Battery module having a stacked busbar assembly

Abstract

A battery module comprising first and second cylindrical battery cells is provided. The module comprises a stacked busbar assembly having a bottom separator, a first busbar layer, an intermediate separator, and a second busbar layer. The bottom separator has a first opening that accommodates the positive electrode of the first battery cell and exposes a portion of the negative electrode of the first battery cell. The first busbar layer has a first opening that accommodates the positive electrode of the first battery cell. A portion of the first busbar layer is electrically in contact with the negative electrode of the first battery cell. The intermediate separator has a first opening that accommodates the positive electrode of the first battery cell. The second busbar layer is electrically in contact with the positive electrode of the first battery cell.

Description

Technology Field

[0001] In this specification, the inventors recognized the need for an improved battery module utilizing 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 the need to change the packaging of the battery cells. Background Technology

[0002] Small battery modules are often manufactured using a wire bonding process with aluminum busbars to create multiple series and parallel configurations of cylindrical battery cells. However, to obtain the desired series or parallel electrical configuration, it is often necessary to modify the packaging of the cylindrical battery cells within the module. Additionally, battery modules often have a relatively high height profile. The problem to be solved

[0003] A battery module according to an exemplary embodiment is provided. The battery module comprises a first cylindrical battery cell having a positive electrode and a negative electrode. The battery module further comprises a stacked busbar assembly having a bottom separator, a first busbar layer, an intermediate separator, and a second busbar layer. The busbar layer is bonded to the bottom separator and the intermediate separator and between the layers. The intermediate separator is bonded to the first busbar layer and the second busbar layer and between the layers. The bottom separator has a first opening extending therethrough, and the first opening is sized and shaped to accommodate the positive electrode of the first cylindrical battery cell and expose a portion of the negative electrode of the first cylindrical battery cell through it. The first busbar layer has a first opening extending therethrough, and the first opening is sized and shaped to accommodate the positive electrode of the first cylindrical battery cell through it. A portion of the first busbar layer adjacent to the first opening is positioned opposite to and electrically contacts the negative electrode of the first cylindrical battery cell. The intermediate separator layer has a first opening extending therethrough, and the first opening is sized and shaped to accommodate the positive electrode of the first cylindrical battery cell through it. The second busbar layer is positioned opposite the positive electrode of the first cylindrical battery cell and is electrically in contact with it. Brief explanation of the drawing

[0004] FIG. 1 is a schematic diagram of a battery module according to an exemplary embodiment of the present invention. Figure 2 is an isometric view of the battery module of Figure 1. Figure 3 is an exploded view of the battery module of Figure 1. Figure 4 is a cross-sectional view of the battery module of Figure 3 taken along line 4-4 of Figure 1. Figure 5 is an isometric view of a battery cell retention frame used in the battery module of Figure 1. FIG. 6 is an isometric view of a first retention housing used in a battery module of FIG. 1, having a plurality of cylindrical battery cells, first and second retaining plates, and a stacked busbar assembly inside. FIG. 7 is another equilateral view of the first retention housing, a plurality of cylindrical battery cells, and the first and second retaining plates of FIG. 6. FIG. 8 is a partially exploded view of the first retention housing, a plurality of cylindrical battery cells, first and second retaining plates, and a stacked busbar assembly of FIG. 6. FIG. 9 is another isometric view of the first retention housing and stacked busbar assembly of FIG. 6. FIG. 10 is a bottom view of the first retention housing, a plurality of cylindrical battery cells, and the first and second retaining plates of FIG. 6. FIG. 11 is an isometric view of the first retention housing of FIG. 6. FIG. 12 is a plan view of the first retention housing of FIG. 11. Fig. 13 is an isometric view of a plurality of cylindrical battery cells of Fig. 6. FIG. 14 is a plan view of a plurality of cylindrical battery cells of FIG. 13. FIG. 15 is an isometric view of one of the battery cells within the plurality of cylindrical battery cells of FIG. 13. FIG. 16 is an isometric view of the first and second retaining plates of FIG. 7. FIG. 17 is a plan view of the first retention housing of FIG. 6 having a plurality of cylindrical battery cells inside. Fig. 18 is an isometric view of the stacked busbar assembly of Fig. 6. Fig. 19 is another isometric view of the stacked busbar assembly of Fig. 18. FIG. 20 is a plan view of the stacked busbar assembly of FIG. 18. FIG. 21 is a bottom view of the stacked busbar assembly of FIG. 18. FIG. 22 is an exploded view of the stacked busbar assembly of FIG. 18. FIG. 23 is a plan view of the bottom separator layer used in the stacked busbar assembly of FIG. 18. FIG. 24 is an equiangular view of the first busbar layer used in the stacked busbar assembly of FIG. 18, which is coupled to the negative electrodes of a plurality of cylindrical battery cells. Fig. 25 is another isometric view of the first busbar layer of Fig. 24. FIG. 26 is a plan view of the first busbar layer of FIG. 24. FIG. 27 is a plan view of an intermediate separator used in the stacked busbar assembly of FIG. 18. FIG. 28 is an equiangular view of a second busbar layer used in the stacked busbar assembly of FIG. 18, which is coupled to the negative electrode of a plurality of cylindrical battery cells. FIG. 29 is a plan view of the second busbar layer of FIG. 28. FIG. 30 is a plan view of the upper separator layer used in the stacked busbar assembly of FIG. 18. FIG. 31 is a plan view of a sensor layer used in the stacked busbar assembly of FIG. 18. Fig. 32 is a bottom view of the sensor layer of Fig. 31. Fig. 33 is an enlarged view of a part of the bottom separation layer of Fig. 23. Fig. 34 is an enlarged view of a part of the first busbar layer of Fig. 26. Fig. 35 is an enlarged view of a part of the intermediate separation layer of Fig. 27. Fig. 36 is an enlarged view of a part of the upper separation layer of Fig. 30. Figure 37 is an enlarged view of a part of the sensor layer of Figure 31. FIG. 38 is an isometric view of a second retention housing used in the battery module of FIG. 1, having a plurality of cylindrical battery cells, first and second retaining plates, and a stacked busbar assembly inside. FIG. 39 is another equilateral view of the second retention housing, a plurality of cylindrical battery cells, and the first and second retaining plates of FIG. 38. FIG. 40 is a plan view of a plurality of cylindrical battery cells of FIG. 39. Specific details for implementing the invention

[0005] Referring to FIGS. 1 to 15, a battery module (32) according to an exemplary embodiment is provided. Referring to FIGS. 3 and 4, the battery module (32) comprises a battery cell retention frame (50), a first retention housing (54), a plurality of cylindrical battery cells (56), retaining plates (60, 62) (shown in FIG. 8), a stacked busbar assembly (68), a second retention housing (154), a plurality of cylindrical battery cells (156), retaining plates (160, 162) (shown in FIG. 31), a stacked busbar 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), It includes a circuit board (240), an electric busbar (242), and a cover plate (246).

[0006] Battery cell retention frame

[0007] Referring to FIGS. 4 and 5, a battery cell retention frame (50) is installed to hold and cool a plurality of cylindrical battery cells (56) and a 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) can hold and cool a plurality of cylindrical battery cells (56, 156) on the opposite side of the central cooling section (280) while supporting and protecting the battery cells (56, 156) with the first and second outer plates (141, 142). In particular, the central cooling section (280) contains a cooling fluid that cools the plurality of cylindrical battery cells (56) and a plurality of cylindrical battery cells (156) thereon. In an exemplary embodiment, the first outer plate (281) and the second outer plate (282) are made of a metal, for example, aluminum. In an exemplary embodiment, the central cooling unit (280) includes an aluminum housing having first and second thermal conductive layers disposed on top, the first and second layers being made of a non-electrically conductive thermally conductive material that comes into contact with the battery cell (56, 156).

[0008] area

[0009] The first and second outer plates (141, 142) and the central cooling unit (280) form a first region (291) for housing a plurality of cylindrical battery cells (56) inside. Additionally, the first and second outer plates (141, 142) and the central cooling unit (280) form a second region (292) for housing a plurality of cylindrical battery cells (156) inside.

[0010] 1st Retention Housing

[0011] Referring to FIGS. 4, 11, 12 and 17, the first retention housing (54) holds a plurality of cylindrical battery cells (56) inside, on and opposite the central cooling unit (280) (shown in FIG. 5), so that the battery cells (56) are thermally connected to the central cooling unit (280). Additionally, the first retention housing (54) holds a stacked busbar assembly (68) (shown in FIG. 6) on it. The first retention housing (54) is positioned within a first region (291) (shown in FIG. 5) formed by the central cooling unit (280) and the first and second outer plates (141, 142). 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 each other. Additionally, the third and fourth side walls (353, 354) extend substantially parallel to each other and perpendicular to the first and second side walls (351, 352). In an exemplary embodiment, the end wall (350) and the first, second, third, and fourth side walls (351, 352, 353, 354) are made of plastic.

[0012] Referring to FIG. 7 and FIG. 12, the end wall (350) is coupled to the first, second, third, and fourth side walls (351, 352, 353, 354) to form an inner region (460) (shown in FIG. 7) and an open end (462). Referring to FIG. 12, the end wall (350) includes a plurality of openings (470) extending therethrough. Each of the plurality of openings (470) is associated with a cylindrical battery cell of a plurality of cylindrical battery cells (56). The plurality of openings (470) include 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, the openings in each row within the end wall (350) are aligned with the cylindrical battery cells in each row within the plurality of cylindrical battery cells (56), and accordingly, each opening within the end wall (350) is aligned and thereby accommodates the upper portion of the cylindrical battery cells.

[0013] 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). Additionally, the second side wall (352) 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). Additionally, the third side wall (353) is connected to the end wall (350) and the first and second side walls (351, 352) and extends in a first direction perpendicular to the end wall (350). Additionally, the fourth side wall (354) is connected to the end wall (350) and the first and second side walls (351, 352) and extends in a first direction perpendicular to the end wall (350).

[0014] First plurality of cylindrical battery cells

[0015] Referring to FIGS. 4, FIGS. 7, FIGS. 13 and FIGS. 14, a plurality of cylindrical battery cells (56) are held in a first retention housing (54) facing a battery cell retention frame (50). Referring to FIG. 4, the plurality of cylindrical battery cells (56) includes a first column of battery cells (501), a second column of battery cells (502), a third column of battery cells (503), a fourth column of battery cells (504), a fifth column of battery cells (505), a sixth column of battery cells (506), and a seventh column of battery cells (507).

[0016] For simplification, only the cylindrical battery cells within the first column of battery cells (501) will be described in more detail below. In particular, the first column of cylindrical battery cells (501) includes cylindrical battery cells (530, 532, 550, 552, 570, 572, 590, 592, 610, 612, 630, 632, 650, 652, 670, 672).

[0017] Referring to FIG. 15, since each cylindrical battery cell within a plurality of cylindrical battery cells (56) has the same structure, for simplification, 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). Additionally, the bottom surface (684) 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).

[0018] 1st and 2nd retaining plates

[0019] Referring to FIGS. 7, 12 and 16, the first and second retaining plates (60, 62) are coupled to the first, second, third, and fourth side walls (351, 352, 353, 354) (shown in FIG. 12) of the first retention housing (54) to hold a first plurality of cylindrical battery cells (56) within the inner region (460) (shown in FIG. 7) of the first retention housing (54). In an exemplary embodiment, the first and second retaining plates (60, 62) are made of plastic.

[0020] Referring to FIG. 16, the retaining plate (60) includes a plurality of openings (730) extending therethrough. The plurality of openings (730) include 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 of the first plurality of openings (730) is sized such that the bottom surface of each cylindrical battery cell can come into contact with the central cooling portion (280) (shown in FIG. 4) while holding a cylindrical battery cell within the internal region (460) (shown in FIG. 7) of the first retention housing (54).

[0021] The retaining plate (62) includes a plurality of openings (760) that extend therethrough. The plurality of openings (760) include a first row opening (761), a second row opening (732), a third row opening (733), a fourth row opening (734), a fifth row opening (735), a sixth row opening (736), and a seventh row opening (767), each aligned with a first row opening (761), a second row opening (762), a third row opening (763), a fourth row opening (764), a fifth row opening (765), a sixth row opening (766), and a seventh row opening (767). Each of the multiple openings (760) is sized so that the bottom surface of each cylindrical battery cell can come into contact with the central cooling portion (280) (shown in FIG. 4) while holding a cylindrical battery cell within the inner region (460) of the first retention housing (54).

[0022] Referring to FIGS. 14 and 16, the opening (731) of the first column of the retaining plate (60) and the opening (761) of the first column of the retaining plate (62) are aligned with the battery cells (501) of the first column. Additionally, the opening (732) of the second column of the retaining plate (60) and the opening (762) of the second column of the retaining plate (62) are aligned with the battery cells (502) of the second column. Additionally, the opening (733) of the third column of the retaining plate (60) and the opening (763) of the third column of the retaining plate (62) are aligned with the battery cells (503) of the third column. Additionally, the opening (734) of the fourth column of the retaining plate (60) and the opening (764) of the fourth column of the retaining plate (62) are aligned with the battery cell (504) of the fourth column. Additionally, the opening (735) of the fifth column of the retaining plate (60) and the opening (765) of the fifth column of the retaining plate (62) are aligned with the battery cell (505) of the fifth column. Additionally, the opening (736) of the sixth column of the retaining plate (60) and the opening (766) of the sixth column of the retaining plate (62) are aligned with the battery cell (506) of the sixth column. Additionally, the opening (737) of the seventh column of the retaining plate (60) and the opening (767) of the seventh column of the retaining plate (62) are aligned with the battery cell (507) of the seventh column.

[0023] Stacked busbar assembly

[0024] Referring to FIGS. 6, FIGS. 14 and FIGS. 18 through 36, a stacked busbar assembly (68) is installed to electrically connect a first plurality of cylindrical battery cells (56) in a desired electrical configuration. Referring to FIG. 22, the stacked busbar assembly (68) includes a bottom separator (800), a first busbar layer (802), an intermediate separator (804), a second busbar layer (806), an upper separator (808), a sensor layer (810), a busbar (811), and a busbar (812). In an exemplary embodiment, the bottom separator (800), the first busbar layer (802), the intermediate separator (804), the second busbar layer (806), the upper separator (808), and the sensor layer (810) are joined together using an adhesive placed on their edges.

[0025] The first busbar layer (802) is bonded to the bottom separation layer (800) and the intermediate separation layer (804) and between the layers. In particular, the first busbar layer (802) is in contact with the bottom separation layer (800) and the intermediate separation layer (804). The second busbar layer (806) is bonded to the intermediate separation layer (804) and the upper separation layer (808) and between the layers. In particular, the second busbar layer is in contact with the intermediate separation layer (804) and the upper separation layer (808). Additionally, the upper separation layer (808) is bonded to the second busbar layer (806) and the sensor layer (810) and between the layers. In particular, the upper separation layer (808) is in contact with the second busbar layer (806) and the sensor layer (810).

[0026] Floor separation layer

[0027] Referring to FIGS. 14, 22 and 23, a bottom separator layer (800) is positioned opposite to and in contact with a first plurality of cylindrical battery cells (56). In an exemplary embodiment, the bottom separator layer (800) is composed of an electrical insulating material. Referring to FIG. 23, the bottom separator layer (800) includes a plurality of openings (840) extending therethrough. In particular, the plurality of openings (840) include 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).

[0028] For the sake of simplification, only the openings (841) of the first column will be discussed below. In particular, the openings (841) of the first column include openings (930, 932, 950, 952, 970, 972, 990, 992, 1010, 1012, 1030, 1032, 1050, 1052, 1070, 1072).

[0029] Referring to FIG. 33, since the shape of each opening within the plurality of openings (840) is identical, only the shape of the opening (930) will be discussed in more detail below. In particular, the 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 part communicates with a part of the negative electrode of the cylindrical battery cell (530) exposed through the skirt-shaped opening (1062).

[0030] Referring to FIGS. 14, 15 and 23, for the sake of simplification, a brief description will be given of how a cylindrical battery cell in a first column of battery cells (501) contacts and communicates with a lower separator layer (800).

[0031] The opening (930) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (530) and expose a portion of the negative electrode of the cylindrical battery cell (530).

[0032] The opening (932) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (532) and expose a portion of the negative electrode of the cylindrical battery cell (532).

[0033] The opening (950) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (550) and expose a portion of the negative electrode of the cylindrical battery cell (550).

[0034] The opening (952) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (552) and expose a portion of the negative electrode of the cylindrical battery cell (552).

[0035] The opening (970) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (570) and expose a portion of the negative electrode of the cylindrical battery cell (570).

[0036] The opening (972) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (572) and expose a portion of the negative electrode of the cylindrical battery cell (572).

[0037] The opening (990) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (590) and expose a portion of the negative electrode of the cylindrical battery cell (590).

[0038] The opening (992) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (592) and expose a portion of the negative electrode of the cylindrical battery cell (592).

[0039] The opening (1010) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (610) and expose a portion of the negative electrode of the cylindrical battery cell (610).

[0040] The opening (1012) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (612) and expose a portion of the negative electrode of the cylindrical battery cell (612).

[0041] The opening (1030) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (630) and expose a portion of the negative electrode of the cylindrical battery cell (630).

[0042] The opening (1032) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (632) and expose a portion of the negative electrode of the cylindrical battery cell (632).

[0043] The opening (1050) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (650) and expose a portion of the negative electrode of the cylindrical battery cell (650).

[0044] The opening (1052) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (652) and expose a portion of the negative electrode of the cylindrical battery cell (652).

[0045] The opening (1070) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (670) and expose a portion of the negative electrode of the cylindrical battery cell (670).

[0046] The opening (1072) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (672) and expose a portion of the negative electrode of the cylindrical battery cell (672).

[0047] 1st busbar level

[0048] Referring to FIG. 22 and FIG. 24 through 26, the first busbar layer (802) is positioned opposite to and in contact with the floor separation layer (800). Referring to FIG. 26, the first busbar layer (802) includes a first layer (1081), a second layer (1082), a third layer (1083), a fourth layer (1084), a fifth layer (1085), a sixth layer (1086), a seventh layer (1087), and an eighth layer (1088). The first busbar layer (802) further includes a first outer wall (1091), a second outer wall (1092), a third outer wall (1093), a fourth outer wall (1094), a fifth outer wall (1095), a sixth outer wall (1096), a seventh outer wall (1097), an eighth outer wall (1098), and a bracket portion (1099).

[0049] Referring to FIG. 26, the first, second, third, fourth, fifth, sixth, seventh, and eighth layers (1081, 1082, 1083, 1084, 1085, 1086, 1087, 1088) are spaced apart from each other and extend substantially parallel to each other. Additionally, each of the first, second, third, fourth, fifth, sixth, seventh, and eighth layers (1081, 1082, 1083, 1084, 1085, 1086, 1087, 1088) is composed of an electrically conductive metal.

[0050] The first busbar layer (802) further includes a plurality of openings (1100) extending therethrough. The plurality of openings (1100) include a first row opening (1101), a second row opening (842), a third row opening (843), a fourth row opening (844), a fifth row opening (845), a sixth row opening (846) and a seventh row opening (847) aligned with the first row opening (841), the second row opening (842), the third row opening (843), the fourth row opening (844), the fifth row opening (845), the sixth row opening (846) and the seventh row opening (847) of the floor separation layer (800) (shown in FIG. 23). Each opening in each row of openings within the first busbar layer (802) is spaced apart from one another. For simplification, only the openings in the first row (1101) will be discussed in more detail here. The openings in the first row (1101) include openings (1130, 1132, 1150, 1152, 1170, 1172, 1190, 1192, 1210, 1212, 1230, 1232, 1250, 1252, 1270, 1272).

[0051] 1st floor

[0052] Referring to FIGS. 14 and 26, the first layer (1081) includes an opening (1130, 1132) extending therethrough. The positive electrode of the cylindrical battery cell (530) extends through the opening (1130). Additionally, a portion of the negative electrode of the cylindrical battery cell (530) is exposed through the bottom separator (800) and contacts the first layer (1081) (within the region (1290) of FIG. 34) adjacent to the opening (1130). In an exemplary embodiment, the region (1290) of the first layer (1081) may be recessed toward the negative electrode of the cylindrical battery cell (530) using a welding tool (not shown) to weld / bond the region (1290) to the negative electrode of the cylindrical battery cell (530). The positive electrode of the cylindrical battery cell (532) extends through the opening (1132). Additionally, a portion of the negative electrode of the cylindrical battery cell (532) is exposed through the bottom separator (800) and comes into contact with the first layer (1081) adjacent to the opening (1132). The first outer wall (1091) is attached to the outer edge of the first layer (1081) and extends substantially perpendicularly to the first layer (1081).

[0053] 2nd floor

[0054] The second layer (1082) includes an opening (1150, 1152) that extends through it. The positive electrode of the cylindrical battery cell (550) extends through the opening (1150). Additionally, a portion of the negative electrode of the cylindrical battery cell (550) is exposed through the bottom separator (800) and contacts the second layer (1082) adjacent to the opening (1150). The positive electrode of the cylindrical battery cell (552) extends through the opening (1152). Additionally, a portion of the negative electrode of the cylindrical battery cell (552) is exposed through the bottom separator (800) and contacts the second layer (1082) adjacent to the opening (1152). The second outer wall (1092) is attached to the outer edge of the second layer (1082) and extends substantially perpendicularly to the second layer (1082).

[0055] 3rd floor

[0056] The third layer (1083) includes an opening (1170, 1172) extending therethrough. The positive electrode of the cylindrical battery cell (570) extends through the opening (1170). Additionally, a portion of the negative electrode of the cylindrical battery cell (570) is exposed through the bottom separator (800) and contacts the third layer (1083) adjacent to the opening (1170). The positive electrode of the cylindrical battery cell (572) extends through the opening (1172). Additionally, a portion of the negative electrode of the cylindrical battery cell (572) is exposed through the bottom separator (800) and contacts the third layer (1083) adjacent to the opening (1172). The third outer wall (1093) is attached to the outer edge of the third layer (1083) and extends substantially perpendicularly to the third layer (1083).

[0057] 4th floor

[0058] The fourth layer (1084) includes an opening (1190, 1192) that extends through it. The positive electrode of the cylindrical battery cell (590) extends through the opening (1190). Additionally, a portion of the negative electrode of the cylindrical battery cell (590) is exposed through the bottom separator (800) and contacts the fourth layer (1084) adjacent to the opening (1190). The positive electrode of the cylindrical battery cell (572) extends through the opening (1192). Additionally, a portion of the negative electrode of the cylindrical battery cell (592) is exposed through the bottom separator (800) and contacts the fourth layer (1084) adjacent to the opening (1192). The fourth outer wall (1094) is attached to the outer edge of the fourth layer (1084) and extends substantially perpendicularly to the fourth layer (1084).

[0059] 5th floor

[0060] The fifth layer (1085) includes an opening (1210, 1212) that extends through it. The positive electrode of the cylindrical battery cell (610) extends through the opening (1210). Additionally, a portion of the negative electrode of the cylindrical battery cell (610) is exposed through the bottom separator (800) and contacts the fifth layer (1085) adjacent to the opening (1210). The positive electrode of the cylindrical battery cell (612) extends through the opening (1212). Additionally, a portion of the negative electrode of the cylindrical battery cell (612) is exposed through the bottom separator (800) and contacts the fifth layer (1085) adjacent to the opening (1212). The fifth outer wall (1095) is attached to the outer edge of the fifth layer (1085) and extends substantially perpendicularly to the fifth layer (1085).

[0061] 6th layer

[0062] The sixth layer (1086) includes an opening (1230, 1232) that extends through it. The positive electrode of the cylindrical battery cell (630) extends through the opening (1230). Additionally, a portion of the negative electrode of the cylindrical battery cell (630) is exposed through the bottom separator (800) and contacts the sixth layer (1086) adjacent to the opening (1230). The positive electrode of the cylindrical battery cell (632) extends through the opening (1232). Additionally, a portion of the negative electrode of the cylindrical battery cell (632) is exposed through the bottom separator (800) and contacts the sixth layer (1086) adjacent to the opening (1232). The sixth outer wall (1096) is attached to the outer edge of the sixth layer (1086) and extends substantially perpendicularly to the sixth layer (1086).

[0063] 7th floor

[0064] The seventh layer (1087) includes an opening (1250, 1252) that extends through it. The positive electrode of the cylindrical battery cell (650) extends through the opening (1250). Additionally, a portion of the negative electrode of the cylindrical battery cell (650) is exposed through the bottom separator (800) and contacts the seventh layer (1087) adjacent to the opening (1250). The positive electrode of the cylindrical battery cell (652) extends through the opening (1252). Additionally, a portion of the negative electrode of the cylindrical battery cell (652) is exposed through the bottom separator (800) and contacts the seventh layer (1087) adjacent to the opening (1252). The seventh outer wall (1097) is attached to the outer edge of the seventh layer (1087) and extends substantially perpendicularly to the seventh layer (1087).

[0065] 8th floor

[0066] The eighth layer (1088) includes an opening (1270, 1272) that extends through it. The positive electrode of the cylindrical battery cell (670) extends through the opening (1270). Additionally, a portion of the negative electrode of the cylindrical battery cell (670) is exposed through the bottom separator (800) and contacts the eighth layer (1088) adjacent to the opening (1270). The positive electrode of the cylindrical battery cell (672) extends through the opening (1272). Additionally, a portion of the negative electrode of the cylindrical battery cell (672) is exposed through the bottom separator (800) and contacts the eighth layer (1088) adjacent to the opening (1272). The eighth outer wall (1098) is attached to the outer edge of the eighth layer (1088) and extends substantially perpendicularly to the eighth layer (1088).

[0067] Intermediate separation layer (804)

[0068] Referring to FIGS. 4, FIGS. 14, FIGS. 22 and FIGS. 27, an intermediate separator layer (804) is positioned opposite to and in contact with a busbar layer (802). In an exemplary embodiment, the intermediate separator layer (804) is composed of an electrical insulating material. Referring to FIG. 27, the intermediate separator layer (804) includes a plurality of openings (1340) extending therethrough. In particular, the plurality of openings (1340) include the first row opening (1341), the second row opening (1102), the third row opening (1103), the fourth row opening (1104), the fifth row opening (1105), the sixth row opening (1106) and the seventh row opening (1107) of the first busbar layer (802) (shown in FIG. 26).

[0069] For simplification, only the openings (1341) of the first column will be discussed below. In particular, the openings (1341) of the first column include openings (1430, 1432, 1450, 1452, 1470, 1472, 1490, 1492, 1510, 1512, 1530, 1532, 1550, 1552, 1570, 1572).

[0070] Referring to FIG. 27 and FIG. 35, since the shape of each opening within the plurality of openings (1340) is identical, only the shape of the opening (1430) will be discussed in more detail below. In particular, the opening (1430) has a circular opening (1590) and a skirt-shaped opening (1592) that communicates with the circular opening (1590). As will be discussed in more detail below, the circular opening (1590) communicates with the positive electrode of the cylindrical battery cell (530), and the skirt-shaped portion (1592) communicates with a part of the first busbar layer (802) that is coupled to the negative electrode of the cylindrical battery cell (530) exposed through the skirt-shaped opening (1592).

[0071] Referring to FIGS. 14, 22 and 27, for the sake of simplification, a brief description will be given of how a cylindrical battery cell in the first column of battery cells (501) communicates with an intermediate separator layer (804).

[0072] The opening (1430) in the intermediate separator layer (804) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (530) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (530).

[0073] The opening (1432) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (532) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (532).

[0074] The opening (1450) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (550) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (550).

[0075] The opening (1452) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (552) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (552).

[0076] The opening (1470) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (570) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (570).

[0077] The opening (1472) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (572) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (572).

[0078] The opening (1490) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (590) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (590).

[0079] The opening (1492) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (592) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (592).

[0080] The opening (1510) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (610) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (610).

[0081] The opening (1512) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (612) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (612).

[0082] The opening (1530) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (630) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (630).

[0083] The opening (1532) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (632) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (632).

[0084] The opening (1550) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (650) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (650).

[0085] The opening (1552) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (652) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (652).

[0086] The opening (1570) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (670) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (670).

[0087] The opening (1572) is sized and shaped to accommodate the positive electrode of the cylindrical battery cell (672) and to expose a portion of the first busbar layer (802) that contacts the negative electrode of the cylindrical battery cell (672).

[0088] 2nd busbar level

[0089] Referring to FIGS. 22, 28 and 29, the second busbar layer (806) is positioned opposite to and in contact with the intermediate separation layer (804). The second busbar layer (806) includes a first layer (1681), a second layer (1682), a third layer (1683), a fourth layer (1684), a fifth layer (1685), a sixth layer (1686), a seventh layer (1687) and an eighth layer (1688). The second busbar layer (806) further includes a first outer wall (1691), a second outer wall (1692), a third outer wall (1693), a fourth outer wall (1694), a fifth outer wall (1695), a sixth outer wall (1696), a seventh outer wall (1697), and an eighth outer wall (1698).

[0090] Referring to FIG. 29, the first, second, third, fourth, fifth, sixth, seventh, and eighth layers (1681, 1682, 1683, 1684, 1685, 1686, 1687, 1688) are spaced apart from each other and extend substantially parallel to each other. Additionally, each of the first, second, third, fourth, fifth, sixth, seventh, and eighth layers (1681, 1682, 1683, 1684, 1685, 1686, 1687, 1688) is composed of an electrically conductive metal.

[0091] The second busbar layer (806) further includes a plurality of openings (1700) extending therethrough. The plurality of openings (1700) include a first row opening (1701), a second row opening (1702), a third row opening (1703), a fourth row opening (1704), a fifth row opening (1705), and a sixth row opening (1706) aligned with the first row opening (1341), second row opening (1342), third row opening (1343), fourth row opening (1344), fifth row opening (1345), and sixth row opening (1346) of the intermediate separation layer (804) (shown in FIG. 27). Each opening in each row of openings within the second busbar layer (806) is spaced apart from one another. For the sake of simplification, only the openings (1701) of the first column will be discussed in more detail here. The openings (1701) of the first column include openings (1730, 1732, 1750, 1752, 1770, 1772, 1790, 1792, 1810, 1812, 1830, 1832, 1850, 1852, 1870, 1872).

[0092] 1st floor

[0093] Referring to FIGS. 14 and 29, the first layer (1681) includes an opening (1730, 1732) extending therethrough. The opening (1730) forms a tab (1930) in contact with the positive electrode of the cylindrical battery cell (530). Additionally, the opening (1730) exposes a portion of the first busbar layer (802) adjacent to an opening (1130) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (530). The opening (1732) forms a tab (1932) in contact with the positive electrode of the cylindrical battery cell (532). Additionally, the opening (1732) exposes a portion of the first busbar layer (802) adjacent to an opening (1132) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (532). Cylindrical battery cells (530, 532) are electrically coupled to each other in parallel using the first layer (1681) and the first layer (1081) (shown in FIG. 26).

[0094] 2nd floor

[0095] The second layer (1682) includes an opening (1750, 1752) extending therethrough. The opening (1750) forms a tab (1950) in contact with the positive electrode of the cylindrical battery cell (550). Additionally, the opening (1750) exposes a portion of the first busbar layer (802) adjacent to the opening (1150) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (550). The opening (1752) forms a tab (1952) in contact with the positive electrode of the cylindrical battery cell (552). Additionally, the opening (1752) exposes a portion of the first busbar layer (802) adjacent to the opening (1152) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (552). Cylindrical battery cells (550, 552) are electrically coupled to each other in parallel using a second layer (1682) and a second layer (1082) (shown in FIG. 26).

[0096] 3rd floor

[0097] The third layer (1683) includes openings (1770, 1772) extending therethrough. The opening (1770) forms a tab (1970) in contact with the positive electrode of the cylindrical battery cell (570). Additionally, the opening (1770) exposes a portion of the first busbar layer (802) adjacent to the opening (1170) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (570). The opening (1772) forms a tab (1972) in contact with the positive electrode of the cylindrical battery cell (572). Additionally, the opening (1772) exposes a portion of the first busbar layer (802) adjacent to the opening (1172) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (572). Cylindrical battery cells (570, 572) are electrically coupled in parallel with each other using the third layer (1683) and the third layer (1083) (shown in FIG. 26).

[0098] 4th floor

[0099] The fourth layer (1684) includes an opening (1790, 1792) extending therethrough. The opening (1790) forms a tab (1990) in contact with the positive electrode of the cylindrical battery cell (590). Additionally, the opening (1790) exposes a portion of the first busbar layer (802) adjacent to an opening (1190) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (590). The opening (1792) forms a tab (1992) in contact with the positive electrode of the cylindrical battery cell (592). Additionally, the opening (1792) exposes a portion of the first busbar layer (802) adjacent to an opening (1192) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (592). Cylindrical battery cells (590, 592) are electrically coupled in parallel with each other using the fourth layer (1684) and the fourth layer (1084) (shown in FIG. 26).

[0100] 5th floor

[0101] The fifth layer (1685) includes openings (1810, 1812) extending therethrough. The opening (1810) forms a tab (2010) in contact with the positive electrode of the cylindrical battery cell (610). Additionally, the opening (1810) exposes a portion of the first busbar layer (802) adjacent to an opening (1210) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (610). The opening (1812) forms a tab (2012) in contact with the positive electrode of the cylindrical battery cell (612). Additionally, the opening (1812) exposes a portion of the first busbar layer (802) adjacent to an opening (1212) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (612). Cylindrical battery cells (610, 612) are electrically coupled to each other in parallel using the fifth layer (1685) and the fifth layer (1085) (shown in FIG. 26).

[0102] 6th layer

[0103] The sixth layer (1686) includes an opening (1830, 1832) extending therethrough. The opening (1830) forms a tab (2030) in contact with the positive electrode of the cylindrical battery cell (630). Additionally, the opening (1830) exposes a portion of the first busbar layer (802) adjacent to an opening (1230) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (630). The opening (1832) forms a tab (2032) in contact with the positive electrode of the cylindrical battery cell (632). Additionally, the opening (1832) exposes a portion of the first busbar layer (802) adjacent to an opening (1232) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (632). Cylindrical battery cells (630, 632) are electrically coupled to each other in parallel using the sixth layer (1686) and the sixth layer (1086) (shown in FIG. 26).

[0104] 7th floor

[0105] The seventh layer (1687) includes an opening (1850, 1852) extending therethrough. The opening (1850) forms a tab (2050) in contact with the positive electrode of the cylindrical battery cell (650). Additionally, the opening (1850) exposes a portion of the first busbar layer (802) adjacent to an opening (1250) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (650). The opening (1852) forms a tab (2052) in contact with the positive electrode of the cylindrical battery cell (652). Additionally, the opening (1852) exposes a portion of the first busbar layer (802) adjacent to an opening (1252) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (652). Cylindrical battery cells (650, 652) are electrically coupled in parallel with each other using the seventh layer (1687) and the seventh layer (1087) (shown in FIG. 26).

[0106] 8th floor

[0107] The eighth layer (1688) includes an opening (1870, 1872) extending therethrough. The opening (1870) forms a tab (2070) in contact with the positive electrode of the cylindrical battery cell (670). Additionally, the opening (1870) exposes a portion of the first busbar layer (802) adjacent to an opening (1270) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (670). The opening (1872) forms a tab (2072) in contact with the positive electrode of the cylindrical battery cell (672). Additionally, the opening (1872) exposes a portion of the first busbar layer (802) adjacent to an opening (1272) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (672). Cylindrical battery cells (670, 672) are electrically coupled in parallel with each other using the eighth layer (1688) and the eighth layer (1088) (shown in FIG. 26).

[0108] outer wall

[0109] Referring to FIGS. 28 and 29, the first outer wall (1691), the second outer wall (1692), the third outer wall (1693), the fourth outer wall (1694), the fifth outer wall (1695), the sixth outer wall (1696), the seventh outer wall (1697), and the eighth outer wall (1698) are made of an electrically conductive material.

[0110] The first outer wall (1691) is joined to the first layer (1681) and extends substantially vertically to the first layer (1681).

[0111] The second outer wall (1692) is coupled to the second layer (1682) and extends substantially perpendicularly to the second layer (1682). The second outer wall (1692) is coupled to the outer wall (1091) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (530, 532) in series with a parallel combination of cylindrical battery cells (550, 552).

[0112] The third outer wall (1693) is coupled to the third layer (1683) and extends substantially vertically to the third layer (1683). The third outer wall (1693) is coupled to the outer wall (1092) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (550, 552) in series with a parallel combination of cylindrical battery cells (570, 572).

[0113] The fourth outer wall (1694) is coupled to the fourth layer (1684) and extends substantially perpendicularly to the fourth layer (1684). The fourth outer wall (1694) is coupled to the outer wall (1093) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (570, 572) in series with a parallel combination of cylindrical battery cells (590, 592).

[0114] The fifth outer wall (1695) is coupled to the fifth layer (1685) and extends substantially perpendicularly to the fifth layer (1685). The fifth outer wall (1695) is coupled to the outer wall (1094) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (590, 592) in series with a parallel combination of cylindrical battery cells (610, 612).

[0115] The sixth outer wall (1696) is coupled to the sixth layer (1686) and extends substantially perpendicularly to the sixth layer (1686). The sixth outer wall (1696) is coupled to the outer wall (1095) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (610, 612) in series with a parallel combination of cylindrical battery cells (630, 632).

[0116] The seventh outer wall (1697) is coupled to the seventh layer (1687) and extends substantially perpendicularly to the seventh layer (1687). The seventh outer wall (1697) is coupled to the outer wall (1096) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (630, 632) in series with a parallel combination of cylindrical battery cells (650, 652).

[0117] The eighth outer wall (1698) is coupled to the eighth layer (1688) and extends substantially perpendicularly to the eighth layer (1688). The second outer wall (1698) is coupled to the outer wall (1097) (shown in FIG. 26) of the first busbar layer (802) to electrically couple a parallel combination of cylindrical battery cells (650, 652) in series with a parallel combination of cylindrical battery cells (670, 672).

[0118] Upper separation layer

[0119] Referring to FIGS. 14, 22 and 30, the upper separating layer (808) is positioned opposite to and in contact with the second busbar layer (806). In an exemplary embodiment, the upper separating layer (808) is composed of an electrical insulating material. Referring to FIG. 30, the upper separating layer (808) includes a plurality of openings (2140) extending therethrough. In particular, the plurality of openings (2140) include a first row of openings (2141), a second row of openings (2142), a third row of openings (2143), a fourth row of openings (2144), a fifth row of openings (2145), a sixth row of openings (2146), and a seventh row of openings (2147). The first row opening (2141), the second row opening (2142), the third row opening (2143), the fourth row opening (2144), the fifth row opening (2145) and the sixth row opening (2146) are aligned with the first row opening (1701), the second row opening (1702), the third row opening (1703), the fourth row opening (1704), the fifth row opening (1705) and the sixth row opening (1706) of the second busbar layer (806) (shown in FIG. 29).

[0120] For the sake of simplification, only the openings (2141) of the first column will be discussed below. In particular, the openings (2141) of the first column include openings (2230, 2232, 2250, 2252, 2270, 2272, 2290, 2292, 2310, 2312, 2330, 2332, 2350, 2352, 2370, 2372).

[0121] Referring to FIGS. 30 and FIGS. 36, since the shape of each opening within the plurality of openings (2140) is identical, only the shape of the opening (2230) will be discussed in more detail below. In particular, the opening (2230) has a circular opening (2390) and a skirt-shaped opening (2392) communicating with the circular opening (2390).

[0122] Referring to FIGS. 29 and 30, the opening (2230) in the intermediate separation layer (804) is aligned with the opening (1730) in the second busbar layer (806). Additionally, the opening (2232) in the intermediate separation layer (804) is aligned with the opening (1732) in the second busbar layer (806).

[0123] The opening (2250) in the intermediate separation layer (804) is aligned with the opening (1750) in the second busbar layer (806). Additionally, the opening (2252) in the intermediate separation layer (804) is aligned with the opening (1752) in the second busbar layer (806).

[0124] The opening (2270) in the intermediate separation layer (804) is aligned with the opening (1770) in the second busbar layer (806). Additionally, the opening (2272) in the intermediate separation layer (804) is aligned with the opening (1772) in the second busbar layer (806).

[0125] The opening (2290) in the intermediate separation layer (804) is aligned with the opening (1790) in the second busbar layer (806). Additionally, the opening (2292) in the intermediate separation layer (804) is aligned with the opening (1792) in the second busbar layer (806).

[0126] The opening (2310) in the intermediate separation layer (804) is aligned with the opening (1810) in the second busbar layer (806). Additionally, the opening (2312) in the intermediate separation layer (804) is aligned with the opening (1812) in the second busbar layer (806).

[0127] The opening (2330) in the intermediate separation layer (804) is aligned with the opening (1830) in the second busbar layer (806). Additionally, the opening (2332) in the intermediate separation layer (804) is aligned with the opening (1832) in the second busbar layer (806).

[0128] The opening (2350) in the intermediate separation layer (804) is aligned with the opening (1850) in the second busbar layer (806). Additionally, the opening (2352) in the intermediate separation layer (804) is aligned with the opening (1852) in the second busbar layer (806).

[0129] The opening (2370) in the intermediate separation layer (804) is aligned with the opening (1870) in the second busbar layer (806). Additionally, the opening (2372) in the intermediate separation layer (804) is aligned with the opening (1872) in the second busbar layer (806).

[0130] sensor layer

[0131] Referring to FIGS. 22, 29 and 31, the sensor layer (810) is positioned opposite to and in contact with the upper separation layer (808). In an exemplary embodiment, the sensor layer (810) comprises an electrical insulating substrate (2400), an electrical connector (2402), and electrical traces (2411, 2412, 2413, 2414, 2415, 2416, 2417, 2418, 2419). Each electrical trace (2411-2410) is electrically coupled to a separate location on the second busbar layer (806) and to the electrical connector (2402).

[0132] The sensor layer (810) includes a plurality of openings (2400) extending through the substrate (2400). In particular, the plurality of openings (2400) include a first row of openings (2441), a second row of openings (2442), a third row of openings (2443), a fourth row of openings (2444), a fifth row of openings (2445), a sixth row of openings (2446), and a seventh row of openings (2447).

[0133] For the sake of simplification, only the opening (2441) of the first column will be discussed below. In particular, the opening (2441) of the first column includes openings (2530, 2532, 2550, 2552, 2570, 2572, 2590, 2592, 2610, 2612, 2630, 2632, 2650, 2652, 2670, 2672).

[0134] Referring to FIGS. 14, 26, 29 and 31, for the sake of understanding, a brief description will be provided of a method for aligning and exposing a tab in a second busbar layer (806) that contacts the positive electrode of a plurality of cylindrical battery cells (56) and also aligning and exposing a portion of a first busbar layer (802) that contacts the negative electrode of a plurality of cylindrical battery cells (56).

[0135] The opening (2530) is sized and shaped to expose the tab (1930) (shown in FIG. 29) of the second busbar layer (806) in contact with the positive electrode of the cylindrical battery cell (530) and to expose a portion of the first busbar layer (802) adjacent to the opening (1130) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (530).

[0136] The opening (2532) is sized and shaped to expose the tab (1932) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (532) and to expose a portion of the first busbar layer (802) that is close to the opening (1132) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (532).

[0137] The opening (2550) is sized and shaped to expose the tab (1950) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (550) and to expose a portion of the first busbar layer (802) that is close to the opening (1150) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (550).

[0138] The opening (2552) is sized and shaped to expose the tab (1952) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (552) and to expose a portion of the first busbar layer (802) that is close to the opening (1152) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (552).

[0139] The opening (2570) is sized and shaped to expose the tab (1970) (shown in FIG. 29) of the second busbar layer (806) in contact with the positive electrode of the cylindrical battery cell (570) and to expose a portion of the first busbar layer (802) adjacent to the opening (1170) (shown in FIG. 26) in contact with the negative electrode of the cylindrical battery cell (570).

[0140] The opening (2572) is sized and shaped to expose the tab (1972) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (572) and to expose a portion of the first busbar layer (802) that is close to the opening (1172) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (572).

[0141] The opening (2590) is sized and shaped to expose the tab (1990) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (590) and to expose a portion of the first busbar layer (802) that is close to the opening (1190) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (590).

[0142] The opening (2592) is sized and shaped to expose the tab (1992) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (592) and to expose a portion of the first busbar layer (802) that is close to the opening (1192) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (592).

[0143] The opening (2610) is sized and shaped to expose the tab (2010) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (610) and to expose a portion of the first busbar layer (802) that is close to the opening (1210) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (610).

[0144] The opening (2612) is sized and shaped to expose the tab (2012) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (612) and to expose a portion of the first busbar layer (802) that is close to the opening (1212) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (612).

[0145] The opening (2630) is sized and shaped to expose the tab (2030) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (630) and to expose a portion of the first busbar layer (802) that is close to the opening (1230) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (630).

[0146] The opening (2632) is sized and shaped to expose the tab (2032) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (632) and to expose a portion of the first busbar layer (802) that is close to the opening (1232) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (632).

[0147] The opening (2650) is sized and shaped to expose the tab (2050) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (650) and to expose a portion of the first busbar layer (802) that is close to the opening (1250) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (650).

[0148] The opening (2652) is sized and shaped to expose the tab (2052) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (652) and to expose a portion of the first busbar layer (802) that is close to the opening (1252) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (652).

[0149] The opening (2670) is sized and shaped to expose the tab (2070) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (670) and to expose a portion of the first busbar layer (802) that is close to the opening (1270) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (670).

[0150] The opening (2672) is sized and shaped to expose the tab (2072) (shown in FIG. 29) of the second busbar layer (806) that contacts the positive electrode of the cylindrical battery cell (672) and to expose a portion of the first busbar layer (802) that is close to the opening (1272) (shown in FIG. 26) that contacts the negative electrode of the cylindrical battery cell (672).

[0151] In the stacked busbar assembly (68), the tabs of the second busbar layer (806) are exposed (e.g., visible above the assembly (68)), so that a welding tool (not shown) can contact the tabs to weld each positive electrode of the cylindrical battery cell. Additionally, it should be noted that a portion of the first busbar layer (802) in contact with the negative electrode of the cylindrical battery cell is exposed so that each portion of the first busbar layer (802) can be welded to the negative electrode of the cylindrical battery cell.

[0152] Second Retention Housing

[0153] Referring to FIGS. 3 and FIGS. 38 through 40, the second retention housing (154) holds a plurality of cylindrical battery cells (156) inside, on and opposite the central cooling unit (280) (shown in FIG. 4), so that the battery cells (156) are thermally connected to the central cooling unit (280). Additionally, the second retention housing (154) holds a stacked busbar assembly (168) on it. Additionally, the second retention housing (154) supports retaining plates (160, 162) on it. The second retention housing (154) is positioned within a second region (292) (shown in FIG. 4) formed by the central cooling unit (280) and the first and second outer plates (141, 142). The structure of the second retention housing (154) is the same as the structure of the first retention housing (54). Also, the structure of the retaining plates (160, 162) is the same as the structure of the retaining plates (60, 62), respectively. Additionally, the structure of the plurality of cylindrical battery cells (156) is the same as the structure of the plurality of cylindrical battery cells (56). Also, the structure of the stacked busbar assembly (168) is the same as the structure of the stacked busbar assembly (68).

[0154] First outer plate

[0155] Referring to FIGS. 2 through 4, the first outer plate (190) is connected to the first retention housing (54) and the battery cell retention frame (50) using bolts (191, 192, 193, 194, 195, 196, 197, 198, 199). In an exemplary embodiment, the first outer plate (190) is made of plastic.

[0156] Second outer plate

[0157] The second outer plate (220) is connected to the second retention housing (154) and the battery cell retention frame (50) using bolts (221, 222, 223, 224, 225, 226, 227, 228, 229). In an exemplary embodiment, the second outer plate (220) is made of plastic.

[0158] circuit board

[0159] Referring to FIGS. 3 and FIGS. 31, the circuit board (240) includes a battery management controller (5000) that is electrically coupled to an electrical connector (2402) of a sensor layer (810) within a stacked busbar assembly (68) to monitor the operation of a plurality of cylindrical battery cells (56). Additionally, the battery management controller (5000) is electrically coupled to an electrical connector of a sensor layer within a stacked busbar assembly (168) to monitor the operation of a plurality of cylindrical battery cells (156). The circuit board (240) is coupled to the ends of a first retention housing (54) and a second retention housing (154).

[0160] electric busbar

[0161] An electric busbar (242) is installed to electrically connect the stacked busbar assemblies (68, 168) together. In particular, the electric busbar (242) is electrically connected to the stacked busbar assembly (68) (electrically connected to a plurality of cylindrical battery cells (56)) and the stacked busbar assembly (168) (electrically connected to a plurality of cylindrical battery cells (156)).

[0162] cover plate

[0163] A cover plate (246) is attached to the first and second outer plates (190, 220) to cover the circuit board (240). In an exemplary embodiment, the cover plate (246) is made of plastic.

[0164] The battery module (32) provides substantial advantages over other battery modules. In particular, the battery module (32) utilizes a stacked busbar assembly (68) having a relatively low height profile and a technical effect of electrically connecting cylindrical battery cells in a desired electrical configuration.

[0165] Although the invention of the claimed invention has been described in detail with respect to only a limited number of embodiments, it should be readily understood that the invention is not limited to these disclosed embodiments. Rather, the invention of the claimed invention may be modified to include any number of variations, modifications, substitutions, or equivalent configurations corresponding to the spirit and scope of the invention, which have not been described so far. Additionally, while various embodiments of the invention 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 invention of the claimed invention should not be construed as being limited by the foregoing description.

Claims

Claim 1 A battery module comprises: a first cylindrical battery cell having a positive electrode and a negative electrode; a stacked busbar assembly having a bottom separator, a first busbar layer, an intermediate separator, and a second busbar layer; wherein the first busbar layer is coupled to the bottom separator and the intermediate separator between the bottom separator and the intermediate separator, and the intermediate separator is coupled to the first busbar layer and the second busbar layer between the first busbar layer and the second busbar layer; and wherein the bottom separator has a first opening penetrating the bottom separator, and the first opening is sized and shaped to allow the positive electrode of the first cylindrical battery cell to pass through and be received within the first opening and to expose a portion of the negative electrode of the first cylindrical battery cell. A battery module comprising: a first busbar layer having a first opening penetrating the first busbar layer, wherein the first opening of the first busbar layer is sized and shaped to accommodate the positive electrode of the first cylindrical battery cell by passing it into the first opening of the first busbar layer, and a portion of the first busbar layer adjacent to the first opening of the first busbar layer is positioned opposite the negative electrode of the first cylindrical battery cell and is electrically in contact with the negative electrode; an intermediate separator layer having a first opening penetrating the intermediate separator layer, wherein the first opening of the intermediate separator layer is sized and shaped to accommodate the positive electrode of the first cylindrical battery cell by passing it into the first opening of the intermediate separator layer; and a second busbar layer being positioned opposite the positive electrode of the first cylindrical battery cell and is electrically in contact with the positive electrode. Claim 2 In claim 1, a second cylindrical battery cell having a positive electrode and a negative electrode; the bottom separator has a second opening penetrating the bottom separator, and the second opening is sized and shaped to allow the positive electrode of the second cylindrical battery cell to pass through and be received within the second opening and to expose a portion of the negative electrode of the second cylindrical battery cell; A battery module comprising: a first busbar layer having a second opening penetrating the first busbar layer, wherein the second opening of the first busbar layer is sized and shaped to accommodate the positive electrode of the second cylindrical battery cell passing through the second opening of the first busbar layer, and a portion of the first busbar layer adjacent to the second opening of the first busbar layer is positioned opposite the negative electrode of the second cylindrical battery cell and electrically contacts the negative electrode of the second cylindrical battery cell; an intermediate separator layer having a second opening penetrating the intermediate separator layer, wherein the second opening of the intermediate separator layer is sized and shaped to accommodate the positive electrode of the second cylindrical battery cell passing through the second opening of the intermediate separator layer; wherein the second busbar layer is positioned opposite the positive electrode of the second cylindrical battery cell and electrically contacts the positive electrode of the second cylindrical battery cell, and the first and second cylindrical battery cells are electrically coupled to each other in parallel. Claim 3 In paragraph 2, the first busbar layer has a first layer and a second layer that are spaced apart from each other and electrically separated from each other; the first and second openings of the first busbar layer penetrate the first layer of the first busbar layer; the second busbar layer has a first and second layer that are spaced apart from each other and electrically separated from each other; the positive electrode of the first cylindrical battery cell and the positive electrode of the second cylindrical battery cell are in contact with the first layer of the second busbar layer; and the first layer of the first busbar layer is electrically coupled to the second layer of the second busbar layer, a battery module. Claim 4 A battery module according to paragraph 3, wherein the first busbar layer further has an outer wall that is coupled to the first layer portion thereof and extends vertically; and the second busbar layer further has an outer wall that is coupled to the second layer portion thereof and extends vertically, and also has an outer wall that is coupled to the outer wall of the first busbar layer. Claim 5 In paragraph 4, the first busbar is coupled to the outer wall coupled to the first layer portion of the first busbar layer and to the outer wall coupled to the second layer portion of the second busbar layer, forming a battery module. Claim 6 In paragraph 3, further comprising a third cylindrical battery cell having a positive electrode and a negative electrode; the bottom separator has a third opening penetrating the bottom separator, and the third opening of the bottom separator is sized and shaped to accommodate the positive electrode of the third cylindrical battery cell by passing it through the third opening of the bottom separator and to expose a portion of the negative electrode of the third cylindrical battery cell; The first busbar layer has a third opening penetrating the second layer portion of the first busbar layer, and the third opening of the first busbar layer is sized and shaped to allow the positive electrode of the third cylindrical battery cell to pass into the third opening of the first busbar layer, and a portion of the first busbar layer adjacent to the third opening of the first busbar layer is positioned opposite the negative electrode of the third cylindrical battery cell and is electrically in contact with the negative electrode of the third cylindrical battery cell; the intermediate separator layer has a third opening penetrating the intermediate separator layer, and the third opening of the intermediate separator layer is sized and shaped to allow the positive electrode of the third cylindrical battery cell to pass into the third opening of the intermediate separator layer and accommodate it; the positive electrode of the third cylindrical battery cell is in contact with the second layer portion of the second busbar layer, and the third cylindrical battery cell is electrically coupled in series with the parallel configuration of the first and second cylindrical battery cells, forming a battery module. Claim 7 In claim 6, further comprising a fourth cylindrical battery cell having a positive electrode and a negative electrode; the bottom separator has a fourth opening penetrating the bottom separator, and the fourth opening of the bottom separator is sized and shaped to allow the positive electrode of the fourth cylindrical battery cell to pass through and be received within the fourth opening of the bottom separator, and to expose a portion of the negative electrode of the fourth cylindrical battery cell; A battery module comprising: a first busbar layer having a fourth opening penetrating the second layer portion of the first busbar layer, wherein the fourth opening of the first busbar layer is sized and shaped to accommodate the positive electrode of the fourth cylindrical battery cell within the fourth opening of the first busbar layer, and a portion of the first busbar layer adjacent to the fourth opening of the first busbar layer is positioned opposite the negative electrode of the fourth cylindrical battery cell and electrically contacts the negative electrode of the fourth cylindrical battery cell; an intermediate separator layer having a fourth opening penetrating the intermediate separator layer, wherein the fourth opening of the intermediate separator layer is sized and shaped to accommodate the positive electrode of the fourth cylindrical battery cell by passing it through the fourth opening of the intermediate separator layer; wherein the positive electrode of the fourth cylindrical battery cell is in contact with the second layer portion of the second busbar layer, and the third cylindrical battery cell and the fourth cylindrical battery cell are electrically coupled to each other in series. Claim 8 A battery module according to claim 1, wherein the first opening in the bottom separator layer has a circular opening and a skirt-shaped opening communicating with the circular opening, the portion of the circular opening communicating with the positive electrode of the first cylindrical battery cell, and the portion of the skirt-shaped opening communicating with a portion of the negative electrode of the first cylindrical battery cell. Claim 9 A battery module according to claim 1, further comprising an upper separating layer coupled to the second busbar layer. Claim 10 A battery module according to claim 9, further comprising a sensor layer coupled to the upper separating layer, wherein the sensor layer has an electrical trace electrically coupled to the second busbar layer.

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