Abstract:
A battery module mounting system includes a housing of the battery module configured to receive a plurality of electrochemical cells, a lid coupled to a side of the housing, and a cage configured to secure the housing to a vehicle. Additionally, the cage includes a coupling mechanism configured to engage with the lid in a tongue and groove configuration to block movement of the housing in at least three directions when engaged.
Abstract:
A battery module includes a housing having an opening and a plurality of electrochemical cells disposed in the housing. The plurality of electrochemical cells have electrode terminals. The battery module also includes a carrier defined by an outside boundary and coupled to the plurality of electrochemical cells. The outside boundary of the carrier and the housing are in a nested arrangement. The battery module also includes a bus bar assembly disposed on the carrier, the bus bar assembly includes bus bars that electrically couple the electrode terminal of one of the plurality of electrochemical cells to a respective electrode terminal of another one of the plurality of electrochemical cells.
Abstract:
A battery module (13) includes a housing (31) having an interior defined by multiple sides, one side of which is a lid (55). The battery module also includes lithium ion electrochemical cells (30) disposed in the housing, each cell having a vent (60) through which gases may be vented. Moreover, the battery module includes a first chamber (64) defined by interior aspects of the housing that receives vented gases directed in a first direction (62) from the electrochemical cells. The first chamber is configured to direct the vented gases in a second direction (68) so that said vented gases then arrive in a second chamber (78) defined partially by the lid (55). Such a configuration of a vent structure helps to mitigate the negative impacts of vented gases from electrochemical cells being released inside a battery module.
Abstract:
Present embodiments include a series of lithium battery modules (28A-28C) having a plurality of electrochemical cells having different electrical characteristics such as voltages and/or capacities. The battery modules are each constructed using components, architectures, production methods, among other things, in common with each other. The lithium ion battery modules may include a first battery module type having a first capacity and a first voltage, a second battery module type having a second capacity and a second voltage, and, in some embodiments, additional battery module types having different voltages and/or capacities. The lithium ion battery modules may all have the same footprint (42).
Abstract:
The present disclosure includes a battery module having a power assembly that includes a plurality of battery cells and a plurality of bus bars that electrically couples a terminal of each of the plurality of battery cells to a terminal of an adjacent battery cell of the plurality of battery cells. The battery module also includes a lead frame that includes a plurality of cell taps respectively electrically coupled to the plurality of bus bars of the power assembly, and a plurality of leads that extends from the plurality of cell taps. The lead frame also includes a plurality of removable interconnects that are broken after assembly to electrically isolate the plurality of cell taps from one another and electrically isolate the plurality of leads from one another.
Abstract:
A method of manufacturing a battery module 22 for use in a vehicle 10 is presented. The method may include disposing battery cells 54 into a lower housing 50 and disposing a lid assembly 56 over the battery cells 54. The lid assembly 56 may include a lid 52 and bus bar interconnects disposed on the lid 52. The method may also include disposing a printed circuit board (PCB) assembly 58 onto the lid assembly 56 and electrically coupling portions of the lid assembly 56, portions of the PCB assembly 58, and the battery cells 54 to each other. The PCB is a multi-layered PCB with internal signal, power and ground layers and external ground cage layers for shielding from electrical noise.
Abstract:
The present disclosure a battery module having electrochemical cells and a bus bar carrier. The bus bar carrier includes a finger having a first surface, a second surface opposite to the first surface and configured to be disposed proximate to a first electrochemical cell of the plurality of electrochemical cells, a thickness extending between the first surface and the second surface, an opening extending through the first surface, through the thickness, and through the second surface, and a cavity disposed adjacent to the opening and exposed through the second surface of the finger. The battery module also includes a lead wire passing through the opening from the first surface of the finger to the second surface of the finger, and a sensor coupled to the lead wire to enable communication between the sensor and the first electrochemical cell, wherein the sensor is disposed in the cavity.
Abstract:
The present disclosure includes a battery module having a group of electrically interconnected electrochemical cells, a battery module terminal configured to be coupled to a load for powering the load, and an electrical path extending between the group of electrically interconnected electrochemical cells and the battery module terminal, where the electrical path includes a bus bar bridge. The battery module also includes a housing, where the group of electrically interconnected electrochemical cells is disposed within the housing, and the housing includes a pair of extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and to block movement of the bus bar bridge in at least one direction.
Abstract:
The present disclosure relates to a battery module that includes a housing having a first absorptive material configured to absorb a laser emission, a cover having a second absorptive material configured to absorb the laser emission, and a collar configured coupled to the housing and coupled to the cover via a laser weld. The collar includes a transparent material configured to transmit the laser emission through the collar and toward the housing or the cover.
Abstract:
A method of manufacturing a battery module for use in a vehicle is presented. The method may include disposing battery cells into a lower housing and disposing a lid assembly over the battery cells. The lid assembly may include a lid and bus bar interconnects disposed on the lid. The method may also include disposing a printed circuit board (PCB) assembly onto the lid assembly and electrically coupling portions of the lid assembly, portions of the PCB assembly, and the battery cells to each other.