Battery module

Abstract

There is provided a battery module comprising: a housing and multiple battery cells positioned within the housing, wherein the housing is manufactured by profiling and folding metal sheets; and a structural potting layer that encapsulates the battery cells within the housing. The structural potting layer self-moulds around the battery cells and maintains mechanical strength across a wide temperature range, such as approximately from -40°C to 75°C, providing both mechanical stability and thermal isolation.

Description

[0001] BATTERY MODULE

[0002] BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The field of the invention relates to a battery module. In particular, the battery module can be applied and tailored to any application requiring custom-shaped battery modules.

[0005] A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records but otherwise reserves all copyright rights whatsoever.

[0006] 2. Description of the Prior Art

[0007] Many industries are transitioning to electric power in response to government efforts to reduce greenhouse gas emissions. While the consumer electric vehicle market has made significant progress, the same level of advancement is needed in sectors like robotics, electric marine vehicles, and industrial machinery.

[0008] Electric vehicles have become increasingly popular due to their environmental benefits, such as reduced fuel consumption and lower vehicle emissions. These vehicles are powered by electric batteries, which function as the main energy source. Typically, battery packs in electric vehicles consist of multiple battery cells arranged into modules, which are then grouped to form a pack. Despite the advancements in battery technology, conventional battery packs face significant challenges, including substantial weight, bulkiness, and low energy density, which impact the overall efficiency and range of the vehicles. Additionally, the high manufacturing costs and lack of adaptability to different battery chemistries and cell types further complicate their widespread adoption.

[0009] The increasing shift to electric power to these various sectors demands customised battery solutions. Additionally, the need for efficient thermal management and enhanced safety is critical but not sufficiently addressed. Moreover, traditional battery packs are not designed for easy customization or integration of various cell types and chemistries, which limits their flexibility and adaptability to evolving technologies.

[0010] There is a need for a flexible battery system that can be easily adapted to meet these specific demands while keeping costs and development time under control.

[0011] SUMMARY OF THE INVENTION

[0012] An aspect of the invention is a battery module comprising: a housing and multiple battery cells positioned within the housing, wherein the housing is manufactured by profiling and folding metal sheets; and a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and maintains mechanical strength across a wide temperature range, such as approximately from -40°C to 75°C, providing both mechanical stability and thermal isolation.

[0013] Another aspect of the invention is a battery module comprising: a housing and multiple battery cells positioned within the housing; a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and provides both mechanical stability and thermal isolation; and a silicon top layer for covering the battery cells, wherein the silicon top layer is designed to deliberately weaken or rupture in response to a specific localised event, such as a localised explosion or venting of a cell.

[0014] Another aspect of the invention is a battery module comprising: a housing and multiple battery cells positioned or aligned in a single orientation / direction within the housing, each battery cell having a positive terminal and a negative terminal; a metallic annulus part welded onto the negative terminal rim of each battery cell, wherein the metallic annulus part has an outer diameter equal to or smaller than the outer diameter of the battery cell, and an inner diameter larger than the positive terminal of the battery cell; and a connection sheet electrically connecting the battery cells to the metallic annulus parts.

[0015] Another aspect of the invention is a battery module comprising: a housing and multiple battery cells positioned within the housing, wherein the housing is manufactured by profiling and folding metal sheets; a metal sheet bonded or welded to the base of the housing and forming an integrated cold plate; and a liquid coolant flow path defined between the metal sheet and the base of the housing; wherein the flow path is configured to circulate coolant to manage the thermal load of the battery cells. Another aspect of the invention is a battery module comprising: a housing made a metal enclosure manufactured by profiling and folding metal sheets; cylindrical battery cells arranged in a single orientation within the housing; a connection sheet positioned on top of the cylindrical battery cells to electrically interconnect the cells; and a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and provides both mechanical stability and thermal isolation.

[0016] Another aspect of the invention is a vehicle or robot including a battery module comprising: a housing and multiple battery cells positioned within the housing; and a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and maintains mechanical strength across a wide temperature range, such as approximately from -40°C to 75°C, providing both mechanical stability and thermal isolation.

[0017] Another aspect of the invention is a method of manufacturing a battery module, comprising automated cell placement mechanism configured to arrange cells within a mould or piece of tooling according to a digital layout file that specifies cell positions for optimized spatial usage.

[0018] Another aspect of the invention is a method of manufacturing a battery module, the method comprising the steps of making an aluminium enclosure from a profiled aluminium sheet; placing cells within the enclosure based a digital layout file that specifies the cell positions; and pouring around the cells a liquid that is configured to cure and become a structural potting layer securing the battery cells in place within the enclosure.

[0019] Another aspect of the invention is a method of designing the battery module above based on specified performance and dimension constraints, comprising selecting battery cell chemistries and configurations to optimise the energy output per unit weight, and providing a digital layout file to define the battery cells positioning with a housing of specific dimensions. Another aspect of the invention is a method of designing the battery module above based on specific operational parameters, comprising determining the target capacity, energy density, weight and dimensions based on the specific operational parameters, selecting battery cell chemistries and configurations to optimise the energy output per unit weight, and providing a digital layout file to define the battery cells positioning with a housing of specific dimensions.

[0020] BRIEF DESCRIPTION OF THE FIGURES

[0021] Aspects of an implementation of the invention will now be described, by way of example(s), with reference to the following Figures, which each show features of an implementation of the invention:

[0022] Figure 1 shows a perspective view of a battery module.

[0023] Figure 2 shows a perspective view of a battery module with optional mounting brackets.

[0024] Figure 3 shows a perspective view of a battery module with an optional cooling tube.

[0025] Figure 4 shows a bottom view of a battery module with an optional cooling tube.

[0026] Figure 5 shows a top view of a battery module with an optional cooling tube.

[0027] Figure 6 shows a perspective view of a battery module with optional cooling section machine cold plated instead of tube.

[0028] Figure 7 shows a perspective view of a battery module with the top cover of the housing removed and the connection sheet visible.

[0029] Figure 8 shows a perspective view of a battery module with the top cover and the connection sheet removed.

[0030] Figure 9 shows a perspective view of a battery module with the aluminium enclosure hidden and the structural potting layer visible.

[0031] Figure 10 shows a perspective view of a part of a battery module with the terminals potted in structural potting layer shown.

[0032] Figure 11 shows a perspective view of a battery module with terminals shown in position relative to battery cells.

[0033] Figure 12 shows a perspective view of a battery module with connector sheet, cells and terminals shown, so full electric circuit is visible.

[0034] Figure 13 shows a perspective view of a battery module enclosure, with the holes for retention pins in bottom face visible.

[0035] Figure 14 shows a perspective view of a terminal shroud component.

[0036] Figure 15 shows two battery cells, one without the metallic annulus part added on top and one with the annulus part added on top.

[0037] Figure 16 shows a cross section of a battery module showing cells, resin, aluminium enclosure, lid, and terminal.

[0038] Figure 17 shows an example of a multiple layer connector sheet. Figure 18 shows an exploded view of the connection sheet comprising a four-layer structure designed to interface with the battery cells.

[0039] Figure 19 shows another close-up of the battery module including lid securing tabs.

[0040] Figure 20 shows another close-up of the battery module including mounting points secured to the bottom surface of the housing.

[0041] Figure 21 shows a battery module including a plastic enclosure located inside the structural housing.

[0042] Figure 22 shows a close-up view of the plastic enclosure that is used to house a cell monitoring unit or BMS.

[0043] Figure 23 shows a perspective view of the battery module with a non-rectangular housing.

[0044] Figure 24 shows a bottom view of battery module with a non-rectangular housing.

[0045] Figure 25 shows a diagram of a battery module.

[0046] Figure 26 shows a diagram illustrating design considerations for a battery module

[0047] Figure 27 shows a diagram illustrating various stages of a process for manufacturing a battery module.

[0048] Figure 28 shows a diagram illustrating various stages of a process for manufacturing a battery module.

[0049] Figure 29 shows a cell crown designed to interface with a battery cell and a printed circuit board (PCB).

[0050] Figure 30 shows a diagram illustrating the manufacturing process of another cell crown.

[0051] Figure 31 shows a diagram of the cell crown.

[0052] Figure 32 shows a flowchart that outlines process steps and their associated benefits for a specific design.

[0053] DETAILED DESCRIPTION

[0054] The present invention relates to a battery module system, specifically designed for mobile applications such as, but not limited to robots, electric watercraft, electric off- highway vehicles, and other low to medium volume products that rely on batteries for performance. A key feature is the ability to produce battery modules in a wide range of shapes and sizes using a standardised manufacturing process, enabling commercially viable solutions for applications with strict space and design constraints.

[0055] These specialised applications face unique challenges, particularly with the size and shape of the battery packs required to fit within design envelopes, which off-the-shelf solutions often cannot address. These design envelopes are not just physical space, but also relate to the voltage, capacity, energy density, battery chemistry choice, and mounting methods.

[0056] In many machinery and vehicle applications such as electric robots, mining equipment, construction machinery, and watercraft, space and shape constraints are critical. Battery packs must fit seamlessly into existing designs without requiring major structural changes. However, creating custom-shaped battery solutions at the right voltage with the right battery chemistry choice traditionally involves high costs and long development times, particularly for low-volume manufacturers who do not benefit from economies of scale. There is a need for a flexible battery system that can be easily adapted to meet these specific demands while keeping costs and development time under control.

[0057] Additionally, it is important that the battery design includes one or more of the following:

[0058] • A cooling method which can be achieved at low part cost, but with high performance (and minimal thermal resistance), using an approach which can be shaped to fit the shape of the battery.

[0059] • An anti-thermal runaway propagation method.

[0060] • An approach where all cells are oriented in the same direction axially to homogenise cooling performance. Typically to build a bespoke battery pack at an affordable cost, several standard battery modules such as a VDA 355 battery module are used. These modules are usually electrically connected in series, and to get to a useful voltage of 350 volts or above, at least 20 battery modules are required. Because battery modules must be connected in series, if the application requires 24 VDA 355 modules to achieve the correct voltage, but can only fit 20 VDA 355 battery modules, then it is a significant challenge for the application to make progress.

[0061] Furthermore, because these VDA 355 modules are designed to be a one size fits all approach, much of the complexity including cell monitoring, cooling and mounting brackets must be added externally to the standard battery modules. The approach described improves upon this by integrating these additional complexities inside the battery module, thus reducing complexity at the battery pack level.

[0062] A modular battery design is therefore introduced that can be produced in any shape or size using the same manufacturing processes and equipment. Furthermore, the equipment used is of standard design and availability and avoids the need for very high capital expenditure to produce the battery modules. This approach allows for the creation of customised battery modules tailored to fit various spatial and power requirements without the need for costly retooling or redesign. As a result, manufacturers of electric watercraft, robots, and off-highway vehicles as well as many other industries can quickly and affordably implement electric power solutions, regardless of the unique design constraints of their applications.

[0063] Key objectives are, but not limited to:

[0064] • Developing a battery module system that can be produced in any shape or size to fit the specific needs of different machines and vehicles.

[0065] • Utilising a standardised production process to minimise the cost and time associated with developing custom battery solutions.

[0066] • Providing a flexible, modular system that can be packaged into battery packs of various shapes and sizes to meet specific design and power requirements.

[0067] • Enabling seamless integration of battery modules into existing designs without requiring significant structural changes. • The battery design includes one or more cells and a thermal management system, with ducts and fluid delivery means to ensure proper temperature control. A core feature lies in the module's ability to be manufactured in any form factor, allowing multiple modules to be arranged and combined in different configurations to create battery packs that perfectly match the physical and performance needs of each application.

[0068] By using a single manufacturing process for all module designs, the system drastically reduces development time and costs, even for complex and highly specific applications. This makes it an ideal solution for industries with unique spatial constraints and power demands, such as robots, electric off-highway vehicles, and electric watercraft, where performance, size, and safety are all critical considerations.

[0069] A versatile, modular battery solution is presented that can be manufactured in any shape or size, offering a commercially viable option for low to medium volume applications. It allows manufacturers to meet the specific design challenges of machinery and vehicles such as electric-powered robots, industrial vehicles, and watercraft, while reducing costs and development time using a standardised production process.

[0070] One or more advantages of the system include, but are not limited to:

[0071] • The system can be integrated into a wide range of machinery and vehicles, such as robots, electric watercraft, off-highway vehicles, industrial machinery and any other electrical vehicles.

[0072] • The system can be easily customised to meet diverse design, power, and volume requirements by producing battery modules in various shapes and sizes, using the same manufacturing process.

[0073] • The system can be produced in low volumes without significant cost for each variant of the design, such as tooling or setup cost.

[0074] • The system can be produced in a wide range of shapes and sizes using the same production equipment across all variants.

[0075] • The system can be produced in a wide range of shapes and sizes using standard production equipment which minimises factory capital expenditure cost and therefore reduces price per battery unit. • The battery solution can be adapted to meet a variety of safety and thermal management needs, ensuring reliable and efficient performance across different applications.

[0076] • The system can be easily incorporated into existing vehicle and machinery designs, reducing the need for significant structural alterations.

[0077] • The system can be retrofitted into existing machines, enabling older models to transition to electric power without extensive reengineering.

[0078] • The design and assembly process are more flexible and adaptable than previous designs, allowing for configurations of various shapes and sizes to suit the specific spatial and performance constraints of low- to medium-volume products.

[0079] Figure 1 shows a perspective view of the battery module 11. The battery module comprises a housing and multiple battery cells arranged within the housing. The housing is constructed from a metal enclosure, such as aluminium, fabricated through processes, including cutting, folding and joining an aluminium sheet using welding or rivets. In the example shown, the battery module enclosure has a rectangular footprint. However, the enclosure is adaptable to any shapes to accommodate spatial or volumetric constraints specific to the design requirement. Additionally, the battery module enclosure may incorporate cutouts to facilitate integration with other design elements of the battery module.

[0080] Multiple modules can be incorporated into a battery pack in adjustable quantities, orientation, and locations to meet specific volumetric and electrical needs.

[0081] Although cylindrical cells are shown in the examples below. Advantageously, the battery module can adapt to any other type of cells, including prismatic or pouch cells, and to any battery chemistries.

[0082] The enclosure includes a removable top cover or lid. The lid is designed to fully enclose and protect the internals components of the battery module such as to prevent ingress or accidental electrical contact with the internal parts. The battery module lid is located at the top of the enclosure, directly above the cell connection sheet. The battery module lid is made from a non-conductive material such as a plastic, PC or ABS or PC / ABS or Acrylic or any other similar plastic materials. The battery module includes a large flat central section and has side sections that extend perpendicularly from the flat section. These side sections sit inside the aluminium enclosure and are secured in place with fixings. The lid is also shaped to fit around the terminal shroud. The lid is secured in place using fixings that pass through pre-drilled holes in the side sections of the lid and corresponding holes in the enclosure. These fixings may be rivets or snap lock fixings or screws or bolts or similar. The pre-drilled holes may also be laser cut as part of the sheet profiling process. The pre-drilled holes may also be on small tabs with an axis vertically upward out of the module. The battery module lid is cut and formed from plastic sheet to avoid the high tooling cost of injection moulded part tooling and setup. The battery module lid may have a thickness ranging from about 1 mm to 2 mm. The battery module lid is configured to provide electrical isolation.

[0083] Figure 2 shows a perspective view of the battery module 11 with optional mounting brackets 21, designed to mechanically secure the module to a pack structure, external structure, or other battery modules. These brackets are separate components, allowing for independent design and flexible placement. The brackets are located on the exterior of the aluminium enclosure and are configured to provide mounting surfaces for attachment to external structure. They can be fabricated from various materials, including aluminium, steel or plastic and may include bracing features for enhanced strength and holes for fixing. The brackets may be attached to the aluminium enclosure using rivets, welding, or bots and can be produced through cutting and forming processes similar to those used for the enclosure.

[0084] A thermal management subsystem for regulating the temperature of the one or more cells, comprising a coolant tube bonded to the external face of the battery module, may also be used. The tube includes an intake end, and an outlet end which may optionally incorporate fluid connectors for integration with external cooling or heating systems. The battery module thermal management subsystem may be adapted to heat and / or cool the cells, as required.

[0085] As illustrated in Figure 3, the battery module may optionally include a cooling tube 31. The cooling tube is bonded or affixed to the bottom surface of the housing, as shown in the bottom view of Figure 4. This cooling tube can replace or complement the serpentine cooling path, providing another thermal management option. The cooling tube includes intake, and outlet ends. The cooling tube 31, visible in the top view of the module in Figure 5, is configured to optimise thermal regulation by maximising heat dissipation or distribution to or from the battery cells.

[0086] The thermal management subsystem is adaptable to various configurations and can be modified to meet the specific thermal requirements of different battery chemistries, cell type or operating conditions.

[0087] A liquid coolant flow path may also be implemented in various configurations to optimise cooling performance, manufacturing flexibility, and integration into other systems.

[0088] Alternatively, the flow path may also be air-cooled or may include a finned heat sink thermally joined to the underside of the module in the case of air cooling.

[0089] One configuration involves integrating a machined cold plated into the module, as shown in the bottom view of Figure 6. This version of the module includes a machined cold plate instead of the cooling tube. The cold plate is integrated into the module to provide efficient cooling with fewer components. In this case, a metal sheet is welded or bonded onto the base of the housing and together with the bottom of the housing forms an integrated cold plate. A flow path, configured to circulate coolant to manage the thermal load of the battery cells, is defined between the metal sheet and the base of the housing.

[0090] The integrated cooling options offer cost and integration advantages in applications where thermal management needs to be embedded directly within the module.

[0091] The coolant flows through the pipe, which could be water, a water / glycol mix or a refrigerant. This coolant is pumped by a pump elsewhere in the overall system which the battery module and pack are part of. The coolant system will also contain a method of rejecting the heat from the coolant to ambient such as a radiator or heat exchanger.

[0092] The liquid coolant flow path can also take the form of a serpentine shaped cooling pipe integrated into the external surface of the module. The battery module cooling pipe is constructed from thermally conductive materials, such as copper or aluminium. The battery module cooling pipe is designed to be an optional add on feature to the battery module which does not add to or take away from the electrical or mechanical performance of the rest of the battery module. This is because in some scenarios the modules will not have the cooling pipe and instead will be cooled using an external cold plate or in other cases will simply be passively cooled, whereby heat is conducted / radiated out of the battery modules without any liquid coolant flow. The cooling pipe may be bonded to the face of the aluminium enclosure to achieve a strong mechanical bond.

[0093] The cooling mechanisms are designed to achieve homogeneous cooling performance, ensuring that all cells are maintained at optimal operating performances. The designs are adaptable, allowing customization for any shapes, sizes, and thermal requirements. By minimising thermal resistance, the configurations enhance the reliability, efficiency, and scalability of the battery module for various applications.

[0094] Figure 7 shows a perspective view of the battery module with the top cover of the housing removed and a connection sheet 71 visible. The connection sheet is positioned on top of battery cells within the housing, providing electrical connections between the battery cells and the output terminals. The connection sheet may be a shaped copper sheet which is welded the battery cell directly or to an interconnect disc (or metallic annulus part) which is in turn welded to the battery cell.

[0095] The battery module may have two output terminals for the purpose of providing an electrical output connection point for the battery module to be connected to other battery modules / pack terminals / a load.

[0096] The output terminals are positioned along one edge of the aluminium enclosure in a "connection zone" which sits sub flush to the principle external faces of the module. The terminals may also be positioned to face upwards or out of the front of the module. This is so that once cables or bus bars are attached to the terminals, these components and their fixings (e.g. bolt head) do not protrude outside the principle faces of the battery module. The terminal shroud is made from a plastic material which may be manufactured through 3D printing or injection moulding. The terminals are made from a conductive metal such as brass, aluminium or copper, or a combination of these. The terminals are designed to be versatile and compatible across various battery module variants, allowing for economies of scale despite higher setup and tooling costs associated with their production.

[0097] The output terminals include a conductive surface for the attachment of external cable lugs or bus. Connection may achieve using threaded fixings, such as bolts, to press the cable lugs or bus bars against the conductive surface, ensuring efficient current transfer from the module to external component. The threaded portion may be made from a separate material if the terminal material is too soft for creating a strong threaded connection. The thread may also be integrated directly into the terminal material.

[0098] The two output terminals are partially encapsulated within the structural potting layer. There may be additional features on the terminals designed to assist in forming a mechanically strong fixing between the terminals and the structural potting layer such as holes, undercuts, or teeth shapes in the terminal or a terminal mounting part.

[0099] The battery module has a terminal shroud designed to create a "connection zone" around the terminals and cell monitoring connectors. This zone is electrically a non- conductive region. The terminal shroud also serves to visually present the output terminals clearly and can have + and - symbols to clearly indicate to an end user the polarity of the terminals.

[0100] The terminal shroud is located along one edge of the aluminium enclosure in a "connection zone" which sits sub-flush to the principal external faces of the module. This is so that once cables or bus bars are attached to the terminals, these components and their fixings (e.g. bolt head) do not protrude outside the principle faces of the battery module.

[0101] The shroud is made from a plastic material which may be 3d printed or injection moulded. These parts are designed to be common to a wide range of variants of the battery module and can therefore afford to use a production process with a higher setup and tooling lead time and cost.

[0102] The terminal shroud has mounting features so that it can be securely fixed to the aluminium enclosure. Overlapping joints on the shroud are designed to interface with neighbouring parts, such as the aluminium enclosure and the lid. It also includes a connector cutout, allowing for easy access and the presentation of the cell monitoring connector.

[0103] The terminal shroud is fabricated from electrically isolating materials.

[0104] Figure 8 shows a perspective view of the battery module with the top cover of the housing and the connection sheet removed. The battery cells 81 are housed within the enclosure and are arranged in a close-packed configuration to optimise space utilisation (minimise the volume occupied by the cells) and efficiency.

[0105] The battery module houses multiple battery cells, arranged as an array. The array of battery cells may comprise a close packed hexagonal array of cylindrical cells. The cells are positioned such that the location of the terminal face of the cell (with positive and negative present) is controlled accurately. The array of battery cells is in contact with a thermal interface material which is sandwiched between the battery cells and the aluminium enclosure to provide good thermal conductivity from the battery cells to the aluminium enclosure.

[0106] The aluminium enclosure is formed from a profiled aluminium sheet which is then folded and joined, and a potting material is applied around the battery cells, which cures into a rigid layer to hold the battery cells securely in place. Figure 9 shows a perspective view of the battery module with the aluminium enclosure hidden and the structural potting layer visible 91. The figure shows the battery cells 81 encapsulated within the structural potting layer, which stabilizes the cells and provides insulation. The minimum separation between the cells may be approximately less than 2 mm, such as 0.8 mm. The isolating wrap or coating often applied to cells may be omitted or never applied. This is to allow improved adhesive bonding between the cells and the structural potting layer, and to expose the negative rim of the cell which the connection sheet electrically connects to.

[0107] The structural potting material surrounds the cells to provide mechanical stability and vibration protection, as well as additional insulation to prevent unwanted electrical and thermal interactions between cells. This layer ensures the cells or internal components of the battery module are mechanically fixed relative to each other and the aluminium enclosure. It is also mechanically stable over the full operational temperature range of the battery.

[0108] The structural potting layer is located around the base of the battery cells and is in contact with the cell outer surface, the aluminium enclosure and the terminals. It is made from a potting material such as a polyurethane, or silicon or epoxy. This may be a material which cures as a solid or may be a self-foaming material which sets solid, but with a foam structure. This reduces mass for the same final occupied volume of the structural potting layer.

[0109] The structural potting layer is constructed by pouring or dispensing the potting layer in a low viscosity liquid format into the aluminium enclosure. It flows around the battery cells and battery terminals and then sets or cures solid becoming a rigid feature. The structural potting layer may have a layer thickness (or depth) within the battery module of more than 5 mm but less than the full height of the battery cells.

[0110] The battery module structural potting layer is electrically isolating and able to permanently withstand a multiple of three times the battery pack output voltage across the minimum thickness of potting material between the cells and the aluminium enclosure (or any electrically conductive parts in electrical conduct with that enclosure), and is able to withstand a multiple of three times the battery module voltage across the minimum thickness of potting material between each cell.

[0111] The isolation layer is a thin layer, with a thickness under about 0.5 mm, located between the base of the battery cells and the aluminium enclosure surface they are closest to. The isolation layer is made of a highly isolating layer such as polyimide or PET or a coating can be used as an alternative such as an epoxy coating or powder coating, or a surface treatment can be used as an alternative such as anodising the aluminium surface. The isolation layer is electrically isolating and able to permanently withstand a multiple of three times the battery pack output voltage across its minimum thickness.

[0112] The isolation layer is designed to provide minimal thermal resistance because cells need to be thermally connected to the aluminium enclosure. This property is mainly achieved due to the relative thinness of the isolation layer.

[0113] For additional protection, a silicon potting layer may be applied to further isolate the internal cells from each other and shield from environment conditions, such as particle ingress or moisture. The silicon layer is a lightweight material that is poured as a liquid on top of the battery cells and connection sheet once all other parts are assembled and welded. This material self-moulds around all the components it is encapsulating and is chosen to withstand high temperatures due to possible heating effects of bus bars. The silicon potting layer has a flat top surface which is formed due to the self-levelling nature of the silicon when it is poured and cures.

[0114] Figure 10 shows a perspective view of a part of a battery module with terminals 101 potted in structural potting layer 91 shown. The terminals 101 of the battery module are encapsulated in the structural potting layer for protection and stability.

[0115] Additionally, an anti-propagation layer may also be used for preventing the propagation from one cell to other cells in the case of a single cell venting in a thermal runaway event.

[0116] The electrically insulating anti-propagation layer may be the same part as the silicon potting layer, where the silicon is chosen to have a very high temperature resistance of more than 800 degC. A different material may also be used.

[0117] The anti-propagation layer remains in place due to being moulded around the other features of the module in the case that a single cell has a thermal runaway event. In this eventuality, the single cell punches through the silicon and connector sheet above it. Importantly, the hot gas which is emitted can escape above the assembly, and the antipropagation layer provides the vital function of protecting the other cells from the hot gas. This therefore prevents a propagation of the thermal runaway to other cells.

[0118] Figure 11 shows a perspective view of a battery module with terminals shown in position relative to battery cells. The terminals 101 are shown in relation to the battery cells, which are strategically placed for optimal current flow and accessibility.

[0119] Figure 12 shows a perspective view of the connector sheet placed on top of the battery cells and the terminals. The connection sheet 71 electrically links the cells 81 to the module’s output terminal 101.

[0120] Figure 13 shows a perspective view of a battery module enclosure, with the holes for retention pins visible. This figure highlights the retention pin holes on the battery module enclosure’s bottom face. These holes secure the module in place within its application.

[0121] Retention pins may be used for ensuring the potting compound and aluminium enclosure remain mechanically joined under harsh mechanical shock and vibration conditions in a wide array of temperatures. The retention pins are located within the aluminium enclosure protruding into the volume of the potting layer. The retention pins are made from aluminium or steel or stainless steel.

[0122] The retention pins may have a wide head to prevent the pins being pulled through the aluminium, and a series of features like a screw thread, encapsulated within the resin. These features mean that to pull the retention pin out of the structural potting layer, a shear force must be overcome within the potting material, greatly increasing the mechanical fixing strength between the structural potting layer and the aluminium enclosure.

[0123] Figure 14 shows a perspective view of a terminal shroud component, shown separately. The terminal shroud provides insulation and protection around the terminals. The shroud also helps with orientation and polarity identification. Figure 15 shows two battery cells 81, without the metallic annulus part added on top and with the annulus part 151 added on top.

[0124] The metallic annulus parts increase the possible weld area of the "negative rim" of a battery cell, which is typically challenging to weld to. These parts may be pre-welded to cylindrical cells in an offline process in advance of being assembled into the cell array in the battery module. If these parts are not present, then a conductive sheet can be welded on to the cell centre tab (positive terminal) with relative ease, but welding a conductive sheet on to the negative terminal is very challenging due to the very small target area for the weld. By prewedding on these metallic annulus parts, the target zone for welding a conductive sheet on to the negative rim from above increases from typically 0.2 to 0.8mm, up to greater than 3mm. This greatly reduces positioning tolerances required on the weld targeting machinery, the cell positioning, the control of the cell terminal shape and size. It also increases the possible cross-sectional area of the weld between the conductive sheet and the negative terminal to reduce electrical resistance.

[0125] The metallic annulus parts are located on top of the battery cells, concentric to the battery cell axis, and welded to the battery cell negative rim in an offline process. The metallic annulus parts are made of a conductive material such as copper, aluminium, nickel or steel. Any of these materials could be used in an alloy form and may be coated to aid welding performance.

[0126] The metallic annulus parts may be designed so that they can be spot welded on to the battery cells, due to the low cost and high controllability of spot-welding equipment. They may be designed so that the connection sheet can be blindly pulse arc welded, or spot welded, or laser welded onto the annulus from above the connection sheet when there is no access to the annulus part due to it being covered by the connection sheet at that point in the assembly.

[0127] The metallic annulus parts are made using a laser cutting process or stamping process in higher volumes. The parts are common to a wide variety of battery module variants so can be made from a high tooling process such as stamping. The metallic annulus parts have an outer diameter of the annulus the same or smaller than the outer diameter of the cell and the inner diameter larger than the outer diameter of the positive terminal of the cell so as not to cause a short circuit between the negative part of the cell and the positive central part of the cell.

[0128] The metallic annulus parts are typically between 0.1 and 0.5mm thick.

[0129] Figure 16 shows a cross section of a battery module showing the battery cells, resin 91, aluminium enclosure, lid, and terminal 101. (Silicon is not shown, retention pins are not visible). The cells are closely packed and uniformly spaced to ensure optimal thermal and electrical performance. The structural potting material surrounds each cell, providing mechanical stability and vibration protection, as well as additional insulation to prevent electrical and thermal interactions between cells.

[0130] Figure 17 shows an example of a multiple layer connection sheet (one layer is also possible in some cases), which allows for complex electrical configurations. It can also be simplified to a single layer. The connection sheet is located above the battery cells, and below the plastic lid.

[0131] The connection sheet provides electrical connections between the cells and the module electrical output terminals, where the electrical connection means comprises a shaped metal sheet which is welded to the battery cells directly on the positive terminal and via an interconnect disc (metallic annulus part) which is in turn welded to the battery cell for the negative connection.

[0132] The connection sheet is made of a conductive material such as copper, aluminium, nickel or steel. Any of these materials could be used in an alloy form and may be coated to aid welding performance. The connection sheet will also have isolated areas which do not contact the battery cells. This may be achieved with a precut sheet of an isolating sheet such as PET or polyimide.

[0133] The connection sheet is shaped so that it is in electrical contact with the battery cells (or their interconnect discs) in selected places so that the correct series and parallel configuration of cells is achieved electrically when the connection sheet is welded to the battery cells below. The connection sheet may also take many different shapes, such as L-shape or hexagon.

[0134] The connection sheet may be temporarily or permanently mounted to a non-conductive board material. This non-conductive board material may be a PCB with cell monitoring tracks on which lead to the cell monitoring connector.

[0135] The sheet is made by bonding the metallic sheet to a support board which may or may not be removed after the connection sheet is joined to the cells. This metallic sheet is then selectively removed via a machining process to leave the metallic sheet present in the correct areas, but in separate islands of sheet which will ultimately be at different voltages once the sheet is electrically connected to the cells.

[0136] The connection sheet is typically 0.1 to 0.5mm thick for the metallic sheet. The support material (which could be FR4) is typically between 0.5mm and 2mm thick.

[0137] Figure 18 shows an exploded view of the connection sheet comprising a four-layer structure designed to interface with the battery cells. The connection sheet includes from bottom to top: a bottom insulation sheet, a first metal layer (e.g. copper), a top insulation sheet and a second metal layer. The bottom insulation sheet is shaped such that the first metal layer does not short circuit any of the battery cells by electrically isolating it from unwanted contacts. The holes in the layers are aligned to match the placement of the battery cells. Specifically, for the case of cylindrical battery cells, the holes correspond to the positive terminal in the centre of the cells and the negative outer rim of the cells. The first metal layer interfaces with the outer rim of each cell, creating electrical contact only where desired. The second layer interfaces with the centre of the positive terminal. The consistent alignment ensures that welding is performed at predefined locations, allowing for a reliable process without variation. Manufacturing tabs can be used, which mechanically join the individual island of the connection sheet together, so that the sheet can be profiled and handled as a single sheet. These manufacturing tabs are then removed prior to installation in the battery so that the separate islands of the connection sheet are no longer electrically connected to each other. Figure 19 shows another close-up of the battery module including lid securing tabs 191. The lid securing tabs are folded parts of the housing wall of the battery module and are used for lid mounting purposes. These lid securing tabs can be used to support, and attach to a fiat profiled lid, such as a top plate covering the battery module.

[0138] Figure 20 shows another close-up of the battery' module including mounting points 201 secured to the bottom surface of the housing. These mounting points 221 can be part of a cold plate and allow for the battery module to be mounted directly onto another structure.

[0139] Additionally, the battery module may include a thermal interface material to transfer the heat from the cell bases to the aluminium enclosure, ensuring efficient thermal management.

[0140] The thermal interface material is a thin layer between the battery cell surface and the aluminium housing of the battery module. The thermal interface material may be a paste or pad which has thermally conductive properties of IW / mK or higher.

[0141] The thermal interface material is chosen to cure to a tacky substance which can tolerate some movement between the two interfaces it is thermally connecting. This means that if there is any relative movement due to mechanical loads of thermal expansion, the thermal interface and conductivity performance is unaffected.

[0142] The thermal interface material is trapped between the cell, the aluminium enclosure (and / or isolation layer) and encapsulated from all other sides by the structural potting layer, and therefore cannot move out of the position it has been placed in.

[0143] The thermal interface material is applied to the battery cells by means of dispensing equipment before the battery cells are placed inside the aluminium enclosure. Alternatively, it is applied as a pad to the aluminium enclosure in advance of the battery cells being placed into the enclosure. Alternatively, it is dispensed into the aluminium enclosure in advance of the cells being placed into the enclosure. It may also have selflevelling properties in the final assembly process. The thermal interface material is compressed to a layer thickness of 1mm or less as part of the battery module assembly process, between the battery cells and the aluminium enclosure, thus ensuring good thermal contact between the surfaces and the thermal interface material.

[0144] The thermal interface material is electrically isolating.

[0145] Additionally, the battery module may also have cell monitoring tracks for the purpose of electrically connecting the parallel cell groups to an output electrical connector or internal cell monitoring unit. This is for the purpose of cell voltage monitoring, and for balancing the cell voltages which is done by a cell monitoring unit.

[0146] The cell monitoring tracks are located on top of the connection sheet support board, which can be a PCB with the tracks on top, as with a standard PCB which has tracks present. These tracks can route to a single area where the outputs are provided to a cell monitoring unit or BMS which could be internal to the battery module or external.

[0147] The cell monitoring tracks are made using a standard PCB manufacturing and assembly process. It will also have the cell monitoring connector on the PCB either surface mounted or through hole mounted. For example, the cell monitoring tracks are made from copper tracks on an FR4 substrate. The cell monitoring tracks may also be individual wires, or a wiring harness, or a flexible PCB used for the same electrical connection purpose.

[0148] The battery module may also have a cell monitoring connector for the purpose of electrically connecting an external wiring harness or cell monitoring unit or BMS system to the battery module. This connector is internally connected to the individual cell groups (of cells connected in parallel) inside the battery module, via the cell monitoring tracks.

[0149] The cell monitoring connector along one edge of the aluminium enclosure in a "connection zone" which sits sub flush to the principal external faces of the module. This is so that once cables / connectors / wiring harnesses are connected to the cell monitoring connector, these parts do not protrude outside the principle faces of the battery module.

[0150] The cell monitoring connector is a standard surface mount or through hole mounted or bulkhead mounted electrical connector.

[0151] Additionally, the battery module may have a heating mat for the purpose of for heating the battery cells using an electrical current passing through a heat mat which can be turned on and off. This component is an optional additional part which some applications will require, and others will not. The battery module design is designed to be unaffected by the presence or lack of presence of the heating mat apart from the self- heating functionality it provides.

[0152] The heating mat is located on top of the electrical connector sheet. It may be an additional component or can be constructed by adding additional copper tracks to the PCB used for constructing the connector sheet, thus removing the need for an additional part to achieve this functionality.

[0153] Additionally, the battery module may have an external or internal cell monitoring unit for monitoring the voltages and temperature of the cells. This component may sit entirely elsewhere in the system, away from the battery module. It may also be fixed to the outside of the battery module. The cell monitoring unit may also be located inside the battery module with its own output connector presented to the outside of the battery module instead of the cell monitoring tracks, which would instead be connected to the cell monitoring unit internally.

[0154] Figure 21 shows a battery module including a plastic enclosure 211 located inside the structural housing. The plastic enclosure 211 is configured to hold a cell monitoring unit or BMS. The enclosure 211 can optionally be embedded in the structural potting layer or resin. A close-up view of the enclosure is shown in Figure 22. The BMS 221 can easily be inserted in or slotted into the plastic enclosure 211.

[0155] Additionally, the battery module may have an external or internal BMS including switch, current sense, protections for the purpose of for the purpose of controlling and monitoring the battery module, including calculating SOC, SOH, resistance, age, and other parameters of the battery module. This BMS may be external to the battery module or in some cases may be internal to the battery module and additionally include the cell monitoring unit functions within the BMS. In any case the BMS will sense the current flowing in or out of the battery module, it will also be able to switch on and off the output of the battery module or pack using a switch. This switch may be a MOSFET or similar on the BMS itself, or the switch may be an external relay or contactor.

[0156] Additionally, the battery module may have a master fuse for the purpose of arresting current flow in the event of an external short circuit applied to the battery module. This can be included by means of a locally smaller cross sectional area section within the connection sheet. This thin area may be of the same thickness of sheet, but just a reduced track width for a short section. This will then act as a fuse.

[0157] Additionally, the battery module may have “per cell” fusing where a fusing element is designed into the connection sheet. The purpose of this is to arrest current flow to a single cell in the case of an over current to or from a cell. This may occur in the case of a short circuit inside the battery module, or even inside one of the battery cells. Like the master fuse, this can be a part of the connection sheet which is deliberately designed to have a higher current density, such that in the event of current being too high when flowing through it, it will break the connection.

[0158] The battery module can have a variant, whereby the cells are instead a 46xx type cell. These cells have the “vent” on the opposite side of the cell to the terminals. If these cells are used in this battery module, they are used “upside down”. Many of the same approaches are employed to build the module, but the connection sheet is sandwiched between the cells and the base of the module. This allows the cell vents to point “up” within the module. This also has the advantage of applying cooling directly to the bus bars of the battery module.

[0159] Additionally, the battery module may have any suitable number of sensors, such as any combination of temperature sensors, strain sensors, pressure sensors, volatile organic compound (VOC) sensors, carbon monoxide (CO) sensors, carbon dioxide (CO2) sensors, smoke sensors, leak detectors, acceleration sensors, microelectromechanical systems (MEMS) sensors, voltage, heat and moisture detection sensors.

[0160] While previous examples have focused on rectangular housings, the battery module can be adaptable to any geometric shapes. Figure 23 shows a non-rectangular (hexagonal in this case) housing. Figure 24 shows a bottom view of the battery module comprising a hexagonal housing, with rivet nuts, such as M6 threaded rivet nuts, located at the bottom of the housing. The rivet nuts allow bolts to be used for mounting the battery module securely.

[0161] Appendix A: Additional features and configurations

[0162] Generative design platform and self-service portal

[0163] A self-service portal, powered by Al algorithms allows customers to optimise their own designs in real time, balancing performance, cost and lead time. Real-time calculations and checks give confidence in design performance and visibility on cost and time. The self-service portal online allows an end-user to fully understand a battery according to specific requirements all while having a clear view of impact on lead time and costs of every design decision. As an example, end-users can explore multiple design configurations and compare how each decision impacts lead time and / or costs.

[0164] Algorithms and machine learning models power design automation, cost analysis, and production planning, providing iterative improvements based on real-world data feedback. The system can adjust costs and lead time based on production metrics, material availability, and current operating conditions. The portal may be fed with all business metrics and operating environment conditions to inform its output to the customer. For example, the quoted sales price can be dependent on the latest component or material purchase pricing, the most up to date operating costs etc. The same goes for quoting lead times - the portal dynamically updates cost and lead times using live data on production rates, backlog and material availability. Further, predictive analytics can also be used to flag potential product details or material shortages. This portal may alternatively have the same or similar functionality but be used as an internal company tool. This allows engineers or sales team members to create designs to suit various applications quickly and then communicate the output of this to customers.

[0165] Integrated simulation tools for fluid, structural, electromechanical, and thermal analysis can also be used to validate the ML-generated designs. Users can therefore visualize simulations of Al-generated designs before their finalisation.

[0166] Customers can specify key features such as connectors, mounting features, and compatible BMS systems guided by manufacturing constraints.

[0167] Generative designs are used to generate and optimise the battery module design based on one or more of the following: performance, dimension constraints or operational constraints. The algorithms are configured to explore different cell configuration, cell arrangement, structural components to optimise the designs for volumetric efficiency, thermal management, or ease of assembly. Algorithms therefore incorporate a multiobjective algorithm that balances trade-offs among performance, cost, lead time or sustainability.

[0168] The Al-generated designs are customisable based on user-defined criteria including specific lead time, performance, shape, dimension, or development cost.

[0169] Battery design

[0170] A (set of) base battery product(s) are optimised for a flexible production line allowing custom shapes, mounting points, connection types, and more, with tuneable performance and weight.

[0171] The integrated battery module takes advantage of the build-in-place structure to fill all available space in the application context, and the weight optimised cell end immersion cooling to deliver the required performance for demanding applications. This combination of design features achieves a very space and mass efficient package.

[0172] Cells are arranged in an array designed to occupy the available space in the application volume. Utilising the ‘build-in-place’ technology, the cells are paced more densely than conventional approaches and accommodates a great number of cells within the same spatial constraints. Integrated mounting features are used to assemble and mount the modules into the application volume.

[0173] Cooling the end of a cell is an order of magnitude more effective than cooling the sides. By directly cooling the cells where it is most effective, we minimise the volume of dielectric fluid or coolant and optimise flow and pressure drop.

[0174] Figure 25 shows a diagram of a battery module. This configuration uses self-moulding foam that fills the volume between the cells and contributes to the overall structural integrity of the module. Low mass foam is used creating a strong composite structure that can be configured in any geometry. The battery module features a cooling system where dielectric oil flows through end cavities to cool the ends of the cells, which are identified as the most effective cooling surfaces of the cell. Coolant connectors are present at the top, allowing the coolant to enter the end cavities. The structure of the module is formed using solid GFP (Glass Fiber Polymer) or a similar material, which provides the necessary rigidity and allows for any module layout. The bus bars, which are directly cooled, are part of the electrical system that distributes power within the module. Flow guide rails are incorporated to optimize the direction of the coolant flow and to eliminate hotspots, ensuring uniform cooling across the module. The seal plate is fixed in place with a gasket seal against the module, ensuring a secure and leak-proof assembly. The module includes a cell monitoring unit, which is responsible for monitoring the voltage and temperature of the cells. Voltage monitoring and thermistors enter the sealed cavity through the seal plate, providing real-time data on the cell conditions. Finally, the mounting features are integrated into the structure, allowing the module to be mounted in any orientation, providing flexibility in installation. In summary, the diagram illustrates a battery module with an advanced cooling system, robust structural components, and integrated monitoring features, designed to ensure efficient operation and flexibility in various applications.

[0175] Using foam technology reduces both cost and lead time relative to current industry standards.

[0176] The production line can either use the outer ‘lid’ or ‘shell’ of the battery as the container inside which the cells and foam material are assembled, or we can have a large fixture tray / skate onto which different sized custom moulds can be attached to then be filled with cells and foam.

[0177] The production line can be automated because robots should be able to position cells and insert foam according to a digital design file and code.

[0178] The unit cost for prototypes may be quite like volume costs because the assembly process is basically the same, with some minor efficiency improvements for volume production. A single investment into an automated line can yield many different types of batteries, as opposed to having multiple lines each specific to a single design and being inflexible. Design files within the portal translates into all the necessary CNC programmes and digital code files which means the line can make a battery based on inputs to the portal, without any human input. This includes everything from materials planning, production scheduling, build, packaging, procurement and logistics.

[0179] Cell layout

[0180] Cells are arrayed horizontally, top-and-tail (or in other embodiments all facing the same direction); this maximises design freedom within the application volume to fit different cell layouts. This arrangement also simplifies connection to a cooling system where present (such as a manifold, pump, or external radiator) by presenting connectors together at one end of the application volume (for example all at top or all at bottom).

[0181] Battery structure

[0182] The ‘build-in-place’ battery structure approach is used, whereby cells are positioned according to the target layout and then the battery structure built around them using various production methods. This allows for complex geometries without investing in expensive tooling and readily supports rapid iterations and changes in configuration or layout.

[0183] The construction optimises for weight by using thin solid structures combined with lightweight structural foam, and removes the need for cell adhesive, plastic mouldings, cold-plates and other parts.

[0184] The approach minimises the overall size of the battery with very tight cell to cell spacing achieved by avoiding assembly tolerances and draft angles. Variable cell spacing is also possible to fit any geometry and allow freedom to change cell type and vendor.

[0185] End cooling

[0186] Our end-cooling directly cools the cells where it is most effective, minimising the volume of dielectric fluid and optimising flow and pressure drop. Cooling the bus bars further reduces weight and leads to higher output currents and better thermal management, ensuring optimal battery performance and longevity.

[0187] Our battery structure supports the cells and mounting features and also creates end cavities for the dielectric fluid to flow through. A benefit of cooling at the ends of the cells is that the bus bars are directly cooled allowing very high peak outputs, without putting heat into the cells. By keeping the bus bars and cells within temperature limits, higher output currents can be achieved.

[0188] Minimising pump size

[0189] Because the cavities are relatively unrestricted (though still flow guided), the pressure drop can be kept low while maintaining sufficient flow rate. This is important because it allows the pumping power (and therefore pump size and mass) to be minimised. Cooling only the ends of the cells also have the potential to reduce the volume (and therefore mass) of dielectric fluid in the battery.

[0190] Sealing and flow guides

[0191] The coolant cavity at the ends of the cells is closed and sealed with a plate which also supports monitoring PCBs and sensors. This seal plate is designed to support low tooling cost / time and high design flexibility. Flow guide features on the inside of the seal plate will be optimised to guide the coolant flow to promote temperature homogeneity.

[0192] Bus bars

[0193] Low tooling bus bar production (e.g. laser cutting or waterjet) can be used to maintain design freedom for the battery. Alternatively stamping and other techniques can be used. Draft angle

[0194] Figure 26 shows a diagram illustrating design considerations for a battery module, specifically focusing on the implications of using injection moulding for the module's casing.

[0195] The diagram highlights several key factors:

[0196] • Assembly tolerance: this refers to the permissible limits of variation in the dimensions of the assembled components. It ensures that the cells fit properly within the casing without excessive gaps or tightness. Assembly (of cells into carrier) requires tolerance, which may mean a loose fit and increased cell-cell spacing.

[0197] • Draft angle: The diagram shows the draft angle, which is a slight taper applied to the walls of the mould to facilitate the removal of the moulded part. This angle is necessary for injection moulding but introduces a loose fit between the cells and the casing, leading to increased spacing between the cells.

[0198] • Material thickness: Indicated by a dot, this refers to the thickness of the material used for the casing. The material thickness is a critical factor in determining the structural integrity and thermal management of the battery module.

[0199] • Injection moulding process: the use of injection moulding for the battery module casing introduces a draft angle, which affects the overall design. Specifically, for a casing with the same height as the battery cells, a draft angle of 0.5° will add 0.61mm to the spacing between cells. This increased spacing can reduce the overall volumetric efficiency (capacity) of the battery module by up to 5%.

[0200] Gravimetric density improvements

[0201] A reduction in cell spacing not only improves volumetric efficiency as illustrated in the section on cell spacing but also improves gravimetric efficiency by reducing the material between cells, and the overall envelope for a given capacity pack.

[0202] Volume of material used to fill the space in between cells: where h is cell height, d is cell diameter, and g is the gap between cells. The module’s weight is reduced by using only end cap immersion, plus package space is smaller, reducing the amount of material required to enclose it.

[0203] Alternative cooling or thermal management subsystem

[0204] • Immersion cooling of different areas of the cell; top, bottom, middle, or any combination of these.

[0205] • Cooling can be done via a cold plate which can either be liquid or air cooled. This can be positioned against the bottom of the cells. It can also be positioned in any location in the module, so it could be on the side of the cells / module or on top of the PCB.

[0206] • We can use resin to mould cavities in the module inside which immersion cooling fluid can flow to cool just certain controlled areas of the battery or cell(s). This can be connected to the vehicle’s cooling system or just have a standalone battery cooling circuit.

[0207] • Being able to form cooling channels using resin or foam in the module means that cooling can be optimised and changed over time. The connection ports can also be positioned in the most convenient places for the customer’s system.

[0208] • It may also be possible to move heat from one area of the battery to another, or even to another system in the vehicle.

[0209] • By designing cooling channels in the module, hot areas may also be used to boil the fluid and then let it condense on the cold plate and thereby recirculate without a pump.

[0210] • We can also position cooling pipes right up against the cell and then encapsulate them by using the resin or foam.

[0211] • Controlling the location of the immersion fluid in the module by forming pathways and reservoirs in the module with different media i.e. set foams and resins.

[0212] • Cells being orientated top and tail.

[0213] • The ability to cool both busbars and cell end caps directly where they are both generating heat.

[0214] Example of assembly process An example of a process for manufacturing a battery module, highlighting various stages is illustrated in Figures 27-28, such as:

[0215] • Using a flowable material to mechanically lock cells in place once the material becomes solid state. For example, resin, wax, foam or similar materials.

[0216] • Having a resin layer at both ends of the cell to provide a liquid seal and structure element at both ends of the cell. The thickness of this layer can be varied to tune strength and weight.

[0217] • The gap created between the two resin layers can be left vacant or infilled with another material i.e. foam or fluid (such as for cooling purposes). A ‘sandwich’ of layers of materials (i.e. resin or foam, dielectric fluid, resin or foam) can be designed to specifically control the flow of cooling fluids. One or more of the resin layers can either go beyond the end of the cell to create a void for dielectric fluid or for busbar housing or for thermal runaway gas escape, or the resin layer(s) can be sub flushed of the end of the cell to allow for cooling or for other mating features.

[0218] • Implementation of a ‘crown’ (or ‘cap’) which can be individually fitted to each cell and incorporates features both to hold and locate the weldable features but also aids the rotational and positional alignment of the cell relative to other cells by connecting to the PCB. Our cell crown design can accommodate a wide range of cylindrical cell manufacturers. In addition, it can be scaled to fit smaller or larger cylindrical cells. The cell crown design allows us to weld each cell individually and removes the need for accurate tooling or parts.

[0219] • The crown would retain both the negative and positive welding tabs.

[0220] • Tubing, sleeving, banding or rings (i.e. O-rings) can be added to the cells, or a portion of the cells, in order to control the spacing of the cells relative to each other and also to avoid short circuiting.

[0221] Welding onto the side of the cell and the positive terminal on an individual cell basis means we can avoid needing all cells to be positioned accurately in a module and then laser welding. This is costly and not easily repeatable or scalable. Welding can be via any process including laser, ultrasonic, spot, resistance. We may weld nickel, copper or nickel coated copper onto the side of the cell. • The positive connection can be a nickel strip (or other material) which is spot welded to the positive terminal of the cell which then pokes up through the underside of the PCB to be welded onto the PCB.

[0222] • The negative connection can be a strip of material welded to the side of the cell which also extends upwards to poke through a hole or slot into the PCB which can then be welded as desired to the PCB.

[0223] • We can automate the welding process for a given cell format as the installation of the crown and the welding process is always the same.

[0224] • Between the underside of the PCB and the top of the cell, we can flood this area with a material such as anti-propagation silicon or similar. This both acts to constrain the position of the cells and acts as an anti-propagation mechanism for battery safety.

[0225] • The PCB itself can be used as a functional lid of the module as well as a method of cooling.

[0226] Figure 29 shows an example of a cell crown, designed to interface with a battery cell and a printed circuit board (PCB). A central T nickel 291 is assembled to the plastic crown before it is attached to the cells. Welding holes 292 are provided for welding the central T nickel, ensuring a secure connection. An outrigger feature 293 extends to the edge of the cell where the nickel strip is held, providing structural support and alignment. A nickel strip attachment feature 294 allows the formed nickel strip to be attached to the plastic crown before assembly to the cell. It is designed to fit into the gap between neighbouring cells and allows access for welding the Nickel to the side of the cell. The Nickel strip 295 is welded to the side of the cell and needs to be held in position by the crown before welding. Clips 296 around the positive terminal securely and accurately position the crown on the cell, ensuring a stable connection. An interfacing feature 297 between crown and PCB positions the crown before the Nickel contacts the PCB. It includes a press-fit type feature, such as raised ribs, which press into the PCB to securely fix the cell. Vent holes 298 through the crown allow vent gases to escape if required, ensuring safety and functionality. A wider diameter flat section 299 allows the cell to rest against the PCB, positioning the cells perpendicular to the PCB for optimal alignment and stability. Other examples of a cell crown and manufacturing process are also provided in Figures

[0227] 30-31

[0228] Immersion Cooling

[0229] There are several ways of using immersion cooling for the battery cells. This can involve flowing a cooling fluid - of any type - over all or part of a specific surface, immersing the whole battery, or using any combination thereof. This can be applied at the top of the cell, bottom of cell or anywhere in between, including parts of the side surface.

[0230] Examples of types of immersion are:

[0231] - using the immersion fluid to take heat away from the cell and forming a thermal bridge between the cell and the cooling system.

[0232] - physically moving the heat away from the cell to another location within the system. This enables a physical relocation of heat, rather than relying on conduction of the fluid.

[0233] Immersion cooling can be advantageous for removing heat from the cell and transferring it to another location for dissipation. This is similar to using a cold plate but with less space. Additionally, immersion cooling allows for the bus bars to be directly immersed in fluid. And conventional method rarely addresses bus bar cooling effectively, but immersing the bus bars in dielectric fluid directly enables an efficient thermal management.

[0234] Another benefit of immersion cooling is that normally you have to insulate a cold plate from the bus bars or cells electrically. Dielectric fluid provides direct thermal connection without any electrical connection thanks to the dielectric insulating properties.

[0235] The most effective way of removing heat from a cell is on the end surface of the cell. This is because it is much more thermally conductive along its axis. However, this is challenging with traditional cold plates when the cells are alternating in direction between different cells. With a cold plate, to extract the heat out of the bottom of the cells, you need all of the cells to face the same direction. However, if all the cells are in the same direction, this makes it difficult to weld the electrical connection as the connection must be made on the thin rim of the cylindrical cells.

[0236] Another option includes the use of dielectric liquid that evaporates against the surface of a hot cell and condenses at a different location. This allows extremely rapid movement of heat from a cell to a cold plate. Alternatively, the system could use a condensing radiator rather than a cold plate.

[0237] Immersion cooling additionally has the benefit for thermal runaway because all of the release gases go straight to the dielectric liquid.

[0238] Due to our construction, we can selectively seal parts of the cell from other parts. This is useful because the amount of material used is minimised and the flow of immersion fluid can be controlled. This means the flow of fluid can be directed to certain areas of the cell that are more beneficial to cool than others, such as the lower end cap of the cell.

[0239] Several types of immersion fluids can be used, such as dielectric oils, caster oils, esters, alcohols, or any suitable material with suitable dielectric properties.

[0240] There is an additional benefit of cooling the busbars directly because this is where heat is produced, and by removing heat at the source (from the bus bars themselves), heat will not have to migrate into the battery cell and then be removed through a cold plate or something similar. This is particularly important because bus bars have a low thermal mass and high peak loads so can reach an increased temperature very quickly, thereby heating the battery cells. In addition, the weld between the busbar and the cell can also produce heat due to resistive losses and it is beneficial to cool this with an immersion fluid.

[0241] Assembly techniques

[0242] An important part of our assembly approach is that it allows a flow of material of some sort which could be a resin or a foam or something else, to be sealed around the cells at either end. This creates a space which the immersion fluid can flow through and cool just the end surface of the cells or the end surface and some of the sides of the cells. The centre part of the curved face of the cells is left exposed and this may be either encapsulated or left exposed. This construction method is a good way to reduce weight and hold structure in place and form cavities for the immersion fluid to flow through. A placeholder material can be used such as a wax or a similar material that is configured to melt at a low temperature. This is therefore used as a construction aid due to its low melting point, to form the cavities.

[0243] Additionally, compliant tool materials can be used to seal certain surfaces of the cell by pressing the surface into the compliant surface of the tool thereby masking that surface of the cell from any flowable material.

[0244] The materials used could be resins, silicones or foams and low temperature construction aids like wax.

[0245] The finished battery module may not require an additional external case. This is because the cells and the structural materials can be combined in a finished product. The assembly method may also incorporate any kind of mounting structural points, such as threaded part, a compression tube, a plastic tube or threaded bar that extends outwards for ease of mounting.

[0246] In summary the material that is cast achieves multiple functions: mechanical support, thermal management, fluid management and structural enclosure. It has some structural features that allow for the module to be mounted including electrical connections or support for electrical connections and it can include fluid connections. Additional inserts may also be embedded to provide extra features.

[0247] Electronics can be incorporated directly into the moulding, such as temperature sensors near the cells.

[0248] An aspect of the design is the sealed cavity or volume created within the battery module. This has the moulding on one side encapsulating the cells, and the busbars positioned inside the sealed volume. A sealant lid caps off the volume. That sealant plate / lid could also be a cold thermal plate, or it could be a plate with heatsink fins on it or it could be a plate with cooling channels in it. It could also be a non-thermally conductive part such as a plastic lid.

[0249] A PCB can be used as the sealing lid for this cavity. This PCB can simultaneously be the sealing lid and carry out other functions such as electrical connection from cell to cell or measurement of different voltages. It could also measure temperatures, and it could have a battery management system on it. It could have some thermal functions like pins and fins on it to guide the fluid. It could additionally have some safety functionality. For example, it could help an evacuation of gases by having certain areas of local weaknesses that allow the gases to break through if a cell goes into thermal runaway. It could also have liquid connectors mounted into it.

[0250] Manufacturing a PCB can be a highly automated process that does not require specialised tooling. The PCB can be customised from one module to the next, even if the module design and cell array remains the same. The PCB layout can be altered such that different voltages and electrical layouts can be achieved such as varying series and parallel connections. A benefit of this is that the PCB is simultaneously acting as the bus bars and as a lid of the sealed cavity.

[0251] The moulding process

[0252] The moulding process can use lots of different types of tools, including hard tooling or soft tooling. It can also be moulded directly inside of the battery casing. A pre-moulded battery case can also be used. This means that a mould would not be demoulded from the resin or foam, and essentially the tool stays with the part and it's consumable.

[0253] The tool may be a skin, a vacuum formed part, or a material applied to the inside of a tool, such as a spray coating. It could even be a thin film, metal stamping, a plastic injection moulded part, or a bent strip of metal where the metal is bent to the perimeter of the battery module.

[0254] Any of these approaches solve the issue of demoulding and releasing the products from a tool, because it never needs to be released. This approach also reduces process time, as there is no need to wait for the material to fully cure before proceeding to the next step. If we use an expanding material like a foam, it may be very difficult to remove from a tool. Using the final part as the tool effectively mitigates this issue and simplifies production.

[0255] Functionalising individual battery cells

[0256] We're functionalizing each cell on its own. This is making it ready to attach both mechanically and electrically and possibly even thermally to the bus bars or PCBs. The cells can then be stored in that state ready to go into a battery, even if that battery is not yet designed or chosen or ordered. The cells can start the production process in advance of a battery being ordered or even designed.

[0257] In addition, by functionalizing each cell to have a standard interface, it is possible to change cells very quickly within a battery product, even if the exact geometry of each cell is slightly different.

[0258] For example, you could switch from one manufacturer of a 21700 cell to a different manufacturer of that cell. Because the interface added offers a standard outward facing interface even for a slightly different design. Each different cell product has slightly different diameters or top cap geometries but can be made to have a common interface into the battery, thereby making it easy to switch cells.

[0259] One of the challenges of making lots of different types of battery with lots of different shapes is that it's different every time and can be difficult to configure machines and production processes in a reliable way.

[0260] A benefit of functionalizing each cell is that the difficult work such as welding and mechanically positioning the cell, with a separate part, is done at the cell level. This is achieved because the cell is common across different battery products.

[0261] By working at the cell level, cells can easily be arranged into different physical shapes depending on the battery product and application.

[0262] The approach of functionalizing each cell avoids requiring expensive revalidation when the cell manufacturer changes. The approach works similarly for any cell types such as both for 21700 cells and 18650 cells and all other types of cylindrical cells; as well as prismatic and pouch cells.

[0263] As discussed above, annulus parts or metallic strips are formed which may be nickel, steel, copper, aluminium or any alloys or other conductive materials. The formed strip may be welded to the top of the cell on the positive cap. This weld could be ultrasonic, or a resistance weld, or a solder joint or a laser weld. The benefit is that this strip can be chosen to be a material which welds readily to the cell can material, thereby reducing the process difficulties of welding to battery cells. The same approach can be used with prismatic and pouch cells, where a formed metal part is pre-welded to individual cells, in order to make battery assembly easier. With cylindrical cells, the metallic component (which may be a strip or formed strip, or stamped part, or folded strip) can also be welded to the side of the cell (the curved surface). This has the benefit of enabling an electrical connection to both positive and negative terminals of the cell at a single end of the cell via a bus bar or PCB above the cell (in the axis of the cell). A plastic part may be used to hold and position these metallic parts too for straightforward assembly on to the cell.

[0264] There are multiple sizes of cylindrical cells such as 21700 or 18650 (and many others including big ones such as 4680), but even between different cells of a fixed standard there are physical differences such as diameter or top cap geometry that make it difficult to change which cell you're using without also having to change something about the manufacturing process. This may be for example from the way cells are handled to the way cells are weld, or the exact fit of an injection moulded cell carrier, where a 0.1mm diameter change may have a large impact. Advantageously, the systems and methods described enable the cells to look identical to the manufacturing process, hence different cells can be chosen, and the methods are agnostic to the supplier used.

[0265] Use of a PCB and electrically connecting the cells

[0266] The PCB may be used to position the cells layout, with for example a plastic part doing a pre-positioning before using some kind of spike or film or other busbar connection which engages with the PCB. And then pressing the cells down, using the press into the PCB to form an electrical connection. Electrical connections may also be achieved by soldering on the top of the PCB or soldering on the bottom press fit or soldering on to a nickel part which is pre-welded on to the cell, such as a spring pin or a metal surface, or an electrical electrically conductive adhesive.

[0267] Submerging the cells

[0268] After the cells are positioned and (before or after) they are electrically connected, picking them up from the base is done using some kind of electromagnetic lifter or vacuum lifter. The cells are then moved to submerge them into a silicone layer or resin layer or foam layer. The silicone may be like a viscous liquid at this point. The benefit of submerging into a preformed pool is that the silicone only must flow a very short distance to get to its correct position. Rather than what is sometimes seen of trying to flow silicone into a tray with cells already present, where the silicone is too viscous to flow around the cells into the correct position before it is cured typically, with some kind of injection method or dispensing method.

[0269] This same technique of lowering cells into a preformed pool / bath / layer of a liquid material can be used with multiple types of material and alongside other techniques. For example, this same technique could be used to submerge cells into a molten wax layer, which one cooled, acts as a 3d masking part which masks part of the cells from a secondary layer of low viscosity material (such as a PU resin) which is flowed on top of the wax to form the structure of the battery. The wax can then be melted out.

[0270] Other methods may incorporate the silicone or a similar material, such as epoxy, polyurethane or other suitable polymer at a later stage. The material may have dielectric, non - electrically conductive, and provide anti-propagation properties in the case of thermal runaway of the cells.

[0271] Silicone offers additional properties: for example, it can be removed or displaced in the event of a thermal event, allowing some gases to escape, where a harder material may not yield under pressure buildup caused by gas expansion.

[0272] Silicone can also be enhanced with additive to make it thermally conductive. In scenarios involving thermal runaway and vents from the top, the gas can punch through the silicone, but then the other parts of the silicone will remain in place. Hence this ensures the silicone hasn't shattered and broken everywhere. It's just locally broken which means the silicone remains protecting the gaskets in the other cells which is the weak point from the hot gases and therefore stops propagation.

[0273] An additional benefit of using a casting material (silicon / resin / foam / other) effectively hermetically seals the cell which can prevent contamination and stop corrosion. If one cell has a problem it prevents this affecting other parts of the pack such as if there's a problem somewhere in the pack like water gets in or similar, you might otherwise have to scrap the whole battery whereas here if the silicone is intact then you know it hasn't been exposed to some of the reactive materials in expelled gases that could damage components, and so you can you can potentially still reuse some of those some of those other parts even if there's been a breach.

[0274] Once it's removed from the mould, in the process the cells can be flipped over such that we can begin the next stage of the assembly process.

[0275] When the parts of the final battery casing are present, the cells are lowed into the mould or casing / lid / tooling which has already has some foam or resin inside it. The cells are lowered in to allow the material to flow around the cells as opposed to injecting it around the cells and that ensures that the material flows evenly and fully around each cell. And effectively rigidly holds them in place as well. When foam is used, it can expand over time as the two parts react with each other and / or with the air. And then finally, the foam which almost entirely encapsulates the cells. This can be varied so that it's only acting on a certain area of the cells as opposed to encapsulating the whole thing. Once the foam has cured and the reaction has completed, the product can either be removed from the mould or retained within it. In the latter case, the mould formed can act as the casing around the cells, such as composite or plastic or metallic housing that acts as the lid of the battery module.

[0276] Assembly Process Continued

[0277] After these moulding processes and any finishing, the module is finished unless it needs some other kind of casing around it or protection on the top covering the PCB.

[0278] A foam block may also be put into a final casing or even whole foam block may have a casing vacuum formed around it as a process. Over moulding a battery

[0279] An over moulding process with the cells is a high-volume process for securing and encapsulating many parts and taking tolerances. This is ideally suited for holding battery cells of different formats. However existing over moulding processes involve too high pressures and temperatures for the battery cells.

[0280] The cells can be mechanically positioned in the correct location and then a flowable material to mechanically lock them in place is used. It's a flowable material that can flow initially and then stops flowing, such as resins and expanding foams.

[0281] Structural Battery

[0282] If the cells are prepared so that the cell surfaces are compatible with the adhesive property of the foam or resin, a strong mechanical connection between the cells or even a chemical bond between the foam and the cell casing can be achieved. This enables the cells to be firmly coupled to the foam, resulting in a robust structure. Further, this can produce a self-structural battery module, eliminating the need for external structure components.

[0283] Low pressure techniques can be employed because gravity can assist in controlling the placement of materials. The processes are built up in layers, such that we can have a thin layer for a thickness-controlled layer where the tooling is only on one side of that, and the top surface is formed under gravity rather than needing to have matched tooling to control both sides of it.

[0284] Immersion Design specifics

[0285] The immersion design has a resin layer at both ends of the cell. This provides a liquid seal and a structural element at both ends. We can vary the thickness of this layer to change the strength versus weight ratio. The gap between the two layers could be filled with something else or it could just be filled with a foam. Good mechanical properties are achieved because of the bond between the resin and the cells or the foam and the cells, as the structure of the cells contribute to the overall structure of the battery.

[0286] The same design may also be used for immersion cooling and non-immersion cooling where the only difference is that instead of flooding the void with a dielectric fluid, we fill it with a thermally conductive thermal interface material or a thermally conductive silicone and this allows the heat to move from the cells to the plate on the other side of the cavity.

[0287] This material may also have other additives to improve features, including fire propagation.

[0288] Premanufactured components can also be that integrated into the sandwich construction. These might be things like pre-moulded pieces of foam to reduce the amount of resin that we use, or things like intumescent materials for thermal runaway propagation reduction.

[0289] Cell cap / cell crown

[0290] Cell cap is a component which functionalizes cells. It has alignment features to the centre of the cell and rotational alignment of the cell. Some configurations have compliant plastic push pins or spring clips that align with holes slots linear or radial in the circuit board in the PCB or in a lid.

[0291] Other designs centre the cells using a bed of nails or cones where cones are at centre of a three-cell grouping in the triangle formed by the three circles of the cylindrical cells. The cones give you a lead in to help position the cells. These nails / rods / cones can be part of a jig or fixture which is used repeatedly or can be something which gets consumed into the product. It could have removable pins where pins get consumed into the product once cast. The pins could have parallel or tapered shape for lead in purposes. Another benefit of removable pins is that there could be a static piece of tooling with many locations which the pins are placed in to selectively depending on the desired cell array. Several designs have been explored, including an assembly aid and alignment fixture with circular apertures for the cells. The circles may be so close together that they break into each other, thereby making little concave triangles, enabling the positioning or alignment of the cell into an array with closely controlled centres. The gaps between the battery cells can therefore be controlled so that the material flows through in the right places.

[0292] The cells may be arranged as a hexagonal array. A crystal lattice may also be used with hexagonally packed areas including dislocations in between or circles. Different shape arrays including regular and irregular arrays can be used.

[0293] Battery Cell sleeving

[0294] The battery cells often come in shrink wrapped plastic to help with handling and to reduce the chance of electrical shorts. However, it could be desirable to remove some or all of that shrink wrap. Complete removal can facilitate enhanced thermal connections with the cells, improved mechanical connections, and more effective electrical connections by exposing the bare metal of the cells.

[0295] Cells are often shrink wrapped to help with handling and reduce likelihood of short circuits. However, it can be advantageous for our processes to remove this wrapping. Doing this allows for better mechanical and thermal connections to the cell.

[0296] One design uses a hoop feature, or wrap, or similar component positioned partway up the cell. This is to prevent the cell from making electrical contact with its neighbour cell in case of angular misalignment within the array. This angular misalignment may occur during assembly due to movement of the array or bowing of the array when it is lifted for example.

[0297] The hoop can be created with shrink wrap or heat shrink, a filament, an O ring, or a sheet of material placed between or around the cells. This could be applied across the entire array or individually to each cell. The purpose is to keep the cells apart from each other, providing space for the over moulding material or resin to fill. Additionally, this design ensures that the cells remain electrically isolated from one another. There might be cases where that material could be an electrical connection as well if the cells need to be connected in parallel.

[0298] The hoop may also be a gauze of net type material which provides a defined minimum thickness separation between cells but leaves a lot of surfaces exposed. This is useful to allow the over moulding material plenty of surface on the cell to adhere to. This is particularly useful with an expanding foam which has stronger adhesion properties earlier in the curing process, and so it is important to achieve a strong bond to the cell at the fill level of the foam in its unexpanded state, and it may be necessary to have the separator hoop at that same level. The gauze / net allows these two features to be present at the same height on the cell.

[0299] Another advantage of using a gauze or net type separator around the cell perimeter is that once the casting material nits into this gauze it forms a very strong hoop structure bonded to the cell like a composite or fiberglass.

[0300] There is a design for a laser cut sheet of electrically conductive material, which has all of the features to connect the cells up but has some bridges between all separate “voltage sections”, which will eventually be separate. This single piece sheet is assembled onto a PCB. And then we can later cut or machine away the connections that are not required, this avoids having lots of separate parts that need to be assembled onto the PCB.

[0301] Welding (or electrically connecting to) both positive and negative terminals at one end of a cylindrical cell is important for several reasons. The following is a selection of designs to enable this:

[0302] • Compliant pins perhaps present on the PCB above the cells which touch down on to the cells.

[0303] • Compliant pins are pre welded to the cells individually which touch on to the PCB when brought together.

[0304] • Above two options repeated but with spring pin components instead of compliant pins.

[0305] • Some kind of clip, with wishes metallic pressing down one end of the cell to form a connection • A set of several cells with potentially a metallic strip welded onto the side of them connecting them in parallel

[0306] Arranging Cells and benefits of casting process

[0307] There is a design of loading battery cells into a tool where the tool is orientated on its side. The cells are positioned horizontally, such that the axis of each cell is horizontal. Gravity is then used to help the cells fill into a tool or mould, in a close-packed array, which can accommodate unusual or non-regular shapes.

[0308] The current state of the art for mechanically holding cylindrical cells in the correct position within a battery typically involves a plastic injection moulded cell carrier. This solution requires a very complex and expensive piece of tooling, with high precision tolerances. These carriers have circular openings or features to hold the battery cells. This approach has some limitations:

[0309] • material wall thickness: injection moulding requires a minimum material thickness which creates gaps between adjacent cells.

[0310] • draft angles: draft angles are included, which further increases cell spacing.

[0311] • Assembly tolerances: additional tolerances are required for the assembly process, including oversize allowances for cell dimensional variations and part precision limitation.

[0312] Our process overcomes these limitations and achieve significantly closer cell to cell spacing. To prevent the cells from touching, (though we might choose for them to be touching), we lock them in place with overloading or casting processes. These casting processes don't have minimum material thicknesses, they don't have draft angles, and they don't have assembly tolerance. This means we can reduce the gap between cells and pack more battery cells into the same space and reduce the material used to hold it all together.

[0313] The proposed process allows for the creation of non-regular shape, without incurring the cost of an injection moulding tool each time a design is altered. By bonding the cells directly to one another via the over moulding or casting material, the resulting product is also stronger. This reduces the need for additional structural components, leading to further material savings.

[0314] Benefits of Any Shape

[0315] Unlike conventional off the shelf solutions, which are often limited to standardised rectangular or square formats, the methods disclosed enable the creation of custom battery shapes tailored to fit specific space constraints, aesthetic requirements as well as performance parameters for a given application. This is advantageous for many applications including E motorcycles, scooters, quad bikes, drones or UAVs. This is particularly advantageous in the case of for example electric motorbikes where maintaining a desired styling is important.

[0316] A key aspect involves encasing the battery cells within structural material, such as foam, resin, or other rigid substance. Using such structural materials for encapsulating the battery cells reduces or eliminate the need for additional structural supports. The structural material serves also as a protective enclosure, offering functionalities, such as crash resistance, penetration protection, and compliance with ingress protection (IP) ratings.

[0317] Advantageously, the structural material can be shaped to resemble a final desired shape of the product itself. For instance, in the case of a motorbike, we can mould the foam to look like the A surface of some of the bike and then either apply a composite shell over the top or a thermoform plastic or anything similar to provide the final appearance as opposed to having to build structure on top of the foam or cast material of the battery. We can just wrap the skin or enclosure around it, providing that the necessary protection the application needs is given.

[0318] Benefits as a high-volume process

[0319] Many of the high value high-volume, low-cost battery packs in use today have cells arranged in an alternating axial orientation configuration between voltage groups). The battery packs are also spot welded, use some nickel or copper nickel busbar strip, and a plastic cell carrier.

[0320] • That means these don't give you thermal runaway protection which is necessary for higher energy cell densities and or larger energy storage e.g. above 2kWh. • They don't give you cell cooling, which limits performance.

[0321] • They don't minimise the cell-to-cell gap which is a detriment to volumetric density.

[0322] • They don't minimise the weight.

[0323] • They don't use a low weight skin as well; they often use a structural housing.

[0324] The process described improves on current methods in various ways and can be used at high volume as well as low volume.

[0325] Using this casting process, current E-bike batteries could be replaced with the system described, providing a high-volume, low-cost way of producing batteries with significantly enhanced performance metrics.

[0326] In conventional battery designs, the individual cells do not contribute to the structural integrity of the battery assembly. The cell arrays often get loaded into a plastic injection moulded housing or an aluminium extrusion. The housing then provides the necessary structural support, environmental and mounting capabilities for the battery system. This approach introduces additional manufacturing step and increases material needed.

[0327] A process is provided that eliminates the need for eternal housing or structural enclosures by integrating the structural and protective functions directly in the battery design.

[0328] The process can also produce a battery system that is not only functional but also aesthetically nice. The manufacturing process can also be augment with in-mould surface treatment, such as inlaid foil, gel coat or additives colouring to achieve a desired visual and tactile appearance. This eliminates the need for separate housing or shrouds to enhance the product’s appearance, allowing the final product to meet functional and design requirements.

[0329] Figure 32 shows a flowchart that outlines process steps and their associated benefits for a specific design.

[0330] The purpose of this flowchart is to look at what process steps give you what benefits for a particular design that we looked at. The key things identified where the welding at one end is important, and welding without an XY gantry onto the tops of the cells was important.

[0331] This allows us to use base cooling of the cell, providing a better cooling performance than many uncooled batteries.

[0332] Welding at one end allows a lift and dip process in which an array of cells is submerged into an already dispensed bath of flow material, which minimises the flow distance and provides an even spread of flow material.

[0333] This allows you to use a much wider array of a much wider set of dispensable materials, rather than having to rather than requiring a very low viscosity to allow flow, which might limit you in other ways. Having this wide variety of materials allows different sandwich constructions and allows small gaps and allows low mass and allows simple construction.

[0334] The welding process at one end ensures that all top caps of the cells are oriented in the same direction. An anti-propagation layer can be applied to this end, such as the silicon we've described.

[0335] Alternatively, materials such as a mica sheet can be pressed onto the top of the cells to achieve similar anti-propagation functionality. The anti-propagation solution can then be managed separately to the cooling solution applied to the other end of the cells.

[0336] This means you can use higher energy cells while maintaining high safety standard because there is no requirement to adopt a higher stability lower energy density cell, such as LFP, to address safety concerts.

[0337] However, welding at one end is difficult. Currently, if you are trying to weld onto the negative rim of the top of the cell, and particularly if you don't know the precise position of that negative rim to within less than 0.1mm or 0.2mm.

[0338] This is very challenging to do. If you can weld onto the cell, per cell, in advance of assembling into the battery right then this makes it easier. Functionalising each individual cell not only simplifies welding but facilitates easier cell replacement and swapping during assembly.

[0339] Further functionalizing the cells can be done offline, prior to module production. This decouples the cell welding from the module assembly, allowing cell welding to continue uninterrupted in the event of a production delay. This is very important because the cell welding, due to the number of welds and the number of cells, is often the slowest part of production. Additionally, using a printed circuit board (PCT) as a connector provides further advantages. High precision PCBs can be procured quickly, at low cost and with very good tolerances, significantly improving development time and accelerating the overall process.

[0340] Different cell format and sizes

[0341] Throughout this document different sizes of cylindrical cells have been discussed but the same considerations and solutions exist for pouch cells and prismatic cells. While some techniques may be adapted, the underlying principles and the many benefits remain consistent across all cell formats and sizes.

[0342] A benefit is that various layers or sandwiches can hold a strain between the cells for prismatic cells or pouch cells which is important for maintaining cell lifetime. This also enables a controlled application of pressure to the cells as they expand over their operational life. The layers between cells can be chosen to allow a certain expansion, while maintaining even resistance across cell surface.

[0343] As compared to pre-moulded components or rigid interlayers that may result in pressure hotspots due to the fixed shape, the layers used ensure a much more uniform of pressure across the cells. This pressure management is essential for long-term cell performance and stability.

[0344] Further, multiple types of cells can be used, as well as different sizes of cylindrical cells within a single design.

[0345] Additional benefits of a PCB as an interconnect layer The use of a PCB enables more complex routing, as compared to a simple, one layer sheet, where you can't cross over busbars without making the part more complex. With a PCB, electrical routes can be crossed over.

[0346] The use of a PCB also enables the precise control of impedance and other electrical properties. Unlike traditional methods using separate nickel strips, bus bars or similar components which add assembly costs and constrain designs to straight-line connections, PCBs eliminate these limitations. Routing on a PCB is essentially a graphic process, allowing for complex shapes without additional manufacturing effort. This enables electrical connections to be optimised for functionality, irrespective of the physical shape of the cell array and the module.

[0347] A reason why off the shelf battery modules are typically rectangular or square blocks is because the width of the block is governed by the number in parallel and the length of the block is governed by the number of cells in series. This approach often leads to a rigid, block-like structure where cells are connected using nickel strips or stamped components of straight-line patterns.

[0348] In contrast, the process described eliminate these constraints. Complex and customised routing is achieved using PCBs, allowing for non-standard geometries while maintaining efficient and precise connections, and without introducing additional complexity in manufacturing.

[0349] Appendix B: Key Features

[0350] We list high level features, each with a number of optional features.

[0351] Note that any of the high-level features can be combined with one or more of the other features, and any of the optional features. Any of the optional features can be combined with one or more of the other optional features.

[0352] Key feature A. Battery module including structural potting layer that self-moulds around the cells

[0353] A battery module comprising: a housing and multiple battery cells positioned within the housing, wherein the housing is manufactured by profiling and folding metal sheets; and a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and maintains mechanical strength across a wide temperature range, such as approximately from -40°C to 75°C, providing both mechanical stability and thermal isolation.

[0354] This process supports the flexible layout of cells, enabling the production of battery modules with varied configurations without requiring distinct production lines or tooling changes. The system is designed to be adaptable to multiple cell types, including cylindrical, prismatic, and pouch cells, and can accommodate different shapes and orientations without requiring tooling changes. This flexibility extends to various battery chemistries, including lithium-ion, NMC, LFP, sodium-ion, and nextgeneration chemistries like solid-state and lithium-sulphur, ensuring that the battery module or pack can evolve with advancements in battery technology without significant structural modifications.

[0355] Key feature B. Battery module including structural potting layer and a silicon top layer that is designed to be deliberately weak in response to a specific event

[0356] A battery module comprising: a housing and multiple battery cells positioned within the housing; a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and provides both mechanical stability and thermal isolation; and a silicon top layer for covering the battery cells, wherein the silicon top layer is designed to deliberately weaken or rupture in response to a specific localised event, such as a localised explosion or venting of a cell.

[0357] This provides a unique safety mechanism using a silicon top layer that is designed to remain intact or stable during normal operating conditions but is also designed to weaken or rupture during specific localised events. This localised rupture for example over an exploding cell reduces impact of failure, minimises the risk of additional cells in the battery entering a thermal runaway state, and improves overall safety.

[0358] Key feature C. Use of a metallic annulus parts with battery cells arranged in a single orientation

[0359] A battery module comprising: a housing and multiple battery cells positioned or aligned in a single orientation / direction within the housing, each battery cell having a positive terminal and a negative terminal; a metallic annulus part welded onto the negative terminal rim of each battery cell, wherein the metallic annulus part has an outer diameter equal to or smaller than the cell’s outer diameter, and an inner diameter larger than the cell’s positive terminal; and a connection sheet electrically connecting the battery cells to the metallic annulus parts.

[0360] By reducing tolerances for welding, this design ensures reliable and efficient electrical connections, improving the overall performance of the battery module or pack. Further, the consistency of cell orientation facilitates uniform cooling and energy distribution. By increasing the weld target area, electrical connections in high-density cell arrays are easily achieved. The overall manufacturing process is simplified.

[0361] Key feature D. Cold plate formed as part of the battery module

[0362] A battery module comprising: a housing and multiple battery cells positioned within the housing, wherein the housing is manufactured by profiling and folding metal sheets; a metal sheet bonded or welded to the base of the housing and forming an integrated cold plate; and a liquid coolant flow path defined between the metal sheet and the base of the housing; wherein the flow path is configured to circulate coolant and manage the thermal load of the battery cells.

[0363] Advantageously, the metal or aluminium sheet serves as both the bottom enclosure of the housing and the top plate of the cold plate, eliminating the need for a separate cold plate component. Hence, the number of components in the battery module assembly is reduced, providing a lightweight, compact and thermally efficient battery design. Further, the metal sheet also provides structural reinforcement to the housing.

[0364] Key feature E. Battery module with single orientation battery cells, laser-cut housing and connection sheet and a structural potting layer.

[0365] A battery module comprising: a housing made a metal enclosure manufactured by profiling and folding metal sheets; cylindrical battery cells arranged in a single orientation within the housing; a connection sheet positioned on top of the cylindrical battery cells to electrically interconnect the cells; and a structural potting layer that encapsulates the battery cells within the housing, wherein the potting layer self-moulds around the battery cells and provides both mechanical stability and thermal isolation.

[0366] Key feature F. Battery module with single orientation battery cells, laser-cut housing and connection sheet comprising two insulation sheets and two metal layers.

[0367] A battery module comprising: a housing made a metal enclosure manufactured by profiling and folding metal sheets; cylindrical battery cells arranged in a single orientation within the housing; a connection sheet positioned on top of the cylindrical battery cells to electrically interconnect the cells, wherein the connection sheet comprises a first insulation sheet, a first metal layer, a second insulation sheet and a second metal layer, arranged sequentially in four layers, wherein the first metal layer interfaces with the positive terminals of the battery cells, wherein the second metal layer interfaces with the negative terminals of the battery cells, wherein the insulation sheets are shaped to prevent short circuits, and wherein the connection sheet is welded to the battery cells at predefined positions.

[0368] Laser-cut metal or aluminium sheets ensure precision and compatibility with automated manufacturing systems, reducing material waste and ensuring a compact, uniform design.

[0369] Optional features:

[0370] Housing

[0371] • housing is made from an aluminium enclosure.

[0372] • housing is manufactured using laser-cut aluminium sheets, joined by welding or rivets.

[0373] Structural potting layer

[0374] • potting material is made from a lightweight, high-temperature-resistant material that starts as a liquid and cures to a flexible isolating layer.

[0375] • potting material has a curing time under 20 minutes.

[0376] • potting material is a low-viscosity resin.

[0377] • potting material is a slow setting polyurethane casting resin.

[0378] • potting material is one of: polyurethane, or silicon or epoxy.

[0379] • potting material is a self-foaming material.

[0380] • potting material, when cured, maintains mechanical strength across a temperature ranging from -40 to 75 °C.

[0381] • potting material includes a silicon top layer for covering the top surface of the cells.

[0382] • potting layer, when cured, has a minimum thickness of approximately 5 mm but does not exceed the height of the enclosed cell.

[0383] • potting material incorporates shock-absorbing additives to enhance impact resistance under extreme mechanical vibrations.

[0384] Silicon top layer • silicon top layer has a thickness ranging from 0.5 mm to 4 mm.

[0385] • silicone top layer is designed to remain intact during normal operation but deliberately weaken or rupture in a controlled manner, in response to a specific localised event, such as a localised explosion or venting of a cell, thereby reducing the risk of propagation or pressure buildup.

[0386] Single orientation and array management

[0387] • cells are arranged as an array in a single orientation, wherein the single orientation ensures consistent heat dissipation across all cells.

[0388] • connection sheets are pre-designed to align with the single-orientation layout.

[0389] • connection sheet integrated directly with the metallic annulus parts.

[0390] • single orientation supports a modular assembly, enabling the array to be easily scaled or reconfigured for different voltage or capacity requirements.

[0391] • single orientation arrays are connected either in series or parallel with minimal changes to the design of electrical connections.

[0392] Annulus

[0393] • metallic annulus parts are attached to the negative terminal rims of the cells.

[0394] • metallic annulus parts are located on top of the cells, concentric to the battery cell axis, and pre-welded to the cell’s negative terminal rim.

[0395] • metallic annulus is made of conductive material such as copper, aluminium, nickel, steel, or alloys.

[0396] • annulus design integrates seamlessly with the thermal management subsystem for uniform cooling.

[0397] • metallic annulus is designed for compatibility with spot welding, pulse arc welding, or laser welding, allowing conductive sheets to be welded to the annulus from above during assembly.

[0398] • metallic annulus parts have an outer diameter equal to or smaller than the outer diameter of the cell, and an inner diameter larger than the positive terminal to prevent short circuits between the cells negative and positive terminals.

[0399] • metallic annulus parts are between 0.1 and 0.5 mm thick.

[0400] • metallic annulus part features surface coatings to improve weldability and reduce contact resistance, such as nickel or graphite. • metallic annulus part includes micro-texture or groves to enhance mechanical bonding with the connection sheet.

[0401] Integrated cooling / thermal management subsystem

[0402] • thermal management subsystem is configured to ensure uniform heat transfer and even distribution of heat generated by the cells.

[0403] • thermal management subsystem comprises serpentine-shaped cooling pipes bonded or affixed to the external surface of the battery module housing.

[0404] • cooling pipes are made from thermally conductive materials, selected from copper, aluminium or alloys.

[0405] • cooling pipes include intake and outlet ends, each equipped with fluid connectors to facilitate the connection of fluid delivery systems.

[0406] • cooling pipes are formed between a metal plate and the base of the housing and attached via welding or bonding.

[0407] • cooling pipes are welded onto the underside of the housing.

[0408] • cold plate and the base of the housing forms a single component.

[0409] • cooling pipes are designed to match the single orientation of the cells.

[0410] • thermal management subsystem includes a thermal interface material disposed between the cells and the enclosure to enhance thermal conductivity.

[0411] • thermal management subsystem includes phase-change materials.

[0412] Heating mat

[0413] • thermal management subsystem includes a heating mat for warming the cells by passing an electrical current through the mat.

[0414] • the heating mat is constructed by adding copper tracks to a PCB used for the connection sheet.

[0415] Isolation layer

[0416] • battery module includes an isolation layer positioned between the battery cells and the enclosure, providing electrical isolation.

[0417] • isolation layer is a thin layer located between the base of the battery cells and adjacent to the surface of the housing. • isolation layer is made from highly electrically insulating materials, such as polyimide, PET, or alternative coatings such as epoxy coating or powder coatings.

[0418] • isolation layer is formed through surface treatments of the aluminium enclosure, including anodizing.

[0419] • isolation layer has a thickness of less than 0.5 mm.

[0420] Thermal interface material

[0421] • battery module includes a thermal interface material positioned between the base surface of the cells to the housing wall, configured to thermally connect the cells to the housing for heat dissipation.

[0422] • thermal interface material is a thin layer between the battery cell surface and the housing.

[0423] • thermal interface material is selected from pastes or pads with thermally conductive properties of IW / mK or higher.

[0424] • thermal interface material is designed to cure into a tacky substance capable of tolerating relative movement between the connected interfaces caused by mechanical loads or thermal expansion.

[0425] • thermal interface material is confined between the cells, the housing and / or isolation layer, and the structural potting layer, preventing it from shifting during operation.

[0426] • thermal interface material is compressed to a layer thickness of 1 mm or less.

[0427] • thermal interface is electrically insulating to at least 2kV / mm.

[0428] Cell

[0429] • cells are arranged as an array.

[0430] • cells are arranged in a close-paced hexagonal array.

[0431] • cells are pre-oriented using automated placement mechanisms.

[0432] • minimum separation between the cells is approximately 0.5 mm.

[0433] • minimum separation between the cells is approximately 0.8 mm.

[0434] • system is adaptable to multiple cell types, including cylindrical, prismatic, and pouch cells.

[0435] • system is adaptable to different shapes and orientation without requiring tooling changes. • various battery chemistries are supported, including lithium-ion, NMC, LFP, sodium-ion, solid-state and lithium sulphur or any next-generation chemistries.

[0436] • battery module also supports the use of 46xx-type cells, with the cells positioned upside down to direct vents upward.

[0437] • when 46xx-type cells are used, the connection sheet is positioned at the housing base, enabling direct cooling of the bus bars.

[0438] Anti-propagation layer

[0439] • an anti-propagation layer is positioned between cells to localise and contain any thermal runaway events.

[0440] • anti-propagation layer has a variable thickness between 0.5mm and 4mm.

[0441] • anti-propagation layer is composed of thermally and electrically insulating materials to maximise safety.

[0442] • anti-propagation layer is configured to prevent the spread of overheating from one cell to adjacent cells, significantly enhancing the battery module.

[0443] • anti-propagation is made from high-temperature-resistant materials, with a tolerance of more than 800°C.

[0444] • anti-propagation layer is integrated with the silicon potting layer, serving dual purposes of encapsulation and thermal containment.

[0445] • anti-propagation layer includes embedded sensors to detect and isolate overheating events in real-time.

[0446] Connection sheet

[0447] • battery module includes a connection sheet for connecting the battery cells to the output terminals.

[0448] • connection sheet is shaped to make selective electrical contact with the battery cells, enabling a desired series and parallel cell configurations.

[0449] • connection sheet includes isolated areas where electrical contact with the cells is avoided.

[0450] • connection sheet is mounted on a non-conductive support board.

[0451] • connection sheet has a thickness of approximately 0.1 to 0.6 mm.

[0452] • support board has a thickness of approximately 0.2 to 2 mm. Cell monitoring unit

[0453] • support board is a printed circuit board with integrated cell monitoring tracks leading to a cell monitoring unit.

[0454] • battery module includes an external or internal cell monitoring unit is configured to track voltages and temperature of the cells.

[0455] • the cell monitoring tracks facilitate cell voltage monitoring and voltage balancing via a cell monitoring unit.

[0456] • monitoring tracks include redundancy features to ensure uninterrupted performance in case of track damage.

[0457] • the cell monitoring tracks are composed of copper on an FR4 substrate.

[0458] • cell monitoring tracks provide outputs for connection to a cell monitoring unit or battery management system (BMS), which may be internal or external to the battery module.

[0459] • battery module includes an external or internal BMS for controlling and monitoring functions such as state of charge (SOC), state of heath (SOH), resistance, and aging.

[0460] • the BMS includes a switch and current sensing mechanisms to manage the flow of current and protect against specific conditions, such as over current, over charge, over voltage, over temperature and under voltage.

[0461] • battery module includes sensors for monitoring temperature, strain, pressure, volatile organic compounds (VOCs), carbon monoxide (CO), carbon dioxide (CO2), smoke, leaks, acceleration, voltage, heat, and moisture.

[0462] Output terminals

[0463] • two output terminals provide electrical connections to external components, such as other battery modules or a load.

[0464] • the output terminals are located along one edge of the housing, and do not protrude beyond the external surfaces of the battery module.

[0465] • a terminal shroud defines a connection zone around the output terminals and cell monitoring connectors.

[0466] • terminal shroud is made of electrically insulating plastic material, which can be manufactured through 3D printing or injection moulding processes.

[0467] Retention pins • retention pins are embedded within the potting material to ensure mechanical stability under conditions of mechanical shock and vibration.

[0468] • retention pins are made of aluminium, steel, or stainless steel, providing strength and durability in a wide range of operation conditions.

[0469] • the retention pins are positioned within the housing, protruding into the volume of the structural potting layer to mechanically join the potting layer and the housing.

[0470] • each retention pin includes a wide head to prevent pull-through from the housing during operation.

[0471] • the retention pins are equipped with features, such as screw threads or other surface modifications, which are encapsulated within the potting layer.

[0472] • the retention pins are designed to maintain the mechanical integrity of the battery module under harsh mechanical shock and vibration conditions, across a wide temperature range.

[0473] Customisation

[0474] • battery module includes tags, such as RFID or NFC tags for traceability during manufacturing or maintenance.

[0475] • customisable based on one or more of the following: weight, dimensions, voltage, capacity, and energy density requirements.

[0476] • a battery pack including multiple battery modules as defined above.

[0477] Use cases

[0478] • A vehicle, such as a motorbike, drone, aircraft, car, boat, watercraft, off-highway vehicle, forklift including a battery module as defined above.

[0479] • A robot including a battery module as defined above.

[0480] • Go kart, AGV, jet ski, industrial machine, portable power supply, electric vehicle charging system, ground support vehicle, defence equipment, defence vehicles, all- terrain vehicle, scooter, electrified mobility product.

[0481] Method of manufacturing

[0482] Method of manufacturing a battery module, comprising automated cell placement mechanism configured to arrange cells within a mould or piece of tooling according to a digital layout file that specifies cell positions for optimized spatial usage. Method of manufacturing a battery module, the method comprising the steps of making an aluminium enclosure from a profiled aluminium sheet; placing cells within the enclosure based a digital layout file that specifies the cell positions; and pouring around the cells a liquid that is configured to cure and become a structural potting layer securing the battery cells in place within the enclosure.

[0483] Method of designing the battery module above based on specified performance and dimension constraints, comprising selecting battery cell chemistries and configurations to optimise the energy output per unit weight, and providing a digital layout file to define the battery cells positioning with a housing of specific dimensions.

[0484] Method of designing the battery module above based on specific operational parameters, comprising determining the target capacity, energy density, weight and dimensions based on the specific operational parameters, selecting battery cell chemistries and configurations to optimise the energy output per unit weight, and providing a digital layout file to define the battery cells positioning with a housing of specific dimensions.

[0485] Optional features

[0486] • aluminium sheet is folded and joined to make the housing / aluminium enclosure based on a required weight and / or space constraints.

[0487] • joining of the folded aluminium sheet is achieved using welding or rivets.

[0488] • cells are positioned using a single orientation.

[0489] • cell arrangement is optimised to utilise a specific available volume.

[0490] • cell arrangement can be reconfigured in series or parallel, using a modular connection sheet adaptable to varying configurations, wherein the voltage requirement is independent of the module dimensions.

[0491] • potting material is tailored based on application-specific requirements, such as curing time, or temperature tolerance.

[0492] • a thermal interface material is applied onto the battery cells before the placement into the housing or applied as a pre-formed pad to the housing prior to the cell placement or applied directly into the housing before the cell placement.

[0493] • metallic annulus parts are attached to the negative terminal rims of the cells. • metallic annulus parts are made using laser cutting or stamping.

[0494] • a silicon top layer is incorporated that is designed to rupture under localized pressure or thermal runaway events.

[0495] • anti-propagation layer between cells, with thickness and material properties adapted to the specified performance parameters is included.

[0496] • a cold plate is incorporated into the battery housing base.

[0497] • custom tooling supports flexible layout of cells, enabling the production of battery module with a varied configuration without requiring distinct production lines or tooling changes.

[0498] • battery module can be scaled using the digital layout file by reconfiguring the cell arrangement for any form factors or applications.

[0499] Generative design

[0500] • method includes generating and optimising the battery module design using generative design algorithms.

[0501] • method includes running the generative design algorithm to generate multiple battery module designs based on one or more of the following: performance, dimension constraints or operational constraints.

[0502] • generative design algorithms are configured to explore different cell configuration, cell arrangement, structural components to optimise the designs for volumetric efficiency, thermal management, or ease of assembly.

[0503] • method includes evaluating the generated designs through simulation.

[0504] • method includes refining the generated designs based on user-defined criteria including specific lead time, performance, shape, dimension, or development cost.

[0505] Note

[0506] It is to be understood that the above-referenced arrangements are only illustrative of the application for the principles of the present invention. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present invention. While the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred example(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications can be made without departing from the principles and concepts of the invention as set forth herein.

Claims

CLAIMS1. A battery module comprising: a housing and multiple battery cells positioned within the housing, wherein the housing is manufactured by profiling and folding metal sheets; and a structural potting layer that encapsulates the battery cells within the housing, wherein the structural potting layer self-moulds around the battery cells and maintains mechanical strength across a wide temperature range, such as approximately from - 40°C to 75°C, providing both mechanical stability and thermal isolation.

2. The battery module of claim 1, wherein the structural potting material is made from a lightweight, high-temperature-resistant material that starts as a liquid and cures to a flexible isolating layer.The battery module of any preceding claim, wherein the structural potting material has a curing time under 20 minutes.The battery module of any preceding claim, wherein the structural potting material is a low-viscosity resin.The battery module of any preceding claim, wherein the structural potting material is one of: polyurethane, or silicon or epoxy.

6. The battery module of any preceding claim, wherein the structural potting material is a self-foaming material.

7. The battery module of any preceding claim, wherein the structural potting layer, when cured, has a minimum thickness of approximately 5 mm but does not exceed the height of the enclosed cell.

8. The battery module of any preceding claim, wherein the structural potting material incorporates shock-absorbing additives to enhance impact resistance under extreme mechanical vibrations.

9. The battery module of any preceding claim, further comprising a silicon top layer for covering the battery cells, wherein the silicon top layer is designed to weaken or rupture in response to a localised event, such as cell venting or explosion.

10. The battery module of claim 9, wherein the silicon top layer has a thickness ranging from 0.5 mm to 4 mm.

11. The battery module of any preceding claim, wherein the cells are arranged as an array in a single orientation, wherein the single orientation ensures consistent heat dissipation across all cells.

12. The battery module of any preceding claim, wherein the battery module includes connection sheets pre-designed to align with the single-orientation layout.

13. The battery module of any preceding claim, wherein a metallic annulus part is welded onto the negative terminal rim of each battery cell, wherein the metallic annulus part has an outer diameter equal to or smaller than cell’s outer diameter, and an inner diameter larger than the cell’s positive terminal; and wherein a connection sheet electrically connects the battery cells to the metallic annulus parts.

14. The battery module of any preceding claim, wherein the metallic annulus parts are designed for compatibility with spot welding, pulse arc welding, or laser welding, allowing conductive sheets to be welded to the annulus from above during assembly.

15. The battery module of any preceding claim, wherein the metallic annulus parts are between 0.1 and 0.5 mm thick.

16. The battery module of any preceding claim, wherein the metallic annulus part feature surface coatings to improve weldability and reduce contact resistance, such as nickel or graphite.

17. The battery module of any preceding claim, wherein the metallic annulus part includes micro-texture or groves to enhance mechanical bonding with a connection sheet.

18. The battery module of any preceding claim, wherein a liquid coolant flow path is configured to circulate coolant and manage the thermal load of the battery cells.

19. The battery module of any preceding claim, wherein the liquid coolant flow path comprises serpentine-shaped cooling pipes bonded or affixed to the external surface of the modular battery module housing, and wherein the cooling pipes include intake and outlet ends, each equipped with fluid connectors to facilitate the connection of fluid delivery systems.

20. The battery module of any preceding claim, wherein the cooling pipes are made from thermally conductive materials, selected from copper, aluminium or alloys.

21. The battery module of any preceding claim, wherein a metal sheet bonded or welded to the base of the housing forms an integrated cold plate; and the liquid coolant flow path is defined between the metal sheet and the base of the housing.

22. The battery module of any preceding claim, wherein the battery module includes a heating mat for warming the cells by passing an electrical current through the mat.

23. The battery module of any preceding claim, wherein the heating mat is constructed by adding copper tracks to a PCB used for the connection sheet.

24. The battery module of any preceding claim, wherein the battery module includes an isolation layer positioned between the battery cells and the enclosure, providing electrical isolation, wherein the isolation layer is a thin layer located between the base of the battery cells and adjacent to the surface of the housing.

25. The battery module of any preceding claim, wherein the isolation layer is made from highly electrically insulating materials, such as polyimide, PET, or alternative coatings such as epoxy coating or powder coatings.

26. The battery module of any preceding claim, wherein the isolation layer is formed through surface treatments of the aluminium enclosure, including anodizing.

27. The battery module of any preceding claim, wherein the isolation layer has a thickness of less than 0.5 mm.

28. The battery module of any preceding claim, further comprising a thermal interface material positioned between the base surface of the cells and the housing wall to enhance dissipation.

29. The battery module of any preceding claim, wherein the thermal interface material is selected from pastes or pads with thermally conductive properties of 1 W / mK or higher.

30. The battery module of any preceding claim, wherein the thermal interface material is designed to cure into a tacky substance capable of tolerating relative movement between the connected interfaces caused by mechanical loads or thermal expansion.

31. The battery module of any preceding claim, wherein the thermal interface material is confined between the cells, the housing and / or isolation layer, and the structural potting layer, preventing it from shifting during operation.

32. The battery module of any preceding claim, wherein the thermal interface material is compressed to a layer thickness of 1 mm or less, and is electrically insulating to at least 2kV / mm.

33. The battery module of any preceding claim, wherein the minimum separation between the cells is approximately 0.5 mm.

34. The battery module of any preceding claim, wherein the battery module is adaptable to multiple cell types, including cylindrical, prismatic, and pouch cells.

35. The battery module of any preceding claim, wherein the battery module is adaptable to different shapes and orientation without requiring tooling changes.

36. The battery module of any preceding claim, wherein various battery chemistries are supported, including lithium-ion, NMC, LFP, sodium-ion, solid-state and lithium sulphur or any next-generation chemistries.

37. The battery module of any preceding claim, wherein the battery module also supports the use of 46xx-type cells, with the cells positioned upside down to direct vents upward, and wherein when 46xx-type cells are used, the connection sheet is positioned at the housing base, enabling direct cooling of the bus bars.

38. The battery module of any preceding claim, wherein an anti-propagation layer is positioned between cells to localise and contain any thermal runaway events, wherein the anti-propagation layer has a variable thickness between 0.5mm and 4mm.

39. The battery module of any preceding claim, wherein the anti-propagation layer is configured to prevent the spread of overheating from one cell to adjacent cells, significantly enhancing the battery module.

40. The battery module of any preceding claim, wherein the anti-propagation is made from high-temperature-resistant materials, with a tolerance of more than 800°C.

41. The battery module of any preceding claim, wherein the anti-propagation layer is integrated with the silicon potting layer, serving dual purposes of encapsulation and thermal containment.

42. The battery module of any preceding claim, wherein the anti-propagation layer includes embedded sensors to detect and isolate overheating events in real-time.

43. The battery module of any preceding claim, wherein the battery module includes a connection sheet for connecting the battery cells to the output terminals.

44. The battery module of any preceding claim, wherein the connection sheet is shaped to make selective electrical contact with the battery cells, enabling a desired series and parallel cell configurations.

45. The battery module of any preceding claim, wherein the connection sheet has a thickness between approximately 0.1 to 0.6 mm, and is mounted on a non-conductive support board that has a thickness of approximately 0.2 to 2 mm.

46. The battery module of any preceding claim, including a support board that is a printed circuit board with integrated cell monitoring tracks leading to a cell monitoring unit.

47. The battery module of any preceding claim, wherein the battery module includes an external or internal cell monitoring unit is configured to track voltages and temperature of the cells.

48. The battery module of any preceding claim, wherein the cell monitoring tracks facilitate cell voltage monitoring and voltage balancing via a cell monitoring unit.

49. The battery module of any preceding claim, wherein the cell monitoring tracks include redundancy features to ensure uninterrupted performance in case of track damage.

50. The battery module of any preceding claim, wherein the cell monitoring tracks provide outputs for connection to a cell monitoring unit or battery management system (BMS), which may be internal or external to the battery module.

51. The battery module of any preceding claim, wherein the battery module includes an external or internal BMS for controlling and monitoring functions such as state of charge (SOC), state of heath (SOH), resistance, and aging.

52. The battery module of any preceding claim, wherein the BMS includes a switch and current sensing mechanisms to manage the flow of current and protect against specific conditions, such as over current, over charge, over voltage, over temperature and under voltage.

53. The battery module of any preceding claim, wherein the battery module includes sensors for monitoring temperature, strain, pressure, volatile organic compounds (VOCs), carbon monoxide (CO), carbon dioxide (CO2), smoke, leaks, acceleration, voltage, heat, and moisture.

54. The battery module of any preceding claim, wherein retention pins are embedded within the structuring potting layer to ensure mechanical stability under conditions of mechanical shock and vibration.

55. The battery module of any preceding claim, wherein the battery module includes tags, such as RFID or NFC tags for traceability during manufacturing or maintenance.

56. A vehicle, such as a motorbike, drone, aircraft, car, boat, watercraft, off- highway vehicle, forklift, go kart, AGV, jet ski, ground support vehicle, defence vehicles and all-terrain vehicle, comprising the battery module as defined in preceding claim 1-56.

57. A robot including a battery module as defined in preceding claim 1-56.

58. A method of manufacturing the battery module as defined in preceding claim 1- 55, comprising automated cell placement mechanism configured to arrange cells within a mould or piece of tooling according to a digital layout file that specifies cell positions for optimized spatial usage.

59. A method of manufacturing the battery module as defined in preceding claim 1- 55, the method comprising the steps of making an aluminium enclosure from a profiled aluminium sheet; placing cells within the enclosure based a digital layout file that specifies the cell positions; and pouring around the cells a liquid that is configured tocure and become a structural potting layer securing the battery cells in place within the enclosure.

60. A method of designing the battery module as defined in preceding claim 1-55 based on specified performance and dimension constraints, comprising selecting battery cell chemistries and configurations to optimise the energy output per unit weight, and providing a digital layout file to define the battery cells positioning with a housing of specific dimensions.

61. A method of designing the battery module as defined in preceding claim 1-55, the method comprising determining a target capacity, energy density, weight and dimensions based on specific operational parameters, selecting battery cell chemistries and configurations to optimise the energy output per unit weight, and providing a digital layout file to define the battery cells positioning with a housing of specific dimensions.

62. The method of any preceding claim 59-61, wherein the method includes generating and optimising the battery module design using generative design algorithms that generate multiple battery module designs based on one or more of the following: performance, dimension constraints or operational constraints.

63. The method of claim 62, wherein the generative design algorithms are configured to explore different cell configuration, cell arrangement, structural components to optimise the designs for volumetric efficiency, thermal management, or ease of assembly.

64. The method of any of claim 62-63, wherein the method includes evaluating the generated designs through simulation.

65. The method of any of claim 62-64, wherein method includes refining the generated designs based on user-defined criteria including specific lead time, performance, shape, dimension, or development cost.

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