Abstract: The present invention provides a module for retaining and cooling a group of primary or secondary electrochemical cells for use in powered devices. To provide more effective cooling and reduce thermal gradients, cells are aligned in a side-by-side configuration within a multi-pass cooling passage. The multi-pass cooling in each module results in potentially longer useful life for the entire array. Large array batteries are formed of multiple modules, the shape and configuration of the modules allowing a variety of compact combinations having high energy density. In one configuration of an array battery according to the invention, two decks of modules are stacked vertically within a rigid enclosure. Air as a cooling medium is induced through each module to reduce cell temperatures. Temperature monitoring of each cell in a module and array allow for maintenance and identification of thermal events effecting continued long term operation.

Abstract: A connector assembly connects a plurality of battery cells in a serial/parallel arrangement. Each battery cell includes a cover and a canister having a side and a bottom. Each battery cell is constructed such that a segment of the side of the canister forms a top crimped portion that retains the cover and is electrically isolated from the cover. The connector assembly includes a conductive weld cup. The conductive weld cup includes a bordered portion and recessed portion. The bordered portion includes a first side wall and a ledge that is substantially planar. The recessed portion is recessed within the ledge. The recessed portion includes a recessed portion and a floor that is substantially planar. The first side wall includes an integrated tab projecting from it. An inner surface of the bordered portion engages an outer surface of the side and the bottom of the canister of an upper adjacent battery cell. An outer surface of the floor engages a cover of a lower adjacent battery cell.