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.
Abstract:
A lid assembly 56 for use in a battery module 22 includes a lid 290 with apertures 292 extending through the lid 290 in a vertical direction, where each of the apertures 292 is configured to receive a terminal 232 of a battery cell 54 of the battery module 22. The lid assembly 56 also includes one or more extensions 332 extending away from the lid 290 in the vertical direction. Each of the one or more extensions 332 is configured to couple the lid 290 to a printed circuit board assembly 58 of the battery module 22. The lid assembly 56 also includes walls 334 extending away from the lid 290 in the vertical direction. Each of the walls 334 is configured to extend between a first terminal 232 of a first battery cell 54 and a second terminal 232 of a second battery cell 54.
Abstract:
A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.
Abstract:
A terminal for a battery module and a method of manufacture of the terminal are provided. The battery module may include a plurality of battery cells and a bus bar. The bus bar may be electrically coupled to the plurality of battery cells. The battery module also may include a battery terminal that carries a voltage from the bus bar. The battery terminal may include a generally cylindrical terminal portion and a connector. The connector may be coupled to the bus bar cell interconnect. The battery terminal also may include a bent portion. The bent portion is disposed between the terminal portion and the connector.
Abstract:
A battery module includes a housing configured to hold prismatic battery cells within a space defined by four interior walls of the housing. The housing includes a first interior wall that includes partitions (e.g., ribs) extending upwards from a bottom of the housing and a second interior wall that includes partitions extending upwards from the bottom of the housing. The first interior wall faces opposite the second interior wall. The partitions disposed on the first interior wall and the partitions disposed on the second interior wall define slots between adjacent partitions, where each of the slots increases in width between the adjacent partitions from the bottom of the housing upwards. Each of the slots is configured to retain one of the prismatic battery cells.
Abstract:
A battery module includes a housing and battery cells disposed in the housing, each of the battery cells including two terminals. The battery module also includes bus bar cell interconnects including a first material, where each bus bar cell interconnect is configured to electrically couple two adjacent battery cells via an electrical coupling with a first terminal of one of the adjacent battery cells and a second terminal of the other adjacent battery cell, where at least one of the first and second terminals includes the first material. The battery module includes welds, each weld being disposed at a corresponding welding point to directly couple one of the bus bar cell interconnects with the corresponding at least one terminal including the first material. Each welding point is accessible for welding from a position above the battery cells when the interconnects are disposed over the battery cells.
Abstract:
A printed circuit board (PCB) assembly 58 may include a PCB 136 and a high current interconnect 140 mounted on the PCB 136. The high current interconnect 140 may be configured to electrically couple a first high current bladed component 153, a second high current bladed component 154, and a trace disposed on the PCB 136. The high current interconnect 140 may include feet 145 made of a conductive material that are coupled to the PCB 136. The trace may be coupled to the feet 148 via a weld.
Abstract:
Present embodiments are directed to a battery module including a venting assembly and a method of manufacturing the battery module. The venting assembly may, in certain embodiments, be designed to vent gases from a plurality of battery cells disposed in a housing of the battery module. Each of the plurality of battery cells may include a battery cell vent. The venting assembly may include a lid designed to be coupled to the housing and disposed over the battery cells in the housing. In some embodiments, the lid includes a vent chamber formed in the lid and designed to receive and direct gases vented from the plurality of battery cells away from the battery module.