes apertures 4030 and 4032. Seventh row of apertures 3847 includes apertures 4050 and 4052.

[0096] 14, 24, and 26, to aid in understanding, a brief description will be given of how the openings in the sensor layer 806 align and expose the tabs in the busbar layer 802 that contact the positive electrodes of the plurality of cylindrical battery cells 56, and also align and expose the portions of the busbar layer 802 that contact the negative electrodes of the plurality of cylindrical battery cells 56.

[0097] The opening 3930 is sized and shaped to expose the tab 1230 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 530 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 530.

[0098] The opening 3932 is sized and shaped to expose the tab 1232 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 532 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 532.

[0099] The opening 3950 is sized and shaped to expose the tab 1350 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 550 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 550.

[0100] The opening 3952 is sized and shaped to expose the tab 1352 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 552 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 552.

[0101] The opening 3970 is sized and shaped to expose the tab 1470 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 570 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 570.

[0102] The opening 3972 is sized and shaped to expose the tab 1472 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 572 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 572.

[0103] The opening 3990 is sized and shaped to expose the tab 1490 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 590 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 590.

[0104] The opening 3992 is sized and shaped to expose the tab 1492 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 592 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 592.

[0105] The opening 4010 is sized and shaped to expose the tab 1710 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 610 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 610.

[0106] The opening 4012 is sized and shaped to expose the tab 1712 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 612 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 612.

[0107] The opening 4030 is sized and shaped to expose the tab 1830 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 630 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 630.

[0108] The opening 4032 is sized and shaped to expose the tab 1832 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 632 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 632.

[0109] The opening 4050 is sized and shaped to expose the tab 1950 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 650 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 650.

[0110] The opening 4052 is sized and shaped to expose the tab 1952 of the busbar layer 802 that contacts the positive terminal of the cylindrical battery cell 652 and to expose a portion of the busbar layer 802 that contacts the negative terminal of the cylindrical battery cell 652.

[0111] In the stacked busbar assembly 68, the tabs of the busbar layers 802 are exposed so that, for example, a welding tool (not shown) visible from above the assembly 68 can contact and weld the tabs to the positive electrodes of the cylindrical battery cells. It should also be noted that the portions of the busbar layers 802 that contact the negative electrodes of the cylindrical battery cells are exposed so that each portion of the busbar layers 802 is welded to the negative electrodes of the cylindrical battery cells.

[0112] [Second retention housing]

[0113] 4, 30, and 31, the second retention housing 154 holds a plurality of cylindrical battery cells 156 therein above and facing the central cooling section 280 (shown in FIG. 4), so that the battery cells 156 are in thermal communication with the central cooling section 280. The second retention housing 154 also holds a stacked bus bar assembly 168 thereon. The second retention housing 154 also supports retaining plates 160 and 162 thereon. The second retention housing 154 is disposed within a second region 292 (shown in FIG. 4) formed by the central cooling section 280 and first and second outer plates 281 and 282. The structure of the second retention housing 154 is the same as that of the first retention housing 54. The structures of the retaining plates 160 and 162 are the same as those of the retaining plates 60 and 62, respectively. Furthermore, the structure of the plurality of cylindrical battery cells 156 is the same as the structure of the plurality of cylindrical battery cells 56. Furthermore, the structure of the stacked bus bar assembly 168 is the same as the structure of the stacked bus bar assembly 68.

[0114] [First outer plate]

[0115] 2-4, the first outer plate 190 couples to the first retention housing 54 and the battery cell retention frame 50 utilizing bolts 191, 192, 193, 194, 195, 196, 197, 198, and 199. In the exemplary embodiment, the first outer plate 190 is constructed of plastic.

[0116] [Second outer plate]

[0117] The second outer plate 220 couples to the second retention housing 154 and the battery cell retention frame 50 utilizing bolts 221, 222, 223, 224, 225, 226, 227, 228, 229. In the exemplary embodiment, the second outer plate 220 is constructed of plastic.

[0118] [Circuit board]

[0119] 3 and 26 , the circuit board 240 includes a battery management controller 5000 that electrically couples to the electrical connectors 3802 of the sensor layer 806 in the stacked bus bar assembly 68 to monitor the operation of the plurality of cylindrical battery cells 56. The battery management controller 5000 also electrically couples to the electrical connectors of the sensor layer in the stacked bus bar assembly 168 to monitor the operation of the plurality of cylindrical battery cells 156. The circuit board 240 is coupled to the ends of the first retention housing 54 and the second retention housing 154.

[0120] [Electric bus bar]

[0121] An electrical bus bar 242 is provided to electrically couple together the stacked bus bar assemblies 68, 168. In particular, the electrical bus bar 242 is electrically coupled to the stacked bus bar assembly 68 (which is electrically coupled to the plurality of cylindrical battery cells 56) and the stacked bus bar assembly 168 (which is electrically coupled to the plurality of cylindrical battery cells 156).

[0122] [Cover plate]

[0123] A cover plate 246 is attached to the first and second outer plates 190, 220 to cover the circuit board 240. In the exemplary embodiment, the cover plate 246 is constructed of plastic.

[0124] Battery module 32 offers substantial advantages over other battery modules. In particular, battery module 32 utilizes stacked busbar assemblies 68, which have a relatively low height profile and have the technical effect of electrically connecting cylindrical battery cells in a desired electrical configuration.

[0125] While the claimed invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the claimed invention may be modified to include any number of variations, modifications, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the claimed invention have been described, it should be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the claimed invention should not be deemed limited by the foregoing description.

Claims

1. In the battery module, a first cylindrical battery cell having a positive electrode and a negative electrode; a second cylindrical battery cell having a positive electrode and a negative electrode; a laminated busbar assembly having a bottom isolation layer, a busbar layer, and a top isolation layer, the busbar layer being bonded to the bottom isolation layer and the top isolation layer between the bottom isolation layer and the top isolation layer; the bottom isolation layer is in contact with the first cylindrical battery cell and the second cylindrical battery cell, the bottom isolation layer having a first opening and a second opening therethrough, the first opening of the bottom isolation layer being sized and shaped to receive the positive electrode of the first cylindrical battery cell through the first opening and to expose a portion of the negative electrode of the first cylindrical battery cell, and the second opening of the bottom isolation layer being sized and shaped to receive the positive electrode of the second cylindrical battery cell through the second opening and to expose a portion of the negative electrode of the second cylindrical battery cell; the busbar layer has a first layer portion and a second layer portion, the second layer portion is spaced apart from the first layer portion, the first layer portion is disposed facing the negative electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell and is in electrical contact with the negative electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell, the second layer portion is disposed facing the positive electrode of the first cylindrical battery cell and the positive electrode of the second cylindrical battery cell and is in electrical contact with the positive electrode of the first cylindrical battery cell and the positive electrode of the second cylindrical battery cell, and the first cylindrical battery cell and the second cylindrical battery cell are electrically coupled to each other in parallel, the first layer has first and second arcuate slots extending into the first layer from a first edge thereof, the first and second arcuate slots being spaced apart from one another; the second layer has first and second tabs disposed on a second edge of the first layer opposite the first edge and extending toward the first and second arcuate slots, respectively, and third and fourth arcuate slots extending into the second layer from a third edge opposite the second edge, the third and fourth arcuate slots being spaced apart from one another; the first and second tabs and the third and fourth arcuate slots are staggered such that neither the third nor the fourth arcuate slot is located opposite each of the first and second tabs.

2. The battery module of claim 1 , wherein the first and second tabs contact the positive electrodes of the first and second cylindrical battery cells, respectively.

3. 3. The battery module according to claim 1, wherein the negative electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell are in contact with the first layer portion adjacent to the first and second arcuate slots, respectively.

4. the busbar layer has a first outer wall and a second outer wall extending perpendicular to the first layer portion and the second layer portion, the first layer portion and the second layer portion being disposed between the first outer wall and the second outer wall; The battery module according to claim 1 or 2, wherein a first bus bar is coupled to the first outer wall of the bus bar layer, and a second bus bar is coupled to the second outer wall of the bus bar layer.

5. 3. The battery module of claim 1, wherein the first opening in the bottom separation layer has a circular opening and a skirt-shaped opening communicating with the circular opening, the circular opening communicating with the positive electrode of the first cylindrical battery cell, and the skirt-shaped opening communicating with a portion of the negative electrode of the first cylindrical battery cell.

6. the upper isolation layer has a first opening extending therethrough; 3. The battery module according to claim 1, wherein the first opening in the upper separation layer is sized and shaped to expose a tab of the bus bar layer that contacts the positive electrode of the first cylindrical battery cell and to expose a portion of the bus bar layer that contacts the negative electrode of the first cylindrical battery cell.

7. 7. The battery module of claim 6, wherein the first opening in the upper separation layer has a circular opening and a skirt-shaped opening communicating with the circular opening, the circular opening exposing the tab of the busbar layer that contacts the positive electrode of the first cylindrical battery cell, and the skirt-shaped opening exposing a portion of the busbar layer that contacts the negative electrode of the first cylindrical battery cell.

8. 8. The battery module of claim 7, further comprising a sensor layer coupled to the upper separation layer, the sensor layer having electrical traces electrically coupled to the positive electrodes of the first cylindrical battery cells.

9. In the battery module, a first cylindrical battery cell having a positive electrode and a negative electrode; a second cylindrical battery cell having a positive electrode and a negative electrode; a laminated busbar assembly having a bottom isolation layer, a busbar layer, and a top isolation layer, the busbar layer being bonded to the bottom isolation layer and the top isolation layer between the bottom isolation layer and the top isolation layer; the bottom isolation layer is in contact with the first cylindrical battery cell and the second cylindrical battery cell, the bottom isolation layer having a first opening and a second opening extending therethrough, the first opening being sized and shaped to receive the positive electrode of the first cylindrical battery cell through the first opening and to expose a portion of the negative electrode of the first cylindrical battery cell, and the second opening being sized and shaped to receive the positive electrode of the second cylindrical battery cell through the second opening and to expose a portion of the negative electrode of the second cylindrical battery cell; the busbar layer has a first layer portion, a second layer portion, and a third layer portion that are spaced apart from one another, the first layer portion being disposed opposite the negative electrode of the first cylindrical battery cell and in electrical contact with the negative electrode of the first cylindrical battery cell, the second layer portion being disposed opposite the positive electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell and in electrical contact with the positive electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell, and the third layer portion being disposed opposite the positive electrode of the second cylindrical battery cell and in electrical contact with the positive electrode of the second cylindrical battery cell, such that the first cylindrical battery cell and the second cylindrical battery cell are electrically coupled to each other in series, the first layer has an arcuate slot extending from an edge thereof into the first layer; the second layer has a plurality of tabs and a plurality of arcuate slots, each of the plurality of tabs of the second layer extending toward the arcuate slot of the first layer, each of the plurality of arcuate slots of the second layer extending from an edge thereof into the second layer, the plurality of tabs of the second layer being spaced apart from one another, and the plurality of arcuate slots of the second layer being spaced apart from one another; the third layer has a tab extending toward the arcuate slot in the second layer; a battery module, wherein the plurality of tabs and the plurality of arcuate slots of the second layer portion are staggered such that none of the plurality of arcuate slots of the second layer portion is located opposite each of the plurality of tabs of the second layer portion.

10. the negative electrode of the first cylindrical battery cell contacts the first layer portion adjacent the arcuate slot of the first layer portion; the tab of the second layer portion contacts the positive electrode of the first cylindrical battery cell; the negative electrode of the second cylindrical battery cell contacts the second layer portion adjacent the arcuate slot of the second layer portion; The battery module according to claim 9 , wherein the tab of the third layer portion contacts the positive electrode of the second cylindrical battery cell.

11. the busbar layer has a first outer wall and a second outer wall extending perpendicular to the first layer portion and the second layer portion, the first layer portion and the second layer portion being disposed between the first outer wall and the second outer wall; The battery module according to claim 9 or 10, wherein a first bus bar is coupled to the first outer wall of the bus bar layer, and a second bus bar is coupled to the second outer wall of the bus bar layer.

12. 11. The battery module of claim 9 or 10, wherein the first opening in the bottom separation layer has a circular opening and a skirt-shaped opening communicating with the circular opening, the circular opening communicating with the positive electrode of the first cylindrical battery cell, and the skirt-shaped opening communicating with a portion of the negative electrode of the first cylindrical battery cell.

13. the upper isolation layer has a first opening extending therethrough; 11. The battery module according to claim 9, wherein the first opening in the upper separation layer is sized and shaped to expose a tab of the busbar layer that contacts the positive electrode of the first cylindrical battery cell and to expose a portion of the busbar layer that contacts the negative electrode of the first cylindrical battery cell.

14. 14. The battery module of claim 13, wherein the first opening in the upper separation layer has a circular opening and a skirt-shaped opening communicating with the circular opening, the circular opening exposing the tab of the busbar layer that contacts the positive electrode of the first cylindrical battery cell, and the skirt-shaped opening exposing a portion of the busbar layer that contacts the negative electrode of the first cylindrical battery cell.

15. 14. The battery module of claim 13, further comprising a sensor layer coupled to the upper separation layer, the sensor layer having electrical traces electrically coupled to the positive electrodes of the first cylindrical battery cells.

16. In the battery module, a first cylindrical battery cell having a positive electrode and a negative electrode; a second cylindrical battery cell having a positive electrode and a negative electrode; a laminated busbar assembly having a bottom isolation layer, a busbar layer, and a top isolation layer, the busbar layer being bonded to the bottom isolation layer and the top isolation layer between the bottom isolation layer and the top isolation layer; the bottom isolation layer is in contact with the first cylindrical battery cell and the second cylindrical battery cell, the bottom isolation layer having a first opening and a second opening therethrough, the first opening of the bottom isolation layer being sized and shaped to receive the positive electrode of the first cylindrical battery cell through the first opening and to expose a portion of the negative electrode of the first cylindrical battery cell, and the second opening of the bottom isolation layer being sized and shaped to receive the positive electrode of the second cylindrical battery cell through the second opening and to expose a portion of the negative electrode of the second cylindrical battery cell; the busbar layer has a first layer portion and a second layer portion, the second layer portion is spaced apart from the first layer portion, the first layer portion is disposed facing the negative electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell and is in electrical contact with the negative electrode of the first cylindrical battery cell and the negative electrode of the second cylindrical battery cell, the second layer portion is disposed facing the positive electrode of the first cylindrical battery cell and the positive electrode of the second cylindrical battery cell and is in electrical contact with the positive electrode of the first cylindrical battery cell and the positive electrode of the second cylindrical battery cell, and the first cylindrical battery cell and the second cylindrical battery cell are electrically coupled to each other in parallel, The second layer portion is a first longitudinal edge having a plurality of tabs; and a second longitudinal edge having a plurality of arcuate slots; The second longitudinal edge is a first edge portion having the plurality of arcuate slots formed therein; and a second edge portion free of the plurality of arcuate slots; the battery module, wherein each of the plurality of tabs defines a central axis, the central axis of each of the plurality of tabs extending through the second edge portion of the second longitudinal edge.

Images