Battery architecture including common components and subassemblies, and method for assembling the same.

Abstract

The system and method for the battery may include cells connected in parallel to form a group and a group of cells connected in series to form a first and second subassembly having components suitable for a plurality of battery configurations. The first subassembly includes a lower cell carrier and an upper cell carrier between which the first group of cells is disposed. The second subassembly includes a lower cell carrier and an upper cell carrier between which the second group of cells is disposed. The flexible current collector includes two or more conductive areas. The first and second subassemblies are connected in parallel or in series to build a desired voltage or capacity of the battery. The flexible current collector is folded around the first and second subassemblies and disposed within a casing to provide environmental protection for the battery, and positive and negative terminals connected to the first and second conductive areas, respectively, form the positive and negative terminals of the battery.

Description

[Technical Field]

[0001] Cross-Reference to Related Applications The present application claims priority from U.S. Patent Application No. 17 / 319,170 filed on May 13, 2021, the entire content of which is incorporated herein by reference.

[0002] Embodiments of the present disclosure generally relate to improved battery architectures including modular components and subassemblies, and methods of manufacturing the same. [Background Art]

[0003] The use of lithium-ion batteries from original equipment manufacturers ("OEM") for industrial applications is increasing. Conventionally, lead-acid batteries have dominated commercial applications for batteries. Industrial applications and uses of OEM batteries include powering material handling equipment such as forklifts, scissor lifts and robots, powering transportation vehicles (i.e., light electric vehicles such as golf carts, and heavy vehicles including automobiles), and diesel generator sets for stationary power applications. Conventional batteries for use in industrial applications envision a number of different form factors and chemistries including, but not limited to, lead-acid, nickel metal hydride ("NiMH"), and lithium-ion (LFP, NMC, etc.). Today, various form factors are commercially available, making it difficult to replace currently used batteries.

[0004] This architecture and broad array of chemicals allows for a wide range of battery sizes and shapes, and multiple batteries are connected in series to achieve higher effective voltages. This involves multiple battery assemblies, connectors, and connections, increasing the bill of materials. Conventional approaches modularize batteries in small units, requiring multiple external connectors and connections. This increases the space occupied by the battery and reduces durability. This creates applications where multiple components are connected by external connections, increasing the size, volume, and weight of the battery assembly, and requiring regular maintenance. Furthermore, many components and connections can be exposed to environmental hazards and degradation, severely limiting marine use and reducing the lifecycle of connections and batteries. Conventional batteries are typically configured to match voltage classes of 12V, 24V, 36V, 48V, 72V, or other voltage specifications. This range of battery configurations requires a variety of batteries with varying energy levels that cannot be met by common conventional designs.

[0005] The GC2 form factor is a common battery form factor. The GC2 form factor has many different battery voltages, typically 6V, 8V, and 12V, which are connected in series to build both system voltages (typically 12V, 24V, 36V, 48V, 72V, or higher) and increase system energy storage. Lithium-ion technology is a relatively new battery technology with many advantages over lead-acid, including increased energy density, faster charging, and reduced degradation during long-term storage.

[0006] It is advantageous to leverage the benefits of the new technology by "dropping in" lithium-ion batteries for lead-acid batteries without having to reconfigure features of other existing applications already developed around space, wiring, battery restraint, and the GC2 form factor. However, building voltage using multiple lithium-ion batteries (as done with lead-acid) becomes expensive due to the addition of multiple batteries connected in series. Such series connections are unnecessary due to the relatively high energy density of lithium-ion batteries and the increased complexity of series connections of lithium-ion batteries.

[0007] An improved battery is needed that is robust, has high energy density and high capacity utilization, lowers total cost of ownership, reduces the overall bill of materials, and is fully integrated within a single module. Providing a battery that fits into a commercially acceptable form factor while having higher energy density increases the energy available to the load in applications with one or more form factors, while maintaining the ability to easily replace conventional batteries. Furthermore, a fully integrated battery is more robust, offers a longer cycle life, requires little to no maintenance due to interconnect failures between modules, has fewer components, and all contribute to a lower total cost of ownership. Additionally, an improved battery is needed that can adapt to various capacity requirements while maintaining the balance of the rest of the bill of materials when properly configured by changing only a limited number of components.

[0008] Improvements beyond current lithium-ion batteries are also needed by integrating monitoring, measurement, and control functions onto a single circuit board, without requiring separate housings wired separately within the current collector. Furthermore, as energy density increases, so do the safety requirements of the system, thus creating a need for battery systems that offer high energy density with improved resistance to abuse.

[0009] Furthermore, improvements to conventional battery assembly methods are needed to produce batteries that offer increased energy density in commercially acceptable form factors, simpler designs, integrated structures, reduced bills of materials, improved structural integrity, enhanced durability of components (resilience to water ingress, spray, dust, etc.), increased reliability, and greater flexibility in manufacturing and use.

[0010] Known methods for assembling batteries typically involve a substantial bill of materials and multiple assembly and mounting steps. The use of multiple fasteners, connectors, fillers, and structural components results in multiple components susceptible to fatigue, loosening, damage, or failure even from vibrations during normal use. Improved methods for assembling batteries eliminate the need for and use of multiple fasteners within the module.

[0011] The improved assembly methods disclosed herein also offer the use of an integrated battery management system ("BMS"). The BMS may be mounted within the battery module case, further reducing the number of components and attachments and minimizing the form factor compared to conventional methods. Several known methods typically use a separate BMS enclosure that requires mounting to the battery or application housing, as well as separate electrical and communication wiring between the battery and the BMS. These improvements help to increase the battery's durability against water or dust ingress. See, for example, ISO standards IP65 and / or IP67. The improved methods also provide flexibility to adapt to voltage or power requirements while utilizing the same components within the same form factor.

[0012] The disclosed embodiments may include non-conventional battery subassemblies, improved components, and battery assembly methods. Compared to conventional known solutions, embodiments of the disclosed embodiments may provide improved batteries that conform to commercially acceptable form factors and have specific advantages, including higher energy density, improved resistance to abuse, robustness to environmental shocks and intrusions, reduced cost of ownership, and complete integration within a single assembly. Other embodiments may include methods for assembling batteries that produce conformable form factors, simpler designs, better integration structures, reduced bill of materials, integrated battery management systems, products compliant with ISO standards IP65 and / or IP67, improved reliability, and improved flexibility in manufacturing and use. [Overview of the project]

[0013] Embodiments of the present invention include improved energy density and flexibility. This flexibility can be provided in two ways. First, multiple batteries can be stacked (electrically connected in parallel) to construct a capacity that meets the energy requirements of an application. Second, embodiments of the present disclosure have a high degree of component commonality, i.e., by using some or all the same components in the same form factor (e.g., GC2), various batteries with different voltages and / or capacities can be produced. Embodiments of the present invention can achieve this degree of flexibility by changing only a few, or preferably one, components. Furthermore, this flexibility allows the energy of the battery to be changed without changing the components by increasing or decreasing the number of cells contained in the battery. This architecture provides great flexibility to manufacturers or users.

[0014] In embodiments of the present disclosure, cells can be connected to form subassemblies to meet desired capacity and / or voltage requirements, and these subassemblies can be electrically connected in a desired configuration. In embodiments of the present disclosure, flexibility may mean having a common bill of materials with modifications to the number of cells, current collector design, and / or BMS.

[0015] This disclosure enables the cost-effective manufacture of lithium-ion batteries with any desired form factor at various system-level voltages and capacities. This is achieved by sharing most internal components between different battery voltages, folding / wrapping current collectors to reduce fasteners and manufacturing costs, allowing cells to be packed more densely without fasteners and / or other additional structural components, and by adding foam to assist in the mechanical fixation of the cells.

[0016] In this disclosure, cells can be connected in parallel to construct a capacity by the voltage of the individual cells, or connected in series to construct a voltage by the capacity of the individual cells. Cells can be connected electrically in series to form a group, and a group of cells can be connected electrically in parallel to form a subassembly. Alternatively, in a preferred embodiment, cells can be connected electrically in parallel to form a group, and a group of cells can be connected electrically in series to form a subassembly. In a preferred embodiment, two subassemblies are electrically connected using a configurable flexible current collector to adapt to a preferred form factor of the system. The first subassembly includes a lower cell carrier and an upper cell carrier, with a first group of cells arranged between them. The second subassembly includes a lower cell carrier and an upper cell carrier, with a second group of cells arranged between them. The flexible current collector includes two or more conductive regions. The first and second subassemblies are connected in parallel or in series to construct a desired voltage or capacity of the battery. The flexible current collector can be folded, and the assembly can be placed in a casing to provide environmental protection for the battery. The positive and negative terminals can be connected to the first and second conductive regions, respectively, to form the positive and negative terminals of a battery.

[0017] This disclosure achieves higher energy density through one or more of several features. The lower and upper cell carriers are configured to fix the cells in place and resist displacement, and to position the cells in close proximity to each other. The placement of foam in the gaps between cells enhances safety and robustness against vibration, shock, mechanical displacement, and environmental disturbances. This combination of features allows embodiments of this disclosure to achieve higher energy density. Furthermore, the integration of the positive and negative terminals into the BMS and flexible current collector, as well as the press-fitting of components, reduces the number of required electrical connections, thereby facilitating efficient manufacturing and effective electrical connection.

[0018] A battery containing cells can be electrically connected to form a group, and a group of cells can be electrically connected to form first and second subassemblies. The first subassembly may include a lower tray and an upper tray, with the first group of cells arranged between them, and the first subassembly may have first and second surfaces. The second subassembly may include a lower tray and an upper tray, with a second group of cells arranged between them, and the second subassembly may have first and second surfaces. A flexible current collector may have two or more conductive regions, and the first and second subassemblies may be electrically connected to construct the voltage or capacity of the battery, and the flexible current collector may be electrically connected to the first and second subassemblies and placed in a casing to provide environmental protection to the battery, and the positive and negative terminals may be electrically connected to the first and second conductive regions to form the positive and negative terminals of the battery, respectively, and a battery management system may be electrically connected to the flexible current collector and the positive and negative terminals adapted to control the flow of energy through the battery.

[0019] A method for assembling a battery may include inserting cells into inner and outer trays of first and second carriers to form two subassemblies, positioning current collectors, electrically connecting the cells to the current collectors, and folding the current collectors and subassemblies.

[0020] The attached drawings are incorporated into and constitute part of this specification, illustrating several embodiments, and together with this description, the disclosed embodiments are explained. [Brief explanation of the drawing]

[0021] [Figure 1] This is a schematic diagram of a battery disassembled according to an embodiment of the present disclosure. [Figure 2] Figures A through C are schematic diagrams of a lid according to an embodiment of the present disclosure. [Figure 3]A to C are schematic diagrams of two partially assembled subassemblies according to an embodiment of the present disclosure. [Figure 4] is a schematic diagram of two partially assembled subassemblies with cells arranged in openings according to an embodiment of the present disclosure. [Figure 5A] is a schematic diagram of two subassemblies according to an embodiment of the present disclosure. [Figure 5B] is a schematic diagram of two subassemblies according to an embodiment of the present disclosure. [Figure 6] is a schematic diagram of a partially assembled assembly with a flexible current collector attached thereto according to an embodiment of the present disclosure. [Figure 7] is a schematic diagram of a partially assembled assembly according to an embodiment of the present disclosure. [Figure 8] A and B are schematic cross-sectional views of current collectors according to an alternative embodiment of the present disclosure. [Figure 9] A and B are schematic diagrams of an assembly according to an embodiment of the present disclosure. [Figure 10A] is a cross-sectional view of an assembly according to an embodiment of the present disclosure. [Figure 10B] is a schematic diagram of an assembly according to an embodiment of the present disclosure. [Figure 11] A to E are assembly diagrams of a battery according to an embodiment of the present disclosure. [Figure 12] is a flowchart of a method for assembling a battery according to an embodiment of the present disclosure. [Figure 13] shows a current collector for a 24V battery according to an embodiment of the present disclosure. [Figure 14] shows an example of a current collector for a 48V battery according to an embodiment of the present disclosure. [Figure 15] shows an exploded view of two subassemblies, a flexible current collector, and a heat sink according to an embodiment of the present disclosure. [Figure 16A] shows a 48V battery using a cell carrier according to a preferred embodiment of the present disclosure. [Figure 16B]An alternative 48V battery according to an embodiment of the present disclosure, using the cell carrier shown in Figure 16A, wherein some of the cell positions in the carrier are empty, and which provides lower energy than the embodiment shown in Figure 16A. [Modes for carrying out the invention]

[0022] Embodiments relating to this disclosure may include batteries, their components, and improved assembly methods. The cells are preferably connected in parallel to form groups of cells. The groups of cells are preferably connected in series to form subassemblies. A subassembly may contain half of the cells of a battery. In embodiments of this disclosure, two or more subassemblies can be connected by a flexible current collector to form a battery. A battery may include multiple cells assembled within a housing to protect the cells from external shocks, vibrations, and environmental factors. Battery cells may be cylindrical or prismatic. Depending on the device or product specifications, the battery may provide nominal voltages of 12V, 24V, 36V, 48V, 72V, or any other suitable voltage. Furthermore, or alternatively, the battery may be configured to supply non-standard nominal voltages according to specific device or product specifications. Preferred embodiments are configured in the 24V, 36V, and 48V classes.

[0023] Embodiments of the present invention improve energy density and offer greater manufacturing flexibility compared to conventional known batteries. Embodiments of the present disclosure are characterized by a high degree of component commonality. That is, by using some or all the same components in the same form factor, various batteries with different voltages and / or capacities can be made by changing only a few components, or preferably without changing any components, for example, by increasing or decreasing the number of cells contained in the battery. This improved architecture offers great flexibility to manufacturers or users.

[0024] Figure 1 shows a battery 100 which may include a case 110, a lid 120, an assembly 200 including a first subassembly 201A, a second subassembly 201B, and a current collector 230, and a battery management system (BMS) 300.

[0025] In one example, case 110 can be sized to accommodate assembly 200 and / or to meet standard or predetermined dimensions. Case 110 may contain one or more of the following: electrical insulating material, thermal insulation material, or flame retardant material. In another example, case 110 may be patterned, textured, coated, or ribbed. Case 110 can accommodate lid 120, thereby forming a seal between lid 120 and case 110.

[0026] Figures 2A–2C are schematic diagrams of a lid 120 that can be dimensioned to accept assembly 200. The lid 120 may include one or more of the following materials: electrical insulating material, thermal insulating material, or flame retardant material. In another example, the lid 120 may be patterned, textured, coated, or ribbed. The lid 120 may include a vent 122 (as shown earlier in Figure 1) configured to vent excess gas. The lid 120 may include a lip 121, a vent 122, and / or a vent opening 124. Furthermore, the lid 120 may include a first terminal opening 126, a second terminal opening 128, an indicator 130A, an indicator wire harness 130B, an electrical interface 132A, and / or an electrical interface wire harness 132B.

[0027] The indicator 130A may include a display, LED light, color-changing strip, or speaker to communicate the battery status to the user when the CAN bus of the battery 100 is not in use. For example, the BMS 300 may change the color or brightness of the indicator to indicate the battery status. In one example, when the battery charge is low, the BMS 300 may change the color of the indicator from green to red. In another example, when the battery is charging, the BMS 300 may change the brightness of the indicator to produce a visible "flashing" or "pulsation." In additional alternative embodiments, an acoustic signal may be provided in addition to, or instead of, the visual signal.

[0028] Furthermore, or if the BMS300's CAN bus interface is utilized, the BMS may use one or more processors to transmit and / or receive data in order to communicate with one or more batteries connected to the CAN bus interface. The data may include self-identification information (e.g., model, serial number, error code), information indicating the battery status, and / or information indicating the battery configuration (e.g., series and / or parallel configuration).

[0029] The indicator wire harness 130B can communicate electrically with the BMS 300 and indicator 130A, and can be configured to transmit data and / or electrical signals to each other.

[0030] The electrical interface 132A may be a receptacle that facilitates data communication between the BMS 300 and an external computing device, such as a computer, mobile device, or battery charger, battery charging station, onboard computer of various vehicles, or other battery management system. The electrical interface wire harness 132B can communicate electrically with the BMS 300 and the electrical interface 132A and can be configured to transmit data and / or electrical signals to each other.

[0031] Figures 3A-3C are schematic diagrams of two partially assembled subassemblies. Figure 3A shows that the first inner cell carrier (e.g., the first bottom cell carrier) 202A may include a plurality of openings 204A. The second inner cell carrier (e.g., the second bottom cell carrier) 202B may include a plurality of openings 204B. The first and second inner cell carriers 202A, 202B may include one or more of the following: electrical insulating material, thermal insulation material, or flame retardant material.

[0032] Figure 3B shows a detailed view of the first inner cell carrier 202A. Each of the multiple openings 204A of the first inner cell carrier 202A may include multiple ribs 210A and multiple windows 212A. The multiple ribs 210A can be crushed together when a cell is received to provide an interference fit. Although only the first inner cell carrier 202A is illustrated, a second inner cell carrier 202B can, of course, have similar features.

[0033] Figure 3C shows a detailed view of the retaining feature. The first inner cell carrier 202A may include a first retaining mechanism 206A located on the first inner cell carrier 204 and a second retaining mechanism 208A located on the first inner cell carrier 202A. The first retaining mechanism 206A may be configured to interlock with the second retaining mechanism of the second inner cell carrier 202B. The retaining mechanism may include at least one of clips, hooks, hook-and-loop fasteners, suction cups, adhesive pads, anchors, dowels, pins, retaining rings, snap fasteners, latches, or other fasteners. Although only the first inner cell carrier 202A is illustrated, the second inner cell carrier 202B can, of course, have a similar function. This retaining feature can function to hold the two subassemblies 201A and 201B in a physically parallel configuration.

[0034] Figure 4 shows two partially assembled subassemblies in which cells are positioned within openings. Each cell in the first set of cells 214A can be positioned within the openings of a plurality of openings 204A. Each cell can be held within the openings through an interference fit between the opening and the cell. The interference fit may result from crushing one or more ribs 210A. Each cell in the first group of cells 214A may have a positive terminal and a negative terminal.

[0035] Each cell in the second set of cells 214B can be positioned within the openings of a plurality of openings 204B. Each cell can be held within the openings through an interference fit between the opening and the cell. This interference fit can be created, in the case of the second inner cell carrier 202B, by crushing one or more ribs. Each cell in the second group of cells 214B may be provided with a positive terminal and a negative terminal.

[0036] In embodiments of the present disclosure, including cylindrical cells, the entire outer surface, excluding a small portion electrically insulated from the positive terminal, may include the negative terminal.

[0037] Figure 5A shows two subassemblies comprising first and second outer cell carriers 218A and 218B. The first subassembly 201A may include a first inner cell carrier (e.g., a first bottom cell carrier) 202A, a first group of cells 214A, and a first set of openings for receiving the cells 204A. Furthermore, the first subassembly 201A may include a first outer cell carrier 216A (e.g., a first top cell carrier), which may include a set of openings 224A adapted to receive a first set of cells 214A, a first lift point 218A, and a set of spacers 220A. The first lift point or contact point 218A may be used in a later stage of assembly to position the completed assembly inside or outside the case 110. Furthermore, the first lift point or contact point 218A may be vibration-welded to the lid 120. Furthermore, multiple spacers 220A can be used to position the first subassembly 201A within the case 110, maintaining the distance between the case 110 and the first outer cell carrier 216A. The first outer cell carrier 216A may include one or more of the following: electrical insulating material, thermal insulation material, or flame retardant material. The first subassembly 201A may include a first surface 226A on which the current collector 230 is positioned, and a second surface 228A configured to interlock with the second subassembly 201B.

[0038] The second subassembly 201B may include a second inner cell carrier (e.g., a second bottom cell carrier) 202B, a second group of cells 214B, and a first set of openings for receiving the cells 204B. Furthermore, the second subassembly 201B may include a second outer cell carrier 216B (e.g., a second top cell carrier), the second outer cell carrier 216B may include a set of openings 224B adapted to receive the second set of cells 214B, a second lift point 218B, and a set of spacers 220B. The second lift point or contact point 218B may be used in a later stage of assembly to position the completed assembly inside or outside the case 110. Furthermore, the second lift point or contact point 218B may be vibration-welded to the lid 120. Furthermore, multiple spacers 220B may be used to position the first subassembly 201A within the case 110, maintaining the distance between the case 110 and the second outer cell carrier 216B. The second subassembly 201B may include a first surface 226B on which the current collector 230 is positioned, and a second surface 228B configured to interlock with the first subassembly 201A.

[0039] Figure 5B shows a first outer cell carrier 216A with a notch 222A around the opening 224A in which cell 214A is located. This feature improves flexibility when assembling batteries with various voltages, currents, and energies derived from common components. The notch in the upper cell carrier provides flexibility in the placement of the flexible current collector 230, facilitating different architectures based on common components while only changing the conductor pattern of the flexible current collector. Although only the first outer cell carrier 216A is illustrated, a second outer cell carrier 216B can, of course, have similar features with similar functions.

[0040] Figure 6 shows a partially assembled assembly with a flexible current collector attached. The flexible current collector 230 may be a single plate containing multiple conductive regions. Referring to Figures 9A and 9B, multiple conductive regions 229a to 229g are shown. Returning to Figure 6, each conductive region may further or alternatively include integrated fuses 234A and 234B, thereby eliminating the need for fuses in the wire harness 232 found in conventional batteries.

[0041] For example, the flexible current collector 230 may include a layered flexible current collector 230. The layers within the flexible current collector 230 can conduct electricity and provide voltage sensing, fusible elements, and reference points. For example, one layer may be a copper conductive layer and the other layers may be non-conductive layers. This allows each cell to be connected to the conductive layer in series and / or parallel groups.

[0042] In the example, the flexible current collector 230 may be bendable (e.g., foldable) without breakage or permanent damage. The flexible current collector 230 can reduce the number of joints in the module, which leads to lower resistance and easier manufacturing. The flexible current collector 230 may be bendable about a central point, line or other axis comparable to a hinge. The flexible current collector 230 may have one or more bends, so that the flexible current collector 300 has a substantially "U" shaped contour in the bent configuration.

[0043] In the example, the flexible current collector 230 may comprise punched or printed fusible links. The flexible current collector 230 may include a variety of suitable materials and coatings. The flexible current collector 230 can be mechanically and electrically connected to battery cells to form subgroups of battery cells connected in series and / or parallel. Subgroups of cells can be connected in series and / or parallel to other subgroups of cells by the flexible current collector 230.

[0044] Figure 7 shows details of a partially assembled assembly with a fusible link. In this example, the flexible current collector 230 can be connected to the cell by wire bonding, laser welding, adhesive or other suitable conductive connection.

[0045] The fusible link 236A can conduct current from the cell to the current collector. The fusible link 236A can function as a fuse, disconnecting the connection between individual cells and the current collector at an appropriate current level. This can enhance safety by preventing combustion or thermal events. Specifically, the fusible link can melt and disconnect the cell from the current collector and therefore from the remaining cells. This design can be adjusted to the desired voltage and / or current. The precise parameters of the fusible link 236A can be controlled by changing its shape, thickness, width and / or material composition.

[0046] The fusible link 236A may be integrally formed within the current collector. The structure of the fusible link 236A can be modified to meet various functional, performance, or safety requirements depending on the individual product design and use.

[0047] The fusible link 236A may include wire bonds, laser-welded connections, or ribbon bonds for joining the current collector to the cell as a fuse. Multiple alternative shapes and designs of fusible links can perform the same function. Those skilled in the art will understand that the shape of the fusible link may depend on individual specifications such as cell-to-cell variability, melting characteristics, material, cell type, manufacturing process, and intended application. In certain embodiments, the fusible link may be laser-welded or punched.

[0048] Fusible links can enhance the overall safety of a battery. They can provide a fusible function to the current collector without requiring special processes or additional components that can accommodate substantial variations and potential errors. Fusible links may be connected to the battery cell terminals using resistance welding, laser welding, wire bonding, adhesive, or other conductive connections.

[0049] Figures 8A and 8B show a flexible current collector 230 which may include one or more layers 231a, 231b, and / or 231c. In the example, the flexible current collector 230 may include a first layer 231a, which may include a pressure-sensitive adhesive configured to bond to the first surfaces 226A, 226B of the first and second subassemblies 201A, 201B. The second layer 231b may include a conductor, such as copper or aluminum. The second layer 231b may include aluminum, copper or other conductive metals and may be configured to receive one or more wire bonds or other suitable connections from one or more of the first group 214A or the second group 214B of the cell. The third layer 231c may include a plastic layer, such as PET.

[0050] In embodiments, the flexible current collector is designed to conduct a current of 400A (preferably 450A) over 30 seconds and a continuous current of 120A (preferably 150A). The thickness of the copper conducting these current loads is preferably 0.20–0.25 mm. Holes may be added to the bending angles to assist in bending and buckling of the current collector. Wire bonds are preferably not located near the folds. Figures 13 and 14 show two alternative current collectors. Negative notches in the conductors are preferably positioned to align with the separation between conductors to hold the conductive material.

[0051] In an alternative embodiment, as shown in Figure 8B, the flexible current collector 230 does not need to include the first layer 231a and can be attached to subassemblies 201A and 201B using mechanical fasteners. Furthermore, the flexible current collector 230 provides substantial flexibility and can be adapted to conduct current in several alternative configurations. It is preferable that sufficient current collector cross-section is maintained so as not to impair heat or current transport.

[0052] In alternative embodiments of the present disclosure adapted for high-voltage applications, a fourth layer may be added to include an additional conductive layer, which may be deposited on the third layer 231c. The fourth layer may include aluminum, copper or other conductive metals and may be configured to accept one or more wire bonds or other suitable connections from one or more of the first group 214A or the second group 214B of the cell. The fourth layer may include a plurality of conductive regions, for example, a plurality of conductive regions.

[0053] Figures 9A and 9B show a current collector 230 having multiple conductive regions 229A to 229G and a folded assembly from a first and second angle. Cells numbered 1 to 7 are shown for illustrative purposes and represent subgroups of cells. Each conductive region 229A to 229G can be electrically connected to various battery components via connections 232.

[0054] In certain embodiments, the conductive region 229D may "wrap around" to the opposite side of the assembly 200. The flexible current collector 230 can be configured so that the battery cells are connected in series and / or parallel.

[0055] Figure 10A is a schematic perspective view of a partially exploded embodiment of the present disclosure, showing an air gap between two subassemblies and a flexible current collector in an embodiment of the present disclosure. In certain embodiments of the present disclosure, a cooling plate or heat sink material may be placed between the first inner cell carrier 202A and the second inner cell carrier 202B to transfer heat away from the module. The cooling plate is electrically insulated from the negative terminal of the cell. Embodiments of the present disclosure may include a heat transfer material placed in this air gap between the bottom of the cell and the cooling plate to facilitate heat transfer while maintaining electrical insulation.

[0056] In certain embodiments, a heat sink or cooling plate can be positioned between the folded subassemblies. The cooling plate or heat sink may be actively cooled, for example, a water-cooled or fan-cooled heat sink. Alternatively, the cooling plate or heat sink may be passively cooled, thereby being configured to dissipate heat substantially by natural convection. Or, the battery 100 may utilize the air gap between the first subassembly 201A and the second subassembly 201B, and does not require a cooling plate or heat sink positioned between the two subassemblies connected by the folded flexible current collector 230.

[0057] Figure 10B is a detailed schematic view of the holding feature section from an oblique angle. As described above, the second holding mechanism 208A of the first inner cell carrier 202A can interlock with the first holding mechanism 206B of the second inner cell carrier 202B. This holding feature section can hold the two subassemblies 201A and 201B in a physically parallel configuration.

[0058] Figures 11A to 11E illustrate the assembly of a battery according to a preferred embodiment of the present disclosure. Figure 11A shows the placement of the assembly 200 within the case 110.

[0059] Figure 11B shows the mounting of the BMS 300 to the assembly 200. The BMS 300 may include a heatsink 302, a first integrated terminal 304, and a second integrated terminal 306. The BMS 300 can be electrically connected to the assembly 200. The BMS may include one or more processors, memory with instructions, and when these instructions are executed, the BMS 300 can be caused to perform one or more functions. One or more functions may include managing electrical and / or thermal loads, detecting errors, or sending and receiving data with an external computing device.

[0060] Figure 11C shows the harness 232 of the current collector 230 connected to the BMS receptacle 308. Furthermore, the cover 120 can be placed on top of the BMS 300, physically connected to the case 110. In addition, the BMS 300 may be electrically connected to the wire harness of the cover 120.

[0061] Figure 11D shows the installation of the vent 122 into the vent hole 124. Several quality and / or safety checks can be performed before the installation of the vent 122. For example, electrical checks may be performed to verify the integrity of various electrical connections. The cover 120 can be vibration welded to the case 120. Leak checks may be performed to verify the physical integrity of the battery 100. Foam, liquid, or gel may be injected into the case 110 through the vent hole 124 and placed around the cells to fill the spaces between cells and between cells and the inner surface of the casing. This foam, liquid, or gel can provide insulation and prevent the propagation of thermal events between individual cells. The foam, liquid, or gel can also provide structural support by resisting vibration and assisting in the mechanical retention of the battery cells and components. The foam, liquid, or gel can provide insulation, deflect and guide exhaust gases, and absorb radiant heat.

[0062] Figure 11E shows battery 100.

[0063] Figure 12 illustrates a method for manufacturing battery 100. The basic steps of an exemplary method are shown in Figure 12. Naturally, the steps, including the method, can be modified, combined, omitted, rearranged, or otherwise altered according to the target specifications of the battery.

[0064] In block 402, method 400 may include inserting cells into cell carriers. The inner and outer cell carriers are preferably adapted to receive cells by interference fit, with or without having inserts to facilitate the insertion of cells into the cell carriers. In embodiments, each cell can be electrically isolated from the cooling plate by placing the inserts in recesses of the inner cell carrier, while at the same time positioning the cells sufficiently close to the cooling plate to promote effective heat transfer. Alternatively, in a preferred embodiment, the components may be supplied by the manufacturer with the threaded inserts attached.

[0065] In block 404, method 400 may include mounting a thermistor in close proximity to one or more cells.

[0066] In block 406, method 400 may include connecting the arranged cells to a flexible current collector. Furthermore, or otherwise, the cells may be a first group of cells, and method 400 may further include connecting the arranged second group of cells to the flexible current collector. Furthermore, or otherwise, the cells may be a first group of cells, and the outer cell carrier may be a first outer cell carrier, and method 400 may further include coupling the flexible current collector to a second outer cell carrier. Furthermore, or otherwise, coupling the flexible current collector to a second outer cell carrier may further include folding the flexible current collector such that the first and second inner cell carriers are physically oriented substantially parallel to each other, engaging retaining features to hold the configuration of the first and second inner cell carriers, and wire bonding the first terminal to the first conductive region of the flexible current collector. Furthermore, or otherwise, coupling a flexible current collector to a second outer cell carrier may further include wire bonding a first terminal to a first conductive region of the flexible current collector, folding the flexible current collector so that the first and second inner cell carriers are in close proximity to each other, and engaging retaining features to maintain the configuration of the first and second inner cell carriers.

[0067] In block 408, method 400 may include press forming a subassembly. Method 400 may include arranging cells within an inner cell carrier (e.g., a bottom cell carrier). The cells may be lithium-ion cells. Furthermore, or or otherwise, the cells may include a first group of cells, the inner cell carrier may include a first inner cell carrier, and the method may further include arranging a second group of cells within a second inner cell carrier. In the example, the cells may have a first terminal and a second terminal. The terminals may be terminals of the cell, for example, the first terminal may be the positive terminal of the cell and the second terminal may be the negative terminal of the cell. The arrangement of each cell in the first and / or second inner cell carrier can be done using a robot or other automated mechanism. In the example, the orientation of the cells (e.g., the orientation of the first and / or second terminals) may be oriented away from other cells. In another example, the orientation of the cells may be such that the tabs are close to the housing. Method 400 may include placing an outer cell carrier (e.g., a top cell carrier) on top of the placed cells, the outer cell carrier including a plurality of recesses configured to receive each cell. Furthermore, or alternatively, the cells may be a first group of cells, the outer cell carrier may be a first outer cell carrier, and Method 400 may further include placing a second outer cell carrier on top of a second group of placed cells, the second outer cell carrier including a plurality of recesses configured to receive each of the cells of the second group.

[0068] In block 408, method 400 may include electrically connecting the cell to a current collector.

[0069] In block 412, method 400 may include folding the current collector and subassembly (and heat sink, if used).

[0070] In block 416, method 400 may include installing a battery management system and electrically connecting the battery management system to a current collector.

[0071] In block 418, method 400 may include vibratory welding the lid and the case together. In the example, the lid can be connected to the housing using vibratory welding. Vibratory welding can fuse the lid material and the housing material together, thereby integrating the lid material and the housing. Furthermore, the lid can be vibratory welded to the subassembly at lift points (e.g., first and second lift points 211, 221). The vibratory welding process can fuse the lift points to the lid, integrating the assembly with the lid.

[0072] In block 420, method 400 may include potting one or more terminals with epoxy resin.

[0073] In block 422, method 400 may include injecting a foam into the housing. In an example, a foam, liquid, or gel may be placed around the cells in the casing to fill the spaces between cells and between cells and the inner surface of the casing. This foam, liquid, or gel can provide insulation and prevent the propagation of thermal events between individual cells. The foam, liquid, or gel can also provide structural support by resisting vibration and assisting in the mechanical retention of the battery cells and components. The foam, liquid, or gel can provide insulation, deflect and guide exhaust gases, and absorb radiant heat.

[0074] In block 424, method 400 may include attaching a vent (e.g., vent 105) to the lid. The vent may comprise a pressure-sensitive permeable membrane that can be configured to rupture when a predetermined pressure threshold is exceeded. For example, the pressure-sensitive membrane may be configured to rupture at 25 psi (e.g., 25 psi higher than the ambient air pressure). When the internal air pressure inside the battery exceeds 25 psi, which is higher than the ambient air pressure, the pressure-sensitive membrane ruptures, releasing the internal pressure of the battery and allowing it to reach equilibrium with the environment or ambient air pressure. This permeable membrane can also equalize the pressure between the battery and the environment, for example, during transport by aircraft.

[0075] Figure 13 shows an example of a current collector for a 24V battery according to an embodiment of the present disclosure.

[0076] Figure 14 shows an example of a current collector for a 48V battery according to an embodiment of the present disclosure.

[0077] Figure 15 shows exploded views of two subassemblies, a flexible current collector, and a heat sink according to an embodiment of the present disclosure.

[0078] Figure 16A shows a 48V battery using a cell carrier according to a preferred embodiment of the present disclosure.

[0079] Figure 16B shows an alternative 48V battery using the cell carrier of Figure 16A according to a preferred embodiment of the present disclosure, in which multiple spaces for cells within the carrier are left empty, providing a lower capacity or energy without altering other components of the battery or the battery manufacturing process.

[0080] Example 1: Twenty-four cells were electrically connected in parallel to form groups, and each of the 3.5 groups of 24 cells was electrically connected in series to form a subassembly. Two such subassemblies were prepared and electrically connected by a flexible current collector. The wrap-around portion of the current collector connects the two 3.5 groups in parallel. The two subassemblies were folded toward each other with the current collector facing outwards and, if a heat sink was used, the heat sink positioned between the inner surfaces of the two subassemblies. If a conductive heat sink was used, an electrically insulating, thermally conductive interface material was placed on the exposed surfaces of the cells on the two open faces of the subassembly. The two subassemblies were then brought together, closed, and locked, with the heat sink positioned in place between the two subassemblies.

[0081] Next, this assembly was placed in the lower part of the case, then the BMS was installed and electrically connected to the electrical contacts of the assembly and the lid. Electrical checks were performed to determine the effectiveness and operability of the electrical components. The lid was vibration-welded to the lower case. The terminals were sealed to the lid. Leak checks were performed to verify the integrity of the housing assembly. Next, foam was injected through the open vent holes in the lid, while maintaining the case at a 10.5-degree angle, to facilitate the exhaust of off-gas during curing and to completely fill the spaces between cells. For the GC2 battery in this embodiment, the filling was 987g, which completely covered the cells. Next, the vents were attached to the lid.

[0082] The resulting GC2 battery has a nominal voltage of 25.8V and a nominal capacity of 118Ah.

[0083] Example 2: Ten cells were electrically connected in parallel to form a group, and each of the sixteen groups of ten cells was electrically connected in series to form a subassembly. Two such subassemblies were prepared and electrically connected in series by a flexible current collector. The two subassemblies were folded toward each other with the current collector facing outwards and, if a heat sink was used, the heat sink was placed between the inner surfaces of the two subassemblies. If a conductive heat sink was used, an electrically insulating, thermally conductive interface material was placed on the exposed surfaces of the cells on the two open faces of the subassembly. The two subassemblies were then brought together, closed, and locked, with the heat sink positioned in place between the two subassemblies.

[0084] Next, this assembly was placed in the lower part of the case, then the BMS was installed and electrically connected to the electrical contacts of the assembly and the lid. Electrical checks were performed to determine the effectiveness and operability of the electrical components. The lid was vibration-welded to the lower case. The terminals were sealed to the lid. Leak checks were performed to verify the integrity of the housing assembly. Next, foam was injected through the open vent holes in the lid, while maintaining the case at a 10.5-degree angle, to facilitate the exhaust of off-gas during curing and to completely fill the spaces between cells. For the GC2 battery in this embodiment, the filling was 987g, which completely covered the cells. Next, the vents were attached to the lid.

[0085] The resulting GC2 battery has a nominal voltage of 36.9V and a nominal capacity of 79Ah.

[0086] Example 3 Twelve cells were electrically connected in parallel to form a group, and each of the seven groups of twelve cells was electrically connected in series to form a subassembly. Two such subassemblies were prepared and electrically connected in series by a flexible current collector. The two subassemblies were folded toward each other with the current collector facing outwards and, if a heat sink was used, the heat sink was placed between the inner surfaces of the two subassemblies. If a conductive heat sink was used, an electrically insulating, thermally conductive interface material was placed on the exposed surfaces of the cells on the two open faces of the subassembly. The two subassemblies were then brought together, closed, and locked, with the heat sink positioned in place between the two subassemblies.

[0087] Next, this assembly was placed in the lower part of the case, then the BMS was installed and electrically connected to the electrical contacts of the lid assembly. Electrical checks were performed to determine the effectiveness and operability of the electrical components. The lid was vibration-welded to the lower case. The terminals were sealed to the lid. Leak checks were performed to verify the integrity of the housing assembly. Next, foam was injected through the open vent holes in the lid, while maintaining the case at a 10.5-degree angle, to facilitate the exhaust of off-gas during curing and to completely fill the spaces between cells. For the GC2 battery in this embodiment, the fill was 987g, which completely covered the cells. Next, the vents were attached to the lid.

[0088] The resulting GC2 battery has a nominal voltage of 51.7V and a nominal capacity of 59Ah.

[0089] Example 4: Fourteen cells were electrically connected in parallel to form a group, and each of the eight groups of fourteen cells was electrically connected in series to form a subassembly. Two such subassemblies were prepared and electrically connected in series by a flexible current collector. The two subassemblies were folded toward each other with the current collector facing outwards and, if a heat sink was used, the heat sink was placed between the inner surfaces of the two subassemblies. If a conductive heat sink was used, an electrically insulating, thermally conductive interface material was placed on the exposed surfaces of the cells on the two open faces of the subassembly. The two subassemblies were then brought together, closed, and locked, with the heat sink positioned in place between the two subassemblies.

[0090] Next, this assembly was placed in the lower part of the case, then the BMS was installed and electrically connected to the electrical contacts of the assembly and the lid. Electrical checks were performed to determine the effectiveness and operability of the electrical components. The lid was vibration-welded to the lower case. The terminals were sealed to the lid. Leak checks were performed to verify the integrity of the housing assembly. Next, foam was injected through the open vent holes in the lid, while maintaining the case at a 10.5-degree angle, to facilitate the exhaust of off-gas during curing and to completely fill the spaces between cells. For the GC2 battery in this embodiment, the filling was 987g, which completely covered the cells. Next, the vents were attached to the lid.

[0091] Naturally, battery cells can be inspected before being incorporated into a battery module. Inspection may include human or automated verification that each cell is free from visible defects or structural damage, that each cell is within physical measurement specifications, that each cell meets material composition and chemical specifications, and that each cell as a whole is suitable for incorporation into a battery module. Battery cells can also be prepared for incorporation into a battery subassembly by removing or removing any temporary or excessive housing or packaging.

[0092] The descriptions of the various embodiments of this disclosure are presented for illustrative purposes only and are not intended to be comprehensive or restrictive. Multiple modifications and variations of the embodiments disclosed will be obvious to those skilled in the art without departing from the scope and spirit of the embodiments described. The terminology used herein has been chosen to best describe the principles of the embodiments, their practical application to market-available technologies, or technical improvements, or to enable those else skilled in the art to understand the embodiments disclosed herein.

[0093] Certain features of this disclosure described in the context of separate embodiments for clarity may be combined in a single embodiment. Conversely, various features of the invention described in the context of a single embodiment for brevity may be provided separately, in any suitable subcombination, or as appropriate in any other embodiment described in the disclosure. Certain features described in the context of different embodiments should not be considered essential features of those embodiments unless the embodiment would be inoperable without those elements.

[0094] While this disclosure has been described in conjunction with specific embodiments thereof, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, all such alternatives, modifications, and variations are intended to be included within the spirit and broad scope of the appended claims.

Claims

1. It is a battery, Cells that are electrically connected to form a group, A group of cells electrically connected to form a first subassembly and a second subassembly, The first subassembly includes a lower tray and an upper tray in which a first group of cells are positioned between them, and has first and second faces, The second subassembly includes a lower tray and an upper tray in which a second group of cells are positioned between them, and has first and second faces. A flexible current collector comprising two or more conductive regions, Equipped with, The first and second subassemblies are electrically connected to construct the voltage or capacity of the battery. The flexible current collector electrically connects the first and second subassemblies and is located within the casing to provide environmental protection to the battery, the flexible current collector is electrically connected to the first surface of the first and second subassemblies, and the flexible current collector and the first and second subassemblies are folded such that the second surfaces of the first and second subassemblies are located close to each other. A heat sink disposed between the second surface of the first and second subassemblies, Positive terminal and negative terminal, which are electrically connected to the first and second conductive regions and form the positive terminal and negative terminal of the battery, respectively, A battery management system electrically connected to the flexible current collector and positive and negative terminals adapted to control the flow of energy through the battery, The battery comprising the aforementioned.

2. Including the first battery, The first battery includes generating a second battery using the same components, Capacity is increased by increasing the number of cells in at least one of the first or second subassemblies, or The battery according to claim 1, wherein the capacity is reduced by reducing the number of cells in at least one of the first or second subassemblies.

3. Includes a first battery equipped with a first current collector, The method further includes generating a second battery using the same components and a second current collector, The battery according to claim 1, wherein the second current collector includes different electrically connected conductive regions, and the second battery has a different voltage or a different capacity than the first battery.

4. Includes a first battery equipped with a first current collector, The method further includes generating a second battery using the same components and a second current collector, The battery according to claim 1, wherein the second current collector includes different electrically connected conductive regions, and the second battery has a different voltage and the same energy as the first battery, or a different capacity and the same energy as the first battery.

5. Includes a first battery equipped with a first current collector, The invention further includes generating a second battery having a different voltage using the same components and a second current collector, wherein the second current collector includes different electrically connected conductive regions. Capacity is increased by increasing the number of cells in at least one of the first or second subassemblies, or The battery according to claim 1, wherein the capacity is reduced by reducing the number of cells in at least one of the first or second subassemblies.

6. The flexible current collector further comprises one or more layers, the layers being A conductive layer including a pattern that defines multiple conductive regions, Separation layer and A battery according to any one of claims 1 to 5, including the battery described in any one of claims 1 to 5.

7. The flexible current collector further comprises one or more layers, the layers being A pressure-sensitive adhesive layer, A conductive layer including a pattern that defines multiple conductive regions, Separation layer and A battery according to any one of claims 1 to 5, including the battery described in any one of claims 1 to 5.

8. The battery according to any one of claims 1 to 5, wherein the flexible current collector is electrically connected to the first surfaces of the first and second subassemblies by wire bonding or laser welding.

9. The battery according to any one of claims 1 to 5, wherein the flexible current collector comprises one or more bent portions, and the flexible current collector has a substantially "U" shaped contour.

10. The aforementioned battery A case configured to house one or more subassemblies, A lid, configured to form a seal between the lid and the case, The battery according to any one of claims 1 to 5, further comprising:

11. A method for assembling a battery, Inserting cells into the inner and outer trays of the first and second carriers to form two subassemblies, The placement of the current collector, The aforementioned cell is electrically connected to the current collector, Folding the current collector and the sub-assembly, Placing the subassembly inside the case, Electrically connecting the battery management system to the subassembly, The lid is vibration-welded to the case, Attaching a thermistor to one or more of the aforementioned cells, Bonding one or more terminals with epoxy resin, Injecting foam into the casing, Attaching a vent to the lid, The method, including the method described above.

12. Electrically connecting the cell to the current collector includes wire bonding the first terminal to a first conductive region of the flexible current collector, and / or The current collector and the sub-assembly can be folded. The flexible current collector is folded such that the first bottom cell carrier and the second bottom cell carrier are substantially parallel to each other. The retaining feature portion engages to hold the configuration of the first bottom cell carrier and the second bottom cell carrier, The method according to claim 11, including the method described in claim 11.

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