Abstract: Systems are disclosed for battery modules with housing systems. In accordance with disclosed embodiments, the housing system may include a four-walled casing (e.g., no top/bottom) with at least one hole and plug that couples with the hole in the casing using a detention mechanism. The casing may house multiple prismatic cells in a face-to-face arrangement. The plug may extend through the hole in the casing to contact and apply a compressive force to the cells within the casing. Further, the casing may have the hole and plug assembly on parallel sides, enabling the compressive force to be applied to the cells from both directions. The compressive force may retain the cells in the casing and limit the swelling of the cells to maintain their product life. The housing system may also include a cooling system in contact with the bottom of the cells and/or compression plates to distribute the compressive force evenly on the prismatic cells.

Abstract: A current collector with improved flexibility and electrical conductivity includes at least one flexible leg coupled to a central portion of the current collector. The flexible leg extends substantially orthogonally to the central portion when a force is applied to the central portion. Specifically, the at least one flexible leg extends at least 16 percent of the outer width when a 1000 Newton loading is applied between the central portion and the outer portion.

Abstract: In an embodiment, a system includes a battery management unit (BMU) coupled to a battery pack of an xEV. Further, the BMU is configured to determine an energy remaining value for the battery pack based, at least in part, on a minimum cell temperature and a minimum cell state of charge percentage (SOC %) determined by the BMU for the battery pack.

Abstract: Provided herein are electrochemical cell element systems. One such system includes a first electrode having a desired length and an interrupted second electrode having one or more interruptions disposed between a plurality of electrode segments. The system also includes one or more separators positioned to separate the first electrode and the interrupted second electrode. The first electrode, the interrupted second electrode, and the one or more separators are wound along the length of the cell element.

Abstract: Provided herein are electrochemical cells having improved heat collection and transfer systems. For example, one electrochemical cell includes a drawn can having a blind side and a second side opposite the blind side. The cell also includes a positive terminal disposed in the blind side of the can and electrically coupled to at least one positive electrode disposed within the can and a negative terminal disposed in the blind side of the can and electrically coupled to at least one negative electrode disposed within the can. The cell further includes a base coupled to a substantially flat edge disposed on the second side of the can. A bottom surface of the base is adapted to maintain a substantially flat configuration when coupled to a heat sink.

Abstract: Battery systems and modules having external thermal management systems are provided. In one embodiment, a battery module includes a housing and at least one electrochemical cell disposed within the housing. The battery module also includes a thermal interface having a first side in contact with the at least one electrochemical cell. The battery module also includes a heat sink in contact with a second side of the thermal interface. The thermal interface is adapted to enable heat transfer from the at least one electrochemical cell to the heat sink.

Abstract: A battery module includes a rigid external casing made, for example, of a metallic sheet material. Securement features, tabs, and so forth may be formed in the material of the casing. The casing may be made by stamping and bending metallic sheet. A liner is disposed in the casing, and one or more battery cells are disposed in the liner. The liner may comprise an insulative sheet material that is cut and folded to generally conform to the casing. The structure may include a bus bar assembly, compression members, a thermal component and other structural and functional elements.

Abstract: Provided battery systems include a plurality of battery electronic control units, each associated with a battery pack of a plurality of battery packs. Each battery electronic control unit is adapted to acquire analog current measurements of the associated battery pack and to convert the acquired analog current measurements to a digital value such that the plurality of battery electronic control units produce a plurality of digital values. The system may sum the digital values, or may process pulse-width modulated signals, analog signals and so forth. A battery system electronic control unit is adapted to receive and monitor the plurality of digital values and to determine a total battery system current value based on the received plurality of digital values.

Abstract: A buss bar for connecting electrochemical cells together includes a conductive member having a first end, a second end, and an elongated body between the first end and second end. The body includes a stress relief region configured to dampen vibrational forces received by the buss bar. The buss bar also includes a voltage sense terminal coupled to the conductive member.