Modular battery pack assembly

Abstract

A battery pack for use in a modular battery pack assembly may be provided with a plurality of cells, having a first subset of cells arranged with positive terminals facing upward and negative terminals facing downward and a second subset of cells arranged with positive terminals facing downward and negative terminals facing upward. One or a plurality of such battery packs may be assembled into an assembly to modularly address power and form factor considerations for an electrically powered device.

Description

Attorney Docket No.: 3726039.00069TITLEMODULAR BATTERY PACK ASSEMBLYPRIORITY CLAIM

[0001] The present disclosure claims priority to U.S. Provisional Patent Application 63 / 687,643, filed on 2024-08-27, titled “MODULAR BATTERY PACK ASSEMBLY”, which is incorporated herein in its entirety.BACKGROUND

[0002] Battery packs are articles of manufacture that are used to manage a plurality’ of electro-chemical cells (generally referred to as “cells”) that store and discharge electrical energy via various chemical reactions. Industrial applications generally prefer the use of secondary or “rechargeable” cells (over primary’ or “non-rechargeable” cells), which may include various chemistries including lead-acid, lithium ion, lithium polymer, magnesium ion, nickel cadmium, nickel hydrogen, nickel zinc, nickel metal hydride, and the like.

[0003] An operating voltage provided by the chemical reaction in a given cell may range between various voltages, (e.g., 1.5 to 4.6 Volts (V)). Therefore, if a higher output voltage is required, a plurality of battery cells may be connected in series to configure a battery pack. In addition, depending on the charge / discharge capacity required for the battery pack, a plurality of battery' cells may be connected in parallel to configure a battery' pack to provide for greater capacity in the pack to sustain a voltage of a desired level over a given time. Accordingly, the number of battery cells included in a battery pack may be variously set according to the output voltage or the demanded charge / discharge capacity for a device powered by the battery pack. Similarly, the number of battery packs included in an assembly may' be variously set to provide more or fewer battery packs to adjust the output voltage or the demanded charge / discharge capacity for a device powered by the battery pack assembly.

[0004] Battery cells, however, are generally heavy and bulky. Accordingly, designers of battery-powered systems may often increase the weight and bulk of those systems by incorporating battery' packs of a standardized design, when smaller or differently shaped battery' packs may be able to provide desired power performance characteristics.11601492289.1Atorney Docket No.: 3726039.00069SUMMARY

[0005] The present disclosure provides a modular batery pack assembly, in which one or more batery packs constructed of several cells are provided with superior ease of construction, improved heat dissipation characteristics, improved conductivity characteristics, and greater flexibility of deployment / replacement, among other benefits that will be apparent on a detailed review of the present disclosure.

[0006] Additional features and advantages of the disclosed method and apparatus are described in, and will be apparent from, the following Detailed Description and the Figures. The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the figures and description. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject mater.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figures 1A-1F illustrate example modular batery packs and assemblies thereof, according to embodiments of the present disclosure.

[0008] Figure 2 illustrates an example cell as may be used in a batery7pack, according to embodiments of the present disclosure.

[0009] Figures 3A-3C illustrate views of an example wiring deck as may be used in a batery pack, according to embodiments of the present disclosure.

[0010] Figures 4A-4E illustrate views of example bussing decks as may be used in a batery pack, according to embodiments of the present disclosure.

[0011] Figures 5A-5E illustrate example bus bars as may be used in the bussing deck shown in Figure 4A, according to embodiments of the present disclosure.

[0012] Figures 6A-6D illustrate example bus bars as may be used in the bussing deck shown in Figure 4B, according to embodiments of the present disclosure.

[0013] Figure 7 illustrates an example insulator cap as may be used with a bussing deck, according to embodiments of the present disclosure.

[0014] Figures 8A and 8B illustrate view of an example connector cap as may be used with a bussing deck, according to embodiments of the present disclosure.

[0015] Figures 9A-9C illustrate a progression of wire bond formation in a top-down view; according to embodiments of the present disclosure.21601492289.1Attorney Docket No.: 3726039.00069

[0016] Figure 10 illustrates a side view of a wire bond, according to embodiments of the present disclosure.

[0017] Figures 11A-11D illustrate a progression of solder lake formation in a cross- sectional view of an example bus bar, according to embodiments of the present disclosure.

[0018] Figures 12A-12F illustrate a progression of thermal conductor application among cells of an example battery pack, according to embodiments of the present disclosure.

[0019] Figures 13A-13D illustrate an example heatsink, as may be used with a battery pack according to embodiments of the present disclosure.

[0020] Figure 14 is a flowchart for an example method of fabricating a modular battery pack assembly, according to embodiments of the present disclosure.DETAILED DESCRIPTION

[0021] The present disclosure provides a modular battery pack assembly , in which one or more battery packs constructed of several cells are provided with superior ease of construction, improved heat dissipation characteristics, improved conductivity characteristics, and greater flexibility of deployment / replacement, among other benefits that will be apparent on a detailed review of the present disclosure.

[0022] Figures 1A-1F illustrate example modular battery packs 100 and an assembly of several such battery packs lOOa-h. according to embodiments of the present disclosure.

[0023] Figure 1 A illustrates a battery pack 100, which includes a plurality of cells 120 that are captured between a first / upper bussing deck 140a (generally or collectively, bussing deck 140) and a second / lower bussing deck 140b that act as assembly fixtures for the cells 120 and the bus bars (not shown in Figure 1A, see Figures 5A-5E and 6A-6D) used to connect those cells 120 together to produce a desired output voltage.

[0024] A wiring deck 130 is secured to a bussing deck 140 to hold various wires and control circuitry physically separate from (and in controlled electrical isolation from) the bus bars in the associated bussing deck 140. Although shown in Figure 1A in connection with the upper bussing deck 140a. the present disclosure contemplates that a wiring deck 130 may be used in conjunction with both, either, or neither of the bussing decks 140a-b in various embodiments.

[0025] An insulator cap 170 may be used in some embodiments with a bussing deck 140 (or a wiring deck 130) to protect the bus bars in the bussing deck 140 (or the wiring and circuitry in a wiring deck 130) from being exposed or making unintentional contact. Although shown in Figure 1 A in connection with the lower bussing deck 140b, the present disclosure contemplates31601492289.1Attorney Docket No.: 3726039.00069 that an insulator cap 170 may be used in conjunction with both, either, or neither of the bussing decks 140a-b in various embodiments.

[0026] A connector cap 180 may be used in some embodiments to present a first (e.g., positive) terminal 110a (generally or collectively, terminal 110) and a second (e.g., negative) terminal 110b to the exterior of the battery pack 100 for connection to a powered device, a charger, or to another battery pack 100 stacked as part of an assembly 105, as illustrated in Figure IF (e.g., in the Z-direction). In some embodiments, the connector cap 180 includes a communication port 150 that allows for sensors, control circuity, charge management circuitry or the like that is held in the cavity of the wiring deck 130 to send or receive messages with another device. Although shown in Figure 1A with a wiring deck 130 mounted to an upper bussing deck 140a, the present disclosure contemplates that a connector cap 180 may be mounted directly to a bussing deck 140 (e.g., omitting an intervening wiring deck 130) or mounted to a wiring deck 130 mounted to lower bussing deck 140b, or mounted to both upper and lower bussing decks 140a-b.

[0027] When arranged in a stack with a first battery pack 100a above a second battery pack 100b (e.g., in the Z-direction), the terminals 110 on the connector cap 180 on the second (lower) battery pack 100b may interface with terminals 110 on a lower connector cap 180 or through- holes in an insulator cap 170 to interface the cells 120 between the tw o battery7packs. Similarly, the communication ports 150 on the upper side of one battery pack 100 may interface with communications ports on lower side of another battery pack 100 to daisy chain a communications pathway through several stacked battery packs 100.

[0028] In addition to establishing electrical communication in the Z-direction by stacking multiple battery7packs 100, multiple battery packs 100 can additionally or alternatively be tiled in one of both of the X-direction and the Y-direction. Electrical communications can be established via access ports 190a-d (generally or collectively, access ports 190) that are provided to allow a fabricator to establish electrical communication between at least one bus bar in one battery7pack 100 with another bus bar in another battery pack through the w iring decks 130 or busing decks 140. A fabricator may bond a wire to the bus bar, run the wire out through an access port 190 of a first battery pack 100 and into another access port 190 of another battery pack 100.

[0029] One or more through-bolts 160a-b (generally or collectively, through-bolts 160) may be placed through a single battery pack 100 or multiple stacked battery packs 100 to ensure that the assembled battery packs 100 stay together. Although illustrated as straight rods, in41601492289.1Attorney Docket No.: 3726039.00069 various embodiments, U-rods or X-rods may be used to link adjacently tiled battery' packs of a battery pack assembly together.

[0030] When battery packs 100 are tiled, an interstitial gap 115 may be defined in the center of each 2x2 tiling, and when multiple tilings are stacked, this interstitial gap 115 may run through each tiling - such as the assembly 105 in Figure IF showing a 2x2x2 arrangement of battery packs 100 that include one interstitial gap 115 running centrally to the group of battery packs 100. In various embodiments, the interstitial gap 115 may be used to hold cabling, structural support elements, permit the natural flow of air (e.g., for cooling), or include ducting for the forced flow of coolants (e.g., water, air, or refrigerants).

[0031] Figure 2 illustrates an example cell 120 as may be used in a battery pack 100, according to embodiments of the present disclosure. The cell 120 includes a positive terminal 210 and a negative terminal 220, and an outer surface 230 that is shown as being substantially cylindrical in shape. In some embodiments, a plurality of such cells 120 are provided in the battery pack 100, with a first subset (e.g., hall) provided in a first orientation (e.g., with the positive terminal 210 pointed up) and a second subset (e.g., half) provided in a second orientation (e.g.. with a the negative terminal 220 pointed up). Various chemistries that are know n to those of ordinary' skill in the art may' be used to produce the electrochemical reaction that produces the voltage difference between the positive terminal 210 and the negative terminal 220, or reverses the reaction to charge the cell 120.

[0032] Figures 3A-3C illustrate views of an example wiring deck 130 as may be used in a battery pack 100, according to embodiments of the present disclosure. Figure 3 A shows the wiring deck 130 with a wiring cavity 310, configured to hold the wiring and control circuitry (not shown) separate from the bus bars held in a bussing deck 140. A first (e.g., positive) bus linkage hole 320a and a second (e.g., negative) bus linkage hole 320b (generally or collectively, bus linkage holes 320) that a bus linkage 520 of bus bars held by the bussing deck 130 may be inserted through (see Figure 3C) are shown.

[0033] Additionally, the cavity' 310 includes various assembly holes 350 (which may be threaded or unthreaded, and include pockets or through-holes) configured to accept assembly fasteners (e.g.. screws, bolts, dowels) to bond adjacent components of the battery pack 100 together or the through-bolts 160 to bond separated components of the battery pack 100 or multiple battery packs 100 together. Additionally, various standoffs 340a-b (generally or collectively, standoffs 340) may be included in the wiring cavity 310 to hold various electrical components off of the surface of the cavity 310. For example, a wiring assembly 370 may be located on the standoffs 340, for connection to the terminals 1 10 in association with the wiring51601492289.1Attorney Docket No.: 3726039.00069380 connected to the bus linkages 520 inserted through the bus linkage holes 320, as shown in Figure 3C.

[0034] An opposite side of the wiring deck 130 to that shown in Figure 3A is shown in Figure 3B, which demonstrates that the wiring deck 130 has a first (inner) perimeter 360a and a second (outer) perimeter 360b that form a lip around the edge of the wiring deck 130 to allow for easy inserting and mating with a bussing deck 140 or a cap.

[0035] As shown, a sensor hole 330 is defined through the first side and the second side of the wiring deck 130 to permit a sensor, such as a temperature probe (not illustrated) to extend through the wiring deck 130 (and through a corresponding sensor hole 430 in a bussing deck 140) to be inserted in a gap between the plurality of cells 120. Generally, a sensor hole 330 may be located anywhere in the base of the wiring deck 130, but an approximately centralized location (e.g., between 40-60% or more of a given length / width of the wiring deck 130 from a perimeter edge thereof) may be advantageous for a temperature probe to measure temperatures at what may be the hottest portion of the plurality of cells 120.

[0036] Figures 4A-4E illustrate views of example bussing decks 140 as may be used in a battery pack 100, according to embodiments of the present disclosure. Each of the illustrated bussing decks 140 have a first side (e.g.. Figures 4A and 4B) and a second side (e.g., Figures 4C and 4D) through which various cell through-holes 410 are defined to permit a plurality of cells 120 to be connected through the non-conductive material that makes up the various decks and caps (e.g., a fiberglass, a nylon, a plastic, etc.). Other holes included in the bussing decks 140 may include assembly holes 420, access ports 190, and (optionally) sensor holes 430. As shown, a sensor hole 430 is defined through the first side and the second side of the bussing deck 130 to permit a sensor, such as a temperature probe (not illustrated) to extend through the bussing deck 130 (from a corresponding sensor hole 330 in a wiring deck 130) to be inserted in a gap between the plurality of cells 120. Generally, a sensor hole 430 may be located anywhere in the base of the bussing deck 140, but an approximately centralized location (e.g., between 40-60% or more of a given length / width of the bussing deck 140 from a perimeter edge thereof) may be advantageous for a temperature probe to measure temperatures at what may be the hottest portion of the plurality of cells 120.

[0037] The first side of the bussing deck 140 has three heights (H1-H3, as shown in Figure 4E) defined at three surfaces 460a-c therein, relative to a fourth surface 460d defined by the second side. A first height (Hl) is defined at a perimeter surface 460a of the bussing deck 140, and a second height (H2) less than the first height (Hl) is defined at a division surface 460b of a dividing extension 440. The dividing extension 440 extends from bus surface 460c, located61601492289.1Attorney Docket No.: 3726039.00069 at a third height (H3) from the fourth surface 460d, and divides the first side of the bussing deck 140 into a plurality of bus cavities 450a-e in Figure 4A or bus cavities 450a-d in Figure 4B (generally or collectively bus cavities 450) that are configured to accept various bus bars therein, and having a conformal shape to the bus bars, which are preferably all of a different shape to prevent or reduce the incidence of mis-assembly.

[0038] The second side of the bussing deck 140 has a fixture surface 460d into which the various lips 412 are formed concentrically around the cell through-holes 410. The lips 412 are formed to a depth (e.g., a lip height (H4) between a lip surface 460e relative to the fixture surface 460d) at a first diameter (DI) substantially equal to the diameter of the cells 120. The cell through-holes 410 are defined at a second diameter (D2) that is less than the first diameter (DI) to thereby permit the second side of the bussing deck 140 to operate as a fixture during assembly to hold the cells 120 in a desired arrangement. For example, the cell through-holes 410 may be arranged in a pattern 470 defining an equilateral triangle between the center points of groups of adjacent cell through-holes 410. In various embodiments, a fabricator may apply an adhesive to the lip 412 to further help secure the cells 120 in place once inserted into the cell through-hole 410.

[0039] Figures 5A-5E illustrate example bus bars 510a-e (generally or collectively, bus bars 510) as may be used in the bussing deck 140 shown in Figure 4A, according to embodiments of the present disclosure. Each bus bar 510 is sized and shaped according to a corresponding bus cavity 450, and has a bus body 530 made of a conductive material (e.g., copper). In various embodiments, the bus body 530 for each bus bar 510 is nominally the same thickness as each other bus bar 510 (and bus bar 610 in Figures 6A-6D), although various solder lakes (see e.g., Figures 11A-11D) may be formed in portions of the bus bars 510 to define bonding regions for connection to other bus bars 510 or to external devices via the access ports 190.

[0040] A plurality of cell-holes 560 are defined through the bus body 530, and are configured to establish a wire bond with one cell 120 per cell-hole 560. The number and placement of the cell-holes 560 corresponds to the number and placement of the cells 120 that the bus body 530 is to be bonded to. Additionally, a plurality of assembly holes 540 are defined through the bus body 530, and are configured to accept a fastener (e.g., a non-conductive screw or bolt) to secure the bus bar 510 into the associated bus cavity 450. In various embodiments, each of the cell-holes 560 and assembly holes 540 are generally circular in shape.

[0041] The first bus bar 520a and the second bus bar 520b each include a bus linkage 520 configured to be inserted through bus linkage holes 320 in a wiring deck 130, that is bent to71601492289.1Attorney Docket No.: 3726039.00069 extend in anon-parallel plane relative to the bus body 530, and defines a linkage through-hole 522.

[0042] Although five bus bars 510a-e are illustrated in Figures 5A-5E for insertion into five corresponding bus cavities 450a-e in Figure 4A, the present disclosure contemplates that different numbers of bus bars 510 having different shapes 550 may be used in various embodiments to correspond for insertion into a different number of bus cavities 450. Additionally, the shapes 550 of the bus bars 510 may be varied to change the output voltage and storage characteristics of the batten- pack 100.

[0043] Figures 6A-6D illustrate example bus bars 610a-d (generally or collectively, bus bars 610) as may be used in the bussing deck 140 shown in Figure 4B, according to embodiments of the present disclosure. Each bus bar 610 is sized and shaped according to a corresponding bus cavity 450, and has a bus body 630 made of a conductive material (e.g., copper). In various embodiments, the bus body 630 for each bus bar 610 is nominally the same thickness as each otherbus bar 610 (and bus bar 510 in Figures 5A-5E), although various solder lakes (see e.g.. Figures 11A-11D) may be formed in portions of the bus bars 610 to define bonding regions for connection to other bus bars 610 or to external devices via the access ports 190.

[0044] A plurality7of cell-holes 660 are defined through the bus body 630, and are configured to establish a wire bond with one cell 120 per cell-hole 660. The number and placement of the cell-holes 660 corresponds to the number and placement of the cells 120 that the bus body 630 is to be bonded to. Additionally, a plurality7of assembly holes 640 are defined through the bus body 630, and are configured to accept a fastener (e.g., a non-conductive screw or bolt) to secure the bus bar 610 into the associated bus cavity 450. In various embodiments, each of the cell-holes 660 and assembly holes 640 are generally circular in shape.

[0045] Although four bus bars 610a-d are illustrated in Figures 6A-6D for insertion into four corresponding bus cavities 450a-d in Figure 4B, the present disclosure contemplates that different numbers of bus bars 610 having different shapes may be used in various embodiments to correspond for insertion into a different number of bus cavities 450. Additionally, the shapes of the bus bars 610 may be varied to change the output voltage and storage characteristics of the battery pack 100.

[0046] The bus bars 610 shown in Figures 6A-6D are intended to have a different shape and number than the bus bars 510 shown in Figure 5A-5E, and the bus bars 610 of Figures 6A- 6D are intended to be bonded to a first end of the cells 120, whereas the bus bars 510 of Figures 5A-5E are intended to be bonded to a second end (opposite to the first end) of the cells 120.81601492289.1Attorney Docket No.: 3726039.00069Each of the bus bars 510 / 610 are bonded to different divisions among the plurality of cells 120, such that no bus bar 510 / 610 is bonded (on either end) to an identical grouping of cells 120. Accordingly, depending on the orientations of the cells 120 and patterns of the bus bars 510 / 610, different conductance patterns (e.g., parallel or series linkages) among the plurality of cells 120 can be formed using the same form factor for the overall shape of the battery pack 100.

[0047] Figure 7 illustrates an example insulator cap 170 as may be used with a bussing deck 140 or wiring deck 130, according to embodiments ofthe present disclosure. The insulator cap 170 is made of a non-conductive material and offers no ports or exits - thereby insulating and preventing electrical contact with any elements held between the insulator cap 170 and a bussing deck 140 or wiring deck 130. Various extended holes 710 or recessed holes 720 may be provided to accept fasteners (e.g., screws or bolts) to secure another component with the insulator cap 170. The insulator cap 170 has a first (inner) perimeter 730a and a second (outer) perimeter 730b that form a lip around the edge of the insulator cap 170 to allow for easy inserting and mating with a bussing deck 140 or wiring deck 130.

[0048] Figures 8A and 8B illustrate views of an example connector cap 180 as may be used with a bussing deck 140 or wiring deck 130, according to embodiments of the present disclosure. Figure 8 A demonstrates that the connector cap 180 has a first (inner) perimeter 810a and a second (outer) perimeter 810b that form a lip around the edge of the connector cap 180 to allow for easy inserting and mating with a wiring deck 130. Additionally, various assembly holes 820 may be provided to accept fasteners (e.g., screws or bolts) to secure another component with the connector cap 180.

[0049] Two terminal holes 810a-b (generally or collectively, terminal holes 810) are defined through the connector cap 180 to allow for the mounting of positive and negative terminals HOa-b to the connector cap 180 (and to the various wiring held in the associated wiring deck 130). A communications hole 840 is defined through the connector cap 180 to a communication port 150. As shown in Figure 8B, the exposed side of the connector cap 180 may include a wire run 850 to accept a communication port 150 from another battery pack 100 into a depression formed in the upper surface 860 of the connector cap 180 and any wiring to connect the communication port 150 of one battery pack 100 with the communication port 150 of another battery pack 100 stacked on top of (or below ) the connector cap 180.

[0050] Figures 9A-9C illustrate a progression of wire bond formation in a top-down view; according to embodiments of the present disclosure. Figure 10 illustrates a side view of a wire bond, according to embodiments of the present disclosure.91601492289.1Attorney Docket No.: 3726039.00069

[0051] In each view in Figures 9A-9C and Figure 10, a terminal surface 910 of a cell 120 is shown (which may include some or all of the positive terminal 210 or the negative terminal 220), and a portion of a bus body 530 / 630 is shown that defines the cell-hole 560 / 660. Various pluralities of bonding wires 920a-c (generally or collectively, bonding wires 920) are placed around the circumference of the cell-hole 560 / 660 and bonded on a first end to the bus body 530 / 630 and on a second end (opposite to the first end) to the terminal surface 910.

[0052] By using several individual bonding wires 920, the battery pack may realize improved current carrying capacity for less material versus using a singular large bonding wire.

[0053] In various embodiments, the bonding wires 920 are made of aluminum, although other metals and alloys may be used in various embodiments. Bond wires 920 of 500-micron pure aluminum wire in the configuration shown herein have been shown to carry currents of roughly 25 amps (A) per bonding wire 920, or 200 A total with eight bonding wires 920 as per the present example.

[0054] As positioned, a portion of a non-conductive bussing deck 140 separates the conductive bus body 530 / 630 from the conductive terminal surface 910 of the cell 120, and the bonding wires 920 establish an electrical connection therebetween. The shape of the bonding wire 920 connects the bus body 530 / 630 with the terminal surface 910, but leaves a test-gap 1010, which permits the insertion of a probe 1020 between the bonding wire 920 and the other elements, and for a test machine connected to the probe 1020 to pull the probe 1020 in a pull direction (e.g., in a direction away from the terminal surface 910 towards the bus body 530 / 630) by a predefined amount of force to ensure that the bonding wire 920 has been bonded with a requisite strength to one or both of the bus body 530 / 630 and the terminal surface 910.

[0055] As show n in Figure 9A, a first set and a second set of three bonding wires 920 each are installed on opposing sides of the cell-hole 560 / 660 (e g., 180 degrees rotationally about the cell-hole 560 / 660), which allows a probe 1020 of a testing device to be easily inserted for a pull test to ensure that the bonding wares 920 are secured to the bus body 530 / 630 and the terminal surface 910. After ensuring that the bonding wires 920 are secured, a third set of (e.g., two) bonding wires 920 may be installed in another location (e.g., approximately 90 degrees from the earlier-installed pluralities of bonding wires 920 as in shown in Figure 9B). The third set of bonding wires 920 may be located in such a way that a pull test is not possible (or not practical using a test machine), and may instead be tested via a conductance test to determine whether electrical communication has been formed between the terminal surface 910 and the bus body 530 / 630.101601492289.1Attorney Docket No.: 3726039.00069

[0056] In the event of a failed test for wire bonding, a fourth location is still available around the circumference of the cell-hole 560 / 660. which allows (when deemed useful) a fourth set of bonding wires 920 to be installed while the failed bonding wires 920 are allowed to remain in place (or to optionally be removed), thereby reducing rework. Wire bonding tests may fail when the test machine pulls a bonding wire away from the terminal or an electrical communication is otherwise broken or not established. Although illustrated in Figure 9C with the second set of bonding wires 920 having failed and being replaced with two bonding wires 920 in the fourth set, the present disclosure contemplates that the fourth set may include any number of bonding wires 920 to match the number of failed bonds (including zero; a null fourth set), whether occurring in one or multiple earlier-installed sets of bonding wires 920.

[0057] Figures 11A-11D illustrate a progression of solder lake formation in a cross- sectional view of two example bus bars 510a-b, according to embodiments of the present disclosure.

[0058] From an initial state in Figure 11A to a second state in Figure 11B, a compressed region 1140a-b (generally or collectively, compressed region 1140) is formed in each bus bar 510a-b (e.g.. by locally compressing the material of the bus bars 510a-b, such as by stamping) to leave other regions of the bus bars 510a-b uncompressed, including regions between the compressed regions 1140a-b and the respective second surfaces 1120a-b of the bus bars 510a- b. In various embodiments, because the bus bars 510a-b are intended to lie flat within the respective bus cavities 450a-b. the formation of the solder lakes 1130 is performed by compressing the first surface 11 10 to a desired depth without imparting a corresponding outward projection or bump from the second surface 1120 (e.g., by using a form or mold to hold the second surface 1120 in place, which may include the bussing deck 140). In some embodiments, the solder lake 1130 is formed by removing material from the first surface 1110 (e.g., by cutting, drilling, scooping, localized heat vaporization or chemical etching). In some embodiments, the solder lake 1130 is formed and any resulting outward projection from the second surface 1120 is removed (e.g., by cutting, sanding / ablating, localized heat vaporization or chemical etching, etc.).

[0059] After the solder lakes 1 130a-b are formed, solder beads 1150a-b (generally or collectively, solder beads 1150) are deposited into the respective solder lakes 1130a-b, as is shown in Figure 11C. The solder beads 1150a-b may be deposited in a solid or in a liquid form, and although not illustrated, a flux may be used to aid in depositing (or limiting spread) of the solder to the solder lakes 1130a-b. When the solder is in a liquid form, a wire 1160 may be inserted into the solder held in the solder lakes 1130a-b as is shown in Figure 1 ID, and on111601492289.1Attorney Docket No.: 3726039.00069 cooling and solidifying, the solder holds the wire 1160 in place to establish electrical communication between the first bus bar 510a and the second bus bar 510b.

[0060] Although referred to herein as solder lakes 1130, the present disclosure contemplates that the joints formed by the progression shown in Figures 11A-11D may be formed via brazing or welding and may connect a bus bar 510 (or bus bar 610) to a wire 1160 that is not connected to another bus bar 510 (or bus bar 610), but to other wiring or to an electrical element in another battery pack 100. Additionally, the present disclosure contemplates that the described solder lake formation process may be used outside of the context of batten- pack assemblies, and in any context for establishing electrical communication between two conductors.

[0061] Figures 12A-12F illustrate a progression of applying a thermally conductive adhesive 1220 among cells 120 of an example battery pack 100, according to embodiments of the present disclosure. Each of the cells 120 are shown held in a bussing deck 140 acting as a fixture on the lower side of the cells 120, with a first subset of the cells 120 in a first orientation and a second subset of the cells 120 in a second orientation. In various embodiments, the thermal conductor 1200 may be applied in the illustrated layout shown in Figures 12A-12D. which are presented without a second bussing deck 140 for ease of seeing the application of the thermally conductive adhesive 1220, but in some embodiments it may be preferrable to have a bussing deck 140 connected on either end of the cells 120, as shown in Figures 12E- 12F so that the thermally conductive adhesive 1220 can extend between the bussing decks 140a-b.

[0062] The cells 120 are regularly spaced, and define inter-cell gaps 1210 between one another. These gaps 1210 may be filled by injecting the thermally conductive adhesive 1220 therein. Once set, the thermally conductive adhesive 1220 solidifies, acting as an adhesive that holds the cells 120 in place and the bussing decks 140 to the cells 120 (and one another). The thermally conductive adhesive 1220 has a higher thermal conductivity than air, which may initially occupy the inter-cell gaps 1210, thereby encouraging heat dissipation among the cells 120 and heat transfer outward from the more central cells 120 to the more peripheral cells 120 in the battery pack 100. In various embodiments, the thermally conductive adhesive 1220 may be CoolTherm® TC 2002 (available form Parker Hannifin Corp, of Mayfield Heights, Ohio USA) or a similar compound.

[0063] Figures 13 A- 13D illustrate an example heatsink 1300, as may be used with a battery pack 100 according to embodiments of the present disclosure. Each heatsink 1300 is designed121601492289.1Attorney Docket No.: 3726039.00069 to be disposed on one face of a battery pack 100, although multiple heatsinks 1300 may be deployed to allow multiple faces of a batten’ pack 100 to include a heatsink 1300.

[0064] The heatsink 1300 includes a plurality of fins 1310 on an exterior side and a plurality of conformal curves 1320 on an interior side. The conformal curves 1320 are configured based on a curvature of the cells 120 and a number of cells 120 on the face of the battery pack 100 to install the heatsink 1300. Each conformal curve 1320 is configured to fit one cell 120 therein. In some embodiments, the conformal curves 1320 are bonded to the outer surfaces of the corresponding cells 120 by a thermally conductive adhesive (e.g., the thermally conductive adhesive 1220 used in the inter-cell gaps 1210). In some embodiments, the upper and lower surface of the heatsink 1300 are bonded to the bussing decks 140, and clean contact or contact aided a dielectric thermally conducive coating is made between the cells 120 and the conformal curves 1320 of the heatsink.

[0065] The body 1330 of the heatsink 1300 carries the thermal energy imparted from the cells 120 to the fins 1310, which offer a greater surface area to allow for radiative cooling of the cells 120 to an external environment, cooling duct within a device powered by the battery pack 100, or the like.

[0066] In various embodiments, the height of the heatsink 1300 (e g., in the Z direction) is substantially equal (less a tolerance distance) to a distance between the upper and lower bussing decks 140, while a length of the heatsink (e.g., in the X direction) is less than (but within 90% of) a length of the bussing decks 140 to account for the generally octagonal shape of the battery pack 100 extending further than the cells 120 on the face to which the heatsink 1300 is mounted. In various embodiments, a depth of the heatsink 1300 (e.g., in the Y direction) is approximately two-thirds of the diameter of the cells 120, and is such that the fins 1310 do not extend past the edges of the bussing decks 140 to allow for tighter tiling with other battery packs 100 than if the fins 1310 were to extend pas the edges of the bussing decks 140.

[0067] In various embodiments, the heatsink 1300 is made of aluminum or an alloy thereof.

[0068] Figure 14 is a flowchart for an example method 1400 of fabricating a modular battery pack assembly, according to embodiments of the present disclosure.

[0069] At block 1410, a fabricator optionally forms solder lakes in one or more bus bars.

[0070] At block 1420, a fabricator installs the bus bars into bussing decks. Each bus bar is associated with a similarly shaped bus cavity to improve an accuracy of assembling the battery pack, and to serve as a fixture as various fasteners are installed to keep the bus bars in place. In various embodiments, the bus bars are secured vianon-conductive fasteners inserted through various assembly holes defined the bus bodies.131601492289.1Attorney Docket No.: 3726039.00069

[0071] At block 1430. a fabricator optionally connects two or more bus bars via wires secured in the solder lakes.

[0072] At block 1440, a fabricator installs a plurality of cells into the bussing decks, on a side opposite to the side in which the bus bars are installed. The bussing decks, in this way, act as fixtures for the assembly of the cells into the battery pack. In various embodiments, the fabricator may place each cell into a corresponding cell-hole and include an adhesive on a lip around the cell-hole to secure the call in place.

[0073] In various embodiments, a fabricator after seating the bussing decks onto the cells injects a thermally conductive adhesive into the gaps between the cells and the bussing decks to hold the bussing decks in place, and improve thermal conductivity from the innermost cells to the outside of the battery pack.

[0074] At block 1450, a fabricator optionally installs a heatsink on one or more faces of the battery pack (e.g., some or all of the faces that will remain exposed from the battery pack in a battery pack assembly). In various embodiments, the fabricator may wait to inject the thermally conductive adhesive into the gaps between the cells until the heat sink is installed, or may secure the heatsink via a second application of the thermally conductive adhesive.

[0075] At block 1460, a fabricator forms wire bonds from the bus bars to the cells. In some embodiments, a fabricator may install the wire bonds on a “top” side exposed to a wire bonding machine, then flip the in-process battery pack to install wire bonds on what was the “bottom” side with the wire bonding machine. In some embodiments, a fabricator may install wire bonds on a “left” side that is exposed to a wire bonding machine and spin the in-pross battery pack to install wire bonds on what was the “right” side with the wire bonding machine. In some embodiments, both the top / bottom or left / right sides are exposed to corresponding aspects or instances of the wire bonding machine, and are bonded at the same time.

[0076] In various embodiments, wire bonding includes a pull test or a conductivity test to ensure proper bonds have been established, and may include repair or replacement operations when a bonding wire pulls away from the in-process battery pack (see e.g., Figures 9A-9C and 10).

[0077] At block 1470. the fabricator installs a wiring deck to at least one of the bussing decks and installs caps on one or more of the bussing decks and wiring decks that are not otherwise covered. The installation of the wiring deck may include installing any associated wiring or circuits for the battery pack in the wiring cavity. In various embodiments, the wiring may include wiring connected to the bus bars to be connected to terminals of the battery pack or wiring to connect bus bars to other battery packs as part of an assembly. In various141601492289.1Attorney Docket No.: 3726039.00069 embodiments, the circuity may include various control and monitoring circuitry and sensors to monitor, manage, and communicate a charge status, a charge health, a temperature, whether a cell has failed, or the like.

[0078] At block 1480, the fabricator optionally connects the battery pack to other battery packs to form a battery pack assembly. In various embodiments, the battery packs may be stacked (e.g.. on top of one another), tiled (e.g., side by side to one another), or both stacked and tiled. In various embodiments, various through-bolts may be used to physically connect the battery packs in an assembly, and various wires (linked via access ports or terminals) may be used to electrically connect the battery packs in the assembly.

[0079] The present disclosure may also be understood with reference to the following clauses:

[0080] Clause 1 : A battery pack as described herein.

[0081] Clause 2: A battery pack assembly comprising a plurality battery packs, as described in clause 1, arranged in a regularly tiling, stacking, or tiling and stacking pattern.

[0082] Clause 3: The battery pack of assembly of clause 2, wherein each group of four battery packs of the plurality of battery packs in a 2x2 tiling arrangement define an interstitial gap central to the group.

[0083] Clause 4: The battery pack of assembly of clause 3, wherein a top group of four battery packs of the plurality of battery packs in the 2x2 tiling arrangement is stacked on a bottom group of four battery packs of the plurality of battery packs in the 2x2 tiling arrangement to be aligned in a 2x2x2 tiling and stacking arrangement such that a first interstitial gap of the top group is aligned with a second interstitial gap of the bottom group to define a shared pathway though the 2x2x2 tiling and stacking arrangement.

[0084] Clause 5: The battery pack of clause 1. wherein battery pack includes a plurality of cells, having a first subset arranged with positive terminals facing upward and negative terminals facing downward and a second subset arranged with positive terminals facing downward and negative terminals facing upward.

[0085] Clause 6: The battery pack of clause 5, further comprising: a first bus bar, connected exclusively among the plurality of cells to a first division of the positive terminals of first subset of cells; a second bus bar, connected exclusively among the plurality of cells to a first division of the negative terminals of the second subset of cells; a third bus bar, connected among the plurality' of cells to a second division of the positive terminals of the first subset of cells and to a second division of the negative terminals of the second subset of cells; and a fourth bus bar, connected among the plurality of cells to a third division of the positive151601492289.1Attorney Docket No.: 3726039.00069 terminals of the first subset of cells and to a third division of the negative terminals of the second subset of cells.

[0086] Clause ?: The batten pack of clause 6, further comprising: a fifth bus bar, connected among the plurality of cells to a first division of the negative terminals of the first subset of cells and to a first division of the positive terminals of the second subset of cells; and a sixth bus bar, connected among the plurality of cells to a second division of the negative terminals of the first subset of cells and to a second division of the positive terminals of the second subset of cells.

[0087] Clause 8 : The batten- pack of clause 7, wherein no two bus bars of the first through sixth bus bars are connected to an identical grouping of cells of the plurality of cells.

[0088] Clause 9: The battery pack of clause 1. further comprising: a bussing deck made of a nonconductive material and including: a first side in which each cell of a plurality of cells included in the battery pack is captured; a second side in which a plurality' of bus bars included in the battery pack is captured, wherein the nonconductive material separates each bus bar of the plurality of bus bars from other bus bars of the plurality of bus bars and from each cell of the plurality of cells: and a plurality of wire bonds structures corresponding in number to the plurality of cells included in the battery pack that electrically connect individual cells of the plurality of cells to individual bus bars of the plurality of bus bars.

[0089] Clause 10: The battery pack of clause 9, wherein the bussing deck includes an access port, configured to establish electrical communication between at least one bus bar of the plurality of bus bars and an external bus bar included in a second battery pack as described in clause 1 via an associated external access port of the second battery pack.

[0090] Clause 11: The battery pack of clause 9, further comprising: a positive terminal; a negative terminal; a wiring deck, made of the nonconductive material, disposed on the second side of the bussing deck, including a deck of the nonconductive material separating the plurality of bus bars from the positive terminal and the negative terminal, and defining a positive bus linkage hole and a negative bus linkage hole; wherein the plurality of bus bars include a positive bus linkage extending from a first bus bar of the plurality of bus bars through the positive bus linkage hole and include a negative bus linkage extending from a second bus bar of the plurality of bus bars through the negative bus linkage hole; and wiring that connects a portion of the positive bus linkage extending through the wiring deck to a positive terminal and that connects a portion of the negative bus linkage extending through the wiring deck to a negative terminal.

[0091] Clause 12: The battery pack of clause 1, further comprising: afirst bus bar, defining a first solder lake in a first compressed region of the first bus bar; a second bus bar, defining a161601492289.1Attorney Docket No.: 3726039.00069 second solder lake in a second compressed region of the second bus bar; a first solder pool, disposed in the first solder lake; a second solder pool, disposed in the first solder lake; a wire, captured in the first solder pool on a first end and in the second solder pool on a second end, establishing electrical communication between the first bus bar and the second bus bar.

[0092] Clause 13 : The battery7pack of clause 1 , further comprising: a wire bond comprising a plurality of bonding wires connecting a bus bar with a terminal surface of a cell of a plurality of cells through a cell-hole defined in the bus bar, wherein the plurality of bonding wires includes: a first plurality7located at a first location around a circumference of a cell-hole; a second plurality7located a second location around the circumference of the cell-hole, rotationally opposite to the first location about the circumference; a third plurality located at a third location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference.

[0093] Clause 14: The battery pack of clause 13, wherein the plurality of bonding wires includes: a fourth plurality7located at a fourth location around the circumference of the cellhole, rotationally between the first location and the second location about the circumference and rotationally opposite to the third location, wherein a number of bonding wires in the fourth plurality equals a number of bonding wires with failed connections in the first, second and third pluralities.

[0094] Clause 15: The battery pack of clause 1, further comprising: a conformal heatsink, bonded on a given face of the battery pack to a plurality of cells via a thermally conductive adhesive.

[0095] Clause 16: The battery pack of clause 1, further comprising: a thermally conductive adhesive injected to fill inter-cell spaces between cells of a plurality7of cells included in the battery pack.

[0096] Clause 17: A battery pack according to any one or more of clauses 1-16.

[0097] Clause 18: A method of constructing a battery pack as in any one or more of clauses1-17.

[0098] Clause 19: A battery pack, comprising: an upper bussing deck, formed of a non- conductive material in which a first cavity and a second cavity are defined; a lower bussing deck, formed of the non-conductive material in which a third cavity' and a fourth cavity are defined; a positive upper bus bar, shaped conformally to the first cavity' and disposed therein with one face exposed therefrom; a negative upper bus bar, shaped conformally to the second cavity and disposed therein with one face exposed therefrom; a positive lower bus bar. shaped conformally to the third cavity and disposed therein with one face exposed therefrom; a171601492289.1Attorney Docket No.: 3726039.00069 negative lower bus bar, shaped conformally to the fourth cavity and disposed therein with one face exposed therefrom; a plurality of battery cells disposed between the upper bussing deck and the lower bussing deck, the plurality of battery cells including: a first subset disposed with positive ends connected to the positive upper bus bar and negative ends connected to the negative lower bus bar; a second subset disposed with positive ends connected to the positive lower bus bar and negative ends connected to the negative upper bus bar; and wherein each cell of the plurality of battery cells is bonded to two respective bus bar via a corresponding cell-hole in each of the two respective bus bars and a plurality of bonding wires; a heat sink conformally installed between the upper bussing deck and the lower bussing deck to a subset of the plurality of battery cells on one face of the battery pack; a thermally conductive adhesive bonding the heat sink with the subset of the plurality of battery cells and filling inter-cell gaps between the plurality of battery cells; and a wiring deck, formed of the non-conductive material, disposed on a first side of the upper bussing deck opposite to a second side of the upper bussing deck connected to the plurality of cells, including a circuitry for controlling a temperature sensor that is inserted through the wiring deck and upper bussing deck into the thermally conductive adhesive.

[0099] Clause 20: A method for fabricating a battery pack, comprising: forming solder lakes on a first plurality of bus bars and a second plurality of bus bars; installing the first plurality of bus bars into first side of a first bussing deck; installing the second plurality of bus bars into first side of a second bussing deck; connecting the first plurality of bus bars to one another via the solder lakes formed thereon; connecting the second plurality of bus bars to one another via the solder lakes formed thereon; installing a plurality of battery' cells into a second side, opposite to the first side, of the first bussing deck and into a second side, opposite to the first side, of the second bussing deck; and forming a plurality of wire bonds between each cell of the plurality of battery cells to a corresponding one of the first plurality of bus bars and a corresponding one of the second plurality of bus bars.

[0100] Clause 21: The method of clause 20 or 21, wherein: each wire bond of the plurality of wire bonds comprises a plurality of bonding wires connecting a terminal surface of a corresponding cell of the plurality of battery cells through a cell-hole defined in a respective bus bar of the corresponding one of the first plurality of bus bars or the corresponding one of the second plurality of bus bars, wherein the plurality of bonding wires includes: a first set of bonding wires located at a first location around a circumference of a cell-hole; a second set of bonding wires located a second location around the circumference of the cell-hole, rotationally opposite to the first location about the circumference; a third set of bonding wires located at a181601492289.1Attorney Docket No.: 3726039.00069 third location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference; and a fourth set of bonding wires located at a fourth location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference and rotationally opposite to the third location, forming the plurality of wire bonds includes testing connections between the corresponding cell of the plurality of battery cells and the respective bus bar for the bonding wires in the first, second and third sets of bonding wires; and a number of bonding wires in the fourth set of bonding wires equals a number of bonding wires in the first, second and third sets of bonding wires with failed connections between the corresponding cell of the plurality of battery cells and the respective bus bar according to the testing.

[0101] Clause 22: The method of any of clauses 20-21 and 23-24. further comprising: affixing a heatsink to at least two cells of the plurality of cells.

[0102] Clause 23: The method of any of clauses 20-22 and 24, further comprising: installing a wiring deck to at least one of the bussing decks or installing caps on one or more of the bussing decks and wiring decks that are not otherwise covered.

[0103] Clause 24: The method of any of clauses 20-23, further comprising: connecting the battery pack to other battery packs to form a battery pack assembly.

[0104] Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function.

[0105] As used herein, the term “optimize” and variations thereof, is used in a sense understood by data scientists to refer to actions taken for continual improvement of a system relative to a goal. An optimized value will be understood to represent “near-best” value for a given reward framework, which may oscillate around a local maximum or a global maximum for a “best” value or set of values, which may change as the goal changes or as input conditions change. Accordingly, an optimal solution for a first goal at a given time may be suboptimal for a second goal at that time or suboptimal for the first goal at a later time.

[0106] As used herein, various chemical compounds are referred to by associated element abbreviations set by the International Union of Pure and Applied Chemistry (IUPAC), which one of ordinary' skill in the relevant art will be familiar with. Similarly, various units of measure may be used herein, which are referred to by associated short forms as set by the International System of Units (SI), which one of ordinary skill in the relevant art will be familiar with.191601492289.1Attorney Docket No.: 3726039.00069

[0107] As used herein, “about,"’ “approximately"’ and “substantially’" are understood to refer to numbers in a range of the referenced number, for example the range of -10% to +10% of the referenced number, preferably -5% to +5% of the referenced number, more preferably - 1% to +1% of the referenced number, most preferably -0.1% to +0.1% of the referenced number.

[0108] Furthermore, all numerical ranges herein should be understood to include all integers, whole numbers, or fractions, within the range. Moreover, these numerical ranges should be construed as providing support for a claim directed to any number or subset of numbers in that range. For example, a disclosure of from 1 to 10 should be construed as supporting a range of from 1 to 8, from 3 to 7, from 1 to 9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth.

[0109] As used in the present disclosure, a phrase referring to “at least one of’ a list of items refers to any set of those items, including sets with a single member, and ever}7potential combination thereof. For example, when referencing “at least one of A, B, or C” or “at least one of A, B, and C”, the phrase is intended to cover the sets of: A, B, C, A-B, B-C, A-C, and A-B-C. where the sets may include one or multiple instances of a given member (e.g., A-A. A- A-A, A-A-B, A-A-B-B-C-C-C, etc.) and any ordering thereof. For avoidance of doubt, the phrase “at least one of A, B, and C” shall not be interpreted to mean “at least one of A, at least one of B, and at least one of C”.

[0110] As used in the present disclosure, the term “determining” encompasses a variety of actions that may include calculating, computing, processing, deriving, investigating, looking up (e.g., via a table, database, or other data structure), ascertaining, receiving (e.g., receiving information), accessing (e.g., accessing data in a memory), retrieving, resolving, selecting, choosing, establishing, and the like.

[0111] Without further elaboration, it is believed that one skilled in the art can use the preceding description to use the claimed inventions to their fullest extent. The examples and aspects disclosed herein are to be construed as merely illustrative and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having skill in the art that changes may be made to the details of the above-described examples without departing from the underlying principles discussed. In other words, various modifications and improvements of the examples specifically disclosed in the description above are within the scope of the appended claims. For instance, any suitable combination of features of the various examples described is contemplated.201601492289.1Attorney Docket No.: 3726039.00069

[0112] Within the claims, reference to an element in the singular is not intended to mean “one and only one” unless specifically stated as such, but rather as “one or more" or “at least one”. Unless specifically stated otherwise, the term “some” refers to one or more. No claim element is to be construed under the provision of 35 U.S.C. § 112(f) unless the element is expressly recited using the phrase “means for” or “step for”. All structural and functional equivalents to the elements of the various embodiments described in the present disclosure that are known or come later to be known to those of ordinary skill in the relevant art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed in the present disclosure is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.211601492289.1

Claims

Atorney Docket No.: 3726039.00069CLAIMSThe invention is claimed as follows:

1. A batery pack, comprising: a plurality of cells, having a first subset of cells arranged with positive terminals facing upward and negative terminals facing downward and a second subset of cells arranged with positive terminals facing downward and negative terminals facing upward.

2. A batery pack assembly comprising a plurality batery packs, as described in claim 1, arranged in a regularly tiling, stacking, or tiling and stacking patern.

3. The batery pack assembly of claim 2, wherein each group of four batery packs of the plurality of batery packs in a 2x2 tiling arrangement define an interstitial gap central to the group.

4. The baten' pack assembly of claim 3. w herein a top group of four batery packs of the plurality' of batery packs in the 2x2 tiling arrangement is stacked on a bottom group of four batery' packs of the plurality' of batery packs in the 2x2 tiling arrangement to be aligned in a 2x2x2 tiling and stacking arrangement such that a first interstitial gap of the top group is aligned w ith a second interstitial gap of the botom group to define a shared pathway though the 2x2x2 tiling and stacking arrangement.

5. The batery' pack of claim 1, further comprising: a first bus bar, connected exclusively among the plurality7of cells to a first division of the positive terminals of the first subset of cells;221601492289.1Attorney Docket No.: 3726039.00069 a second bus bar, connected exclusively among the plurality of cells to a first division of the negative terminals of the second subset of cells; a third bus bar, connected among the plurality of cells to a second division of the positive terminals of the first subset of cells and to a second division of the negative terminals of the second subset of cells; and a fourth bus bar, connected among the plurality7of cells to a third division of the positive terminals of the first subset of cells and to a third division of the negative terminals of the second subset of cells.

6. The battery7pack of claim 5, further comprising: a fifth bus bar, connected among the plurality of cells to a first division of the negative terminals of the first subset of cells and to a first division of the positive terminals of the second subset of cells; and a sixth bus bar, connected among the plurality of cells to a second division of the negative terminals of the first subset of cells and to a second division of the positive terminals of the second subset of cells.

7. The battery pack of claim 6, wherein no two bus bars of the first through sixth bus bars are connected to an identical grouping of cells of the plurality of cells.

8. The battery pack of claim 1, further comprising: a bussing deck made of a nonconductive material and including: a first side in which each cell of the plurality of cells included in the battery pack is captured; and231601492289.1Attorney Docket No.: 3726039.00069 a second side in which a plurality of bus bars included in the battery pack is captured, wherein the nonconductive material separates each bus bar of the plurality7of bus bars from other bus bars of the plurality of bus bars and from each cell of the plurality7of cells; and a plurality7of wire bonds structures corresponding in number to the plurality7of cells included in the battery7pack that electrically connect individual cells of the plurality of cells to individual bus bars of the plurality of bus bars.

9. The battery7pack of claim 8, wherein the bussing deck includes an access port, configured to establish electrical communication between at least one bus bar of the plurality7of bus bars and an external bus bar included in a second battery7pack as described in claim 1 via an associated external access port of the second battery pack.

10. The battery^ pack of claim 8, further comprising: a positive terminal; a negative terminal; a wiring deck, made of the nonconductive material, disposed on the second side of the bussing deck, including a deck of the nonconductive material separating the plurality of bus bars from the positive terminal and the negative terminal, and defining a positive bus linkage hole and a negative bus linkage hole; wherein the plurality of bus bars include a positive bus linkage extending from a first bus bar of the plurality of bus bars through the positive bus linkage hole and include a negative bus linkage extending from a second bus bar of the plurality of bus bars through the negative bus linkage hole; and241601492289.1Attorney Docket No.: 3726039.00069 wiring that connects a portion of the positive bus linkage extending through the wiring deck to a positive terminal and that connects a portion of the negative bus linkage extending through the wiring deck to a negative terminal.

11. The battery' pack of claim 1 , further comprising: a first bus bar, defining a first solder lake in a first compressed region of the first bus bar; a second bus bar, defining a second solder lake in a second compressed region of the second bus bar; a first solder pool, disposed in the first solder lake; a second solder pool, disposed in the first solder lake; and a wire, captured in the first solder pool on a first end and in the second solder pool on a second end, establishing electrical communication between the first bus bar and the second bus bar.

12. The battery pack of claim 1 , further comprising: a wire bond comprising a plurality of bonding wires connecting a bus bar with a terminal surface of a cell of the plurality of cells through a cell-hole defined in the bus bar, wherein the plurality of bonding wires includes: a first set of bonding wires located at a first location around a circumference of a cell-hole; a second set of bonding wires located a second location around the circumference of the cell-hole, rotationally opposite to the first location about the circumference; and251601492289.1Attorney Docket No.: 3726039.00069 a third set of bonding wires located at a third location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference.

13. The battery' pack of claim 12, wherein the plurality' of bonding wires includes: a fourth set of bonding wires located at a fourth location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference and rotationally opposite to the third location, wherein a number of bonding wires in the fourth plurality7of bonding wires equals a number of bonding wires with failed connections in the first, second and third sets of bonding wires.

14. The battery' pack of claim 1, further comprising: a conformal heatsink, bonded on a given face of the battery pack to the plurality of cells via a thermally conductive adhesive.

15. The battery pack of claim 1 , further comprising: a thermally conductive adhesive injected to fill inter-cell spaces between cells of the plurality of cells included in the battery pack.

16. A battery pack, comprising: an upper bussing deck, formed of a non-conductive material in which a first cavity and a second cavity are defined; a lower bussing deck, formed of the non-conductive material in which a third cavity and a fourth cavity are defined;261601492289.1Attorney Docket No.: 3726039.00069 a positive upper bus bar, shaped conformally to the first cavity and disposed therein with one face exposed therefrom; a negative upper bus bar, shaped conformally to the second cavity and disposed therein with one face exposed therefrom; a positive lower bus bar, shaped conformally to the third cavity7and disposed therein with one face exposed therefrom; a negative lower bus bar, shaped conformally to the fourth cavity7and disposed therein with one face exposed therefrom; a plurality7of battery cells disposed betw een the upper bussing deck and the low7er bussing deck, the plurality7of battery7cells including: a first subset disposed with positive ends connected to the positive upper bus bar and negative ends connected to the negative low er bus bar; and a second subset disposed with positive ends connected to the positive low er bus bar and negative ends connected to the negative upper bus bar; wherein each cell of the plurality7of battery cells is bonded to two respective bus bar via a corresponding cell-hole in each of the two respective bus bars and a plurality of bonding wires; a heat sink conformally installed between the upper bussing deck and the low er bussing deck to a subset of the plurality of battery cells on one face of the battery7pack; a thermally conductive adhesive bonding the heat sink with the subset of the plurality7of battery7cells and filling inter-cell gaps between the plurality of battery cells; and a wiring deck, formed of the non-conductive material, disposed on a first side of the upper bussing deck opposite to a second side of the upper bussing deck connected to the plurality of cells, including a circuitry for controlling a temperature sensor that is inserted through the wiring deck and upper bussing deck into the thermally conductive adhesive.271601492289.1Attorney Docket No.: 3726039.0006917. A method for fabricating a battery pack, comprising: forming solder lakes on a first plurality of bus bars and a second plurality of bus bars; installing the first plurality of bus bars into first side of a first bussing deck; installing the second plurality7of bus bars into first side of a second bussing deck; connecting the first plurality7of bus bars to one another via the solder lakes formed thereon; connecting the second plurality of bus bars to one another via the solder lakes formed thereon; installing a plurality of battery cells into a second side, opposite to the first side, of the first bussing deck and into a second side, opposite to the first side, of the second bussing deck; and forming a plurality of wire bonds between each cell of the plurality of battery cells to a corresponding one of the first plurality7of bus bars and a corresponding one of the second plurality of bus bars.

18. The method of claim 17, wherein: each wire bond of the plurality of wire bonds comprises a plurality of bonding wires connecting a terminal surface of a corresponding cell of the plurality of battery cells through a cell-hole defined in a respective bus bar of the corresponding one of the first plurality of bus bars or the corresponding one of the second plurality of bus bars, wherein the plurality of bonding wires includes: a first set of bonding wires located at a first location around a circumference of a cell-hole;281601492289.1Attorney Docket No.: 3726039.00069 a second set of bonding wires located a second location around the circumference of the cell-hole, rotationally opposite to the first location about the circumference; a third set of bonding wires located at a third location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference; and a fourth set of bonding wires located at a fourth location around the circumference of the cell-hole, rotationally between the first location and the second location about the circumference and rotationally opposite to the third location, forming the plurality of wire bonds includes testing connections between the corresponding cell of the plurality of battery cells and the respective bus bar for the bonding wires in the first, second and third sets of bonding wires; and a number of bonding wires in the fourth set of bonding wires equals a number of bonding wires in the first, second and third sets of bonding wires with failed connections between the corresponding cell of the plurality of battery cells and the respective bus bar according to the testing.291601492289.1

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