Abstract: An improved battery module and methods of assembly are disclosed. A battery module may include carriers for holding battery cells via interference fit. The carriers may include a busbar with a stamped fusible link between each battery cell and the busbar. The battery module may be held together via interference fit, laser welding, and friction welding. A method of assembly may electrically and mechanically connect battery cells by laser welding stamped fusible links within a busbar. The method may further enclose the battery cells within a case and create a seal between the lid and case using friction welding.

Abstract: A battery cell assembly is provided. The battery cell assembly includes a battery cell and a heat exchanger disposed adjacent the battery cell configured to cool the battery cell. The heat exchanger has an outer housing. The outer housing defines an interior region and first and second flow guide members. The first and second flow guide members define a serpentine flow path in the interior region. The first and second flow guide members are tilted generally upwardly in the interior region. The serpentine flow path extends from an inlet aperture in the outer housing to another flow path in the outer housing. The another flow path extends from the serpentine flow path to an outlet aperture.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a battery cell having a first side and a second side, and a first graphite sheet disposed on the first side of the battery cell that conducts heat energy from the battery cell into the first graphite sheet to cool the battery cell. The battery module further includes a first cooling manifold coupled to the first graphite sheet that conducts heat energy from the first graphite sheet into the first cooling manifold. The first cooling manifold is further configured to receive a fluid that flows therethrough to conduct heat energy from the first cooling manifold into the fluid.

Abstract: A frame member for housing a battery cell, frame assembly and frame/battery cell assembly made therefrom, as well as respective methods of making the same, are disclosed. A frame member for housing a battery cell includes an integral frame having a peripheral wall, the peripheral wall having an attachment face and an opposed cooling face, and an attachment feature located on the attachment face and a complementary attachment feature located on the attachment face that is symmetrically opposed to the attachment feature about a plane of symmetry of the frame, the peripheral wall defining an opening that is configured to matingly receive a battery cell therein. A pair of frame members having a cooling member placed therebetween and attached to the respective attachment faces comprises a frame assembly. A frame/battery cell assembly includes a pair of frame assemblies having at least one battery cell placed therebetween.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a housing having an electrically non-conductive oil disposed therein, and a battery cell disposed in the housing that contacts the electrically non-conductive oil. The battery module further includes first and second heat conductive fins disposed in the housing that contacts the electrically non-conductive oil. The first and second heat conductive fins extract heat energy from the electrically non-conductive oil. The battery module further includes first and second conduits extending through the first and second heat conductive fins, respectively. The first and second conduits receive first and second portions of a fluid, respectively, therethrough and conduct heat energy from the first and second heat conductive fins, respectively, into the fluid to cool the battery cell.

Abstract: A battery module and a related method are provided. The module includes battery cells having electrical terminals extending from battery portions. The module further includes an interconnect board having apertures for receiving the electrical terminals therethrough, and an elastomeric layer having apertures extending therethrough. The elastomeric layer is disposed proximate to the interconnect board such that the electrical terminals extend through the apertures of the interconnect board and further extend through the apertures of the elastomeric layer. The module further includes a potting compound disposed on the elastomeric layer such that the layer prevents the potting compound from contacting the battery portions.

Abstract: A battery module is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers therein. The battery module includes a first rubber cooling manifold configured to route a fluid into the plurality of heat exchangers. The first rubber cooling manifold has a first tubular member, a first inlet port, a first plurality of outlet ports, and first and second end caps. The first end cap is coupled to a first end of the first tubular member. The second end cap is coupled to a second end of the first tubular member. The first inlet port is disposed on a top portion of the first tubular member for routing the fluid into the first tubular member. The first plurality of outlet ports is disposed collinearly and longitudinally along an outer surface of the first tubular member and spaced apart from one another. The first plurality of outlet ports extend outwardly from the outer surface of the first tubular member.

Abstract: A battery system is provided. The battery system includes a first battery cell assembly having first and second interconnect members. The first and second interconnect members have first and second blades, respectively. The battery system further includes an electrically non-conductive base member having first and second grooves. The battery system further includes first and second bus bar members disposed in the first and second grooves, respectively. The first bus bar member has a first aperture configured to removably receive the first blade therein. The second bus bar member has a second aperture configured to removably receive a second blade therein.

Abstract: A battery module is provided. The battery module includes a battery cell and a heat exchanger disposed adjacent to the battery cell. The battery module further includes a cooling manifold having a tubular wall, a first fluid port, and a ring shaped member. The tubular wall defines an interior region and having first and second end portions. The first fluid port extends outwardly from an outer surface of the tubular wall and fluidly communicates with the interior region of the tubular wall. The ring shaped member is disposed on an outer surface of the first fluid port a predetermined distance from the outer surface of the tubular wall.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a battery cell having a first side and a second side, and a first graphite sheet disposed on the first side of the battery cell that conducts heat energy from the battery cell into the first graphite sheet to cool the battery cell. The battery module further includes a first cooling manifold coupled to the first graphite sheet that conducts heat energy from the first graphite sheet into the first cooling manifold. The first cooling manifold is further configured to receive a fluid that flows therethrough to conduct heat energy from the first cooling manifold into the fluid.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a battery cell having a first side and a second side, and a first graphite sheet disposed on the first side of the battery cell that conducts heat energy from the battery cell into the first graphite sheet to cool the battery cell. The battery module further includes a first cooling manifold coupled to the first graphite sheet that conducts heat energy from the first graphite sheet into the first cooling manifold. The first cooling manifold is further configured to receive a fluid that flows therethrough to conduct heat energy from the first cooling manifold into the fluid.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a housing having an electrically non-conductive oil disposed therein, and a battery cell disposed in the housing that contacts the electrically non-conductive oil. The battery module further includes first and second heat conductive fins disposed in the housing that contacts the electrically non-conductive oil. The first and second heat conductive fins extract heat energy from the electrically non-conductive oil. The battery module further includes first and second conduits extending through the first and second heat conductive fins, respectively. The first and second conduits receive first and second portions of a fluid, respectively, therethrough and conduct heat energy from the first and second heat conductive fins, respectively, into the fluid to cool the battery cell.

Abstract: A lead-acid battery is disclosed, wherein the battery comprises battery modules connected in series, a sealed container, a positive terminal, and a negative terminal. A battery module, in turn, comprises one or more cell assemblies electrically connected in parallel. Next in the hierarchical design, each cell assembly comprises a plurality of electrochemical cells connected in series. Finally, each electrochemical cell comprises a cathode and an anode ionically connected via a separator. In some embodiments, the plurality of modules are disposed within a common cavity in fluid communication via a common fluid. In some embodiments, each battery module has an electric potential of approximately 12 V. In some embodiments, the battery comprises four battery modules and provides a minimum electric potential of approximately 48V.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a housing having an electrically non-conductive oil disposed therein, and a battery cell disposed in the housing that contacts the electrically non-conductive oil. The battery module further includes first and second heat conductive fins disposed in the housing that contacts the electrically non-conductive oil. The first and second heat conductive fins extract heat energy from the electrically non-conductive oil. The battery module further includes first and second conduits extending through the first and second heat conductive fins, respectively. The first and second conduits receive first and second portions of a fluid, respectively, therethrough and conduct heat energy from the first and second heat conductive fins, respectively, into the fluid to cool the battery cell.

Abstract: A battery cell assembly, a heat exchanger, and a method for manufacturing the heat exchanger are provided. The heat exchanger includes a rectangular-shaped sheet having first and second rectangular-shaped sheet portions coupled together at a bent edge such that the sheet portions are disposed proximate to one another. Outer edges of the first and second rectangular-shaped sheet portions are coupled together such that an interior region is formed between the first and second rectangular-shaped sheet portions. The bent edge has first and second apertures extending therethrough. The heat exchanger further includes a first inlet port disposed on the bent edge over the first aperture, and a second outlet port disposed on the bent edge over the second aperture, such that fluid can flow through the first inlet port and into the interior region and then through the outlet port.

Abstract: Battery systems, a battery module, and a method for cooling the battery module are provided. The battery module includes a housing having a non-conductive oil disposed therein. The battery module further includes a battery cell disposed in the housing. The battery module further includes a cooling manifold disposed in the housing that contacts the non-conductive oil. The cooling manifold is configured to receive a fluid therethrough and to conduct heat energy from the non-conductive oil into the fluid to cool the battery cell.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a first battery cell, and a first cooling fin having a first panel portion and first and second rail portions that are disposed on first and second ends, respectively, of the first panel portion. The first battery cell is disposed adjacent to a first side of the first panel portion. The first and second rail portions have a thickness greater than the first panel portion. The first cooling fin conducts heat energy from the first battery cell into the first cooling fin to cool the first battery cell. The battery module further includes first and second conduits extending through the first and second rail portions, respectively, that receive a fluid that flows through the first and second conduits to conduct heat energy from the first cooling fin into the fluid.

Abstract: A battery module is provided. The battery module includes a battery cell and a heat exchanger disposed adjacent to the battery cell. The battery module further includes a cooling manifold having a tubular wall, a first fluid port, and a ring shaped member. The tubular wall defines an interior region and having first and second end portions. The first fluid port extends outwardly from an outer surface of the tubular wall and fluidly communicates with the interior region of the tubular wall. The ring shaped member is disposed on an outer surface of the first fluid port a predetermined distance from the outer surface of the tubular wall.

Abstract: A battery module having a cooling manifold is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers. The battery module further includes a first cooling manifold having a first inlet aperture extending therethrough and a first plurality of outlet apertures extending therethrough. The battery module further includes a first plurality of ported screws disposed through the first plurality of outlet apertures and configured to fluidly and physically couple the plurality of heat exchangers to the first cooling manifold.

Abstract: A battery module having a cooling manifold is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers. The battery module further includes the cooling manifold operably coupled to the plurality of battery cell assemblies. The cooling manifold has a manifold portion and a cover plate. The manifold portion has a peripheral wall, a rear wall coupled to the peripheral wall, and a flow diverter. The peripheral wall has a top portion with an inlet aperture extending therethrough. The rear wall has a plurality of outlet apertures extending therethrough. The cover plate is coupled to the peripheral wall opposite to the rear wall. The flow diverter extends from the rear wall and is disposed below the inlet aperture.