Abstract:
A lithium-ion (Li-ion) battery (28) includes a plurality of battery cell stacks (50), wherein each battery cell stack (50) of the plurality of battery cell stacks (50) includes a plurality of Li-ion battery cells (54). The Li-ion battery (28) also includes a battery housing (42), the battery housing (42) having a plurality of cell compartments (74) formed by internal dividers (72) integral with the battery housing (42). Each cell compartment (74) of the plurality of cell compartments (74) is sized to receive a corresponding one battery cell stack (50) of the plurality of battery cell stacks (50).
Abstract:
The present disclosure includes a battery module having a plurality of battery cells disposed in a housing. Each of the plurality of battery cells has a positive terminal, a negative terminal, an overcharge protection assembly, and a casing having an electrically conductive material. The overcharge protection assembly includes a vent, a first spring component, a second spring component, and an insulative component. The first spring component is coupled to the positive terminal, the second spring component is coupled to the negative terminal, the insulative component is between the first spring component and a conductive piece and between the second spring component and the conductive piece, and the vent is configured to drive the insulative component from between the first and second spring components and the conductive piece, such that the first and second spring components contact the conductive piece, when a pressure in the casing exceeds a threshold.
Abstract:
A method for bonding components of a lithium ion battery module includes positioning an energy absorbing insert adjacent to a first thermoplastic layer of the lithium ion battery module and to a second thermoplastic layer of the lithium ion battery module. Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer. The first thermoplastic layer is a transmissive or semi- transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert.
Abstract:
The present disclosure includes a battery module having a stack of electrochemical cells that includes terminals, a housing that receives the stack of electrochemical cells, and a bus bar carrier disposed over the stack of electrochemical cells such that bus bars disposed on the bus bar carrier interface with the terminals of the stack of electrochemical cells. The bus bar carrier includes opposing first and second guide extensions, the stack of electrochemical cells is disposed between the opposing first and second guide extensions, and the opposing first and second guide extensions physically contact a first outer electrochemical cell and a second outer electrochemical cell, respectively, of the stack of electrochemical cells to guide the terminals of the stack of electrochemical cells toward corresponding ones of the bus bars disposed on the bus bar carrier.
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 having a housing and a stack of battery cells disposed in a receptacle area of the housing, where each battery cell has a top having a battery cell terminal and a bottom, where the top of the battery cells face outwardly away from the receptacle area. The battery module includes an integrated sensing and bus bar subassembly positioned against the stack of battery cells and has a carrier, a bus bar integrated onto the carrier, and a biasing member integrated onto the carrier. The bus bar electrically couples battery cells in an electrical arrangement, and the biasing member is between the top of each battery cell and the carrier, where the biasing member has a first material, more compliant than a second material of the carrier, and the biasing member biases the stack of battery cells inwardly toward the housing.
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 battery 24 includes a cell element 46 that is disposed in a housing 26, and the housing 26 is sealed with a top cover 28 made primarily of plastic. The top cover 28 may include a layer of metallic foil 68, which may make the top cover 28 more impermeable to moisture. The top cover 28 may also include a vent 38, which may or may not utilize the metallic foil 68 to determine the primary opening force of the vent. The top cover 28 may also have one or more stiffening ribs 102 that extend downwardly from a bottom portion of the top cover 28 to contact the cell element 46, so as to limit movement of the cell element 46 within the housing 26. In addition, the top cover 28 may have one or more conductive terminals 34, 36 that are at least partially overmolded by the plastic of the top cover 28.
Abstract:
A battery system includes an electrochemical cell. The electrochemical cell includes a cover having an opening therein. The electrochemical cell also includes an aluminum terminal pad disposed proximate an outer surface of the cover, and having a pad opening aligned with the opening in the cover. The pad opening includes a tapered surface such that the pad opening has a larger cross-sectional width proximate an upper surface of the aluminum terminal pad than proximate a lower surface of the aluminum terminal pad opposite the upper surface and facing the outer surface of the cover. The electrochemical cell also includes a rivet having a body portion extending through the opening in the cover, a head portion disposed in the pad opening of the aluminum terminal pad, and a shoulder extending between the body portion and the head portion. The head portion includes an inverted cone shape corresponding with the tapered surface of the pad opening and having a maximum cross-sectional width greater than a minimum cross-sectional width of the pad opening.
Abstract:
The present disclosure includes a battery module having a first electrochemical cell and a second electrochemical cell positioned adjacent to the first electrochemical cell. The battery module also includes a separator plate disposed between the first electrochemical cell and the second electrochemical cell. The separator plate includes a body comprising a first side and a second side opposite the first side. The first side is disposed adjacent a first face of the first electrochemical cell and includes a first indention. The first indention defines a first space between the first face of the first electrochemical cell and the first side of the separator plate. The first space is configured to enable swelling of the first electrochemical cell into the first space.