Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A battery pack includes a thermally conductive plate that can be cooled or heated, and an array of electrochemical cells. The cells include a stacked or rolled arrangement of electrode plates, and a current collector disposed in the battery cell that forms an electrical connection with the electrode plates and provides a thermal conduction pathway for conducting heat from the electrode plates to the thermally conductive plate.

Abstract: A battery system includes a first battery cell that is electrically connected to a second battery cell via directed contact between compliant terminals of the first and second battery cells. The compliant terminals include a first end that is electrically connected an electrode assembly disposed within the cell, a second end disposed outside the cell, and an elastically compliant portion disposed between the second end and a cell housing.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and an elastic restraint that surrounds a plate stack of the electrode assembly.

Abstract: A battery pack includes a two-dimensional or three-dimensional array of battery cells, each cell having a polygonal (i.e, rectangular) shape and a “three side-and-one side” terminal configuration. In some embodiments, the terminal configuration allows the cells to be electrically connected in any configuration, series, parallel, or series parallel simply by changing the orientation of the cell relative to adjacent cells and applying pressure to maintain contact. For a rectangular cell shape, this is achieved by providing three like charged terminals (such as positive) on three respective sides of the cell and one oppositely charged terminal (such as negative) on a fourth side of the cell while maintaining a neutral charge on both of the end surfaces of the cell.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A pouch cell (20A, 20) includes a generally rectangular cell housing (20, 21) formed of a metal laminated film, an electrode assembly (60) that is sealed within the cell housing (20, 21), and a current collector device disposed in the cell housing (20, 21). The electrode assembly (60) includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis (66). The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing (20, 21) via an opening (28, 428) formed in the cell housing (20, 21). The opening (28, 428) is formed in a side (22, 24) wall of the cell housing (20, 21) at a location spaced apart from the sealed joint (40) that closes the cell housing (20, 21) and at a location facing the stack axis (66).

Abstract: A vehicle battery system includes a battery housing and a plurality of straps. The battery housing is configured to house a battery for powering the vehicle. Each of the plurality of straps is configured to extend about the battery housing, and includes a first end portion and a second end portion that are configured to be attached to the vehicle. The plurality of straps is configured such that upon application of a shock load to the battery housing along a first axis, the plurality of straps deforms prior to deformation of the battery housing.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and a current collector device disposed in the cell housing. The electrode assembly includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis. The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing via an opening formed in the cell housing. The opening is formed in a side wall of the cell housing at a location spaced apart from the sealed joint that closes the cell housing and at a location facing the stack axis.

Abstract: An electrochemical pouch cell includes a stacked or rolled arrangement of electrode plates disposed in a cell housing, and a lead tab that protrudes through the cell housing. The lead tab forms an electrical connection with the electrode plates within the cell and permits transfer of current out of the cell via an opening in a seal joint of the pouch cell housing. The lead tab has a configuration that improves reliability of the seal between the lead tab and the opening.

Abstract: An electrochemical pouch cell includes a stacked or rolled arrangement of electrode plates disposed in a cell housing, and a lead tab that protrudes through the cell housing. The lead tab forms an electrical connection with the electrode plates within the cell and permits transfer of current out of the cell via an opening in a seal joint of the pouch cell housing. The lead tab has a configuration that improves reliability of the seal between the lead tab and the opening.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and a current collector device disposed in the cell housing. The electrode assembly includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis. The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing via an opening formed in the cell housing. The opening is formed in a side wall of the cell housing at a location spaced apart from the sealed joint that closes the cell housing and at a location facing the stack axis.

Abstract: A battery pack housing forms a container that receives battery modules. The battery pack housing includes container portion and a cover that closes an open end of the container portion. The container portion includes a base, sidewalls that surround the base, and parallel rails that protrude from the base inner surface. The rails have longitudinally-spaced slots that open facing the cover. In addition, an inner surface of the cover portion includes parallel rails having longitudinally spaced slots that open facing the base. The slots are configured to receive and retain pins provided on side surfaces of the battery module housing. The cooperation between the pins of the battery module housing and the slots of the container portion and cover portion permit modules to be easily and securely located within the battery pack housing, and to be quickly removed from the battery pack housing during maintenance.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A battery pack includes a two-dimensional or three-dimensional array of battery cells, each cell having a polygonal (i.e, rectangular) shape and a “three side-and-one side” terminal configuration. In some embodiments, the terminal configuration allows the cells to be electrically connected in any configuration, series, parallel, or series parallel simply by changing the orientation of the cell relative to adjacent cells and applying pressure to maintain contact. For a rectangular cell shape, this is achieved by providing three like charged terminals (such as positive) on three respective sides of the cell and one oppositely charged terminal (such as negative) on a fourth side of the cell while maintaining a neutral charge on both of the end surfaces of the cell.

Abstract: A battery system includes a first battery cell that is electrically connected to a second battery cell via directed contact between compliant terminals of the first and second battery cells. The compliant terminals include a first end that is electrically connected an electrode assembly disposed within the cell, a second end disposed outside the cell, and an elastically compliant portion disposed between the second end and a cell housing.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and an elastic restraint that surrounds a plate stack of the electrode assembly.

Abstract: A pouch cell (20A, 20) includes a generally rectangular cell housing (20, 21) formed of a metal laminated film, an electrode assembly (60) that is sealed within the cell housing (20, 21), and a current collector device disposed in the cell housing (20, 21). The electrode assembly (60) includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis (66). The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing (20, 21) via an opening (28, 428) formed in the cell housing (20, 21). The opening (28, 428) is formed in a side (22, 24) wall of the cell housing (20, 21) at a location spaced apart from the sealed joint (40) that closes the cell housing (20, 21) and at a location facing the stack axis (66).

Abstract: A battery pack includes a battery pack housing and an array of pouch cells disposed in the pack housing. The battery pack also includes a force generating assembly disposed in the battery pack housing. The force generating assembly is configured to apply a force to the array of cells along a first direction corresponding to a row of cells, and a force to the array of cells along a second direction corresponding to a column of cells. The forces result in a weld-free, direct electrical connection being formed between a first pair of adjacent cells within a row, and the second force results in a weld-free, direct electrical connection being formed between a second pair of adjacent cells within a column.