Abstract: A repeating frame assembly for a battery pack includes a first cooling frame member having a first electrically conductive connection terminal adjacent a first end of the first cooling frame member. The connection terminal includes a top leg forming at least a portion of the first surface of the first cooling frame member and a bottom leg forming at least a portion of the second surface of the first cooling frame member. A first electrically conductive tab of a first battery cell is attached to the top leg of the first electrically conductive connection terminal. A second battery cell may be contained within a second cooling frame member or a first spacer frame member having a second electrically conductive connection terminal adjacent a first end thereof for providing a compression joint having a low resistance electrical connection to the second tab of the first battery cell.

Abstract: A repeating cell frame for a battery pack assembly is disclosed having a cooling module and a spacer module. The cooling module includes a frame having a first electrical connector and a second electrical connector disposed thereon, wherein a first battery cell includes a first electrically conductive tab in electrical communication with the first electrical connector and a second electrically conductive tab in electrical communication with the second electrical connector. The spacer module includes a frame having a third electrical connector and a fourth electrical connector disposed thereon, wherein a second battery cell includes a first electrically conductive tab in electrical communication with the third electrical connector and a second electrically conductive tab in electrical communication with the fourth electrical connector. The third electrical connector of the spacer module is releasably joined to the second electrical connector of the cooling module to form the repeating cell frame.

Abstract: A module for a battery pack includes a cooling frame and a spacer frame. At least one of the first and second surfaces of the cooling frame is adapted to transfer heat to a coolant flow. A first battery cell having first and second electrically conductive tabs abuts a cooling frame member first surface. A second end of the cooling frame member includes a connection terminal for electrically connecting to the first electrically conductive tab. A spacer frame member first surface abuts the first battery cell, and a second surface abuts a second battery cell. A first end of the spacer frame member includes a connection terminal for electrically connecting to the second electrically conductive tab of the first battery cell and the first electrically conductive tab of the second battery cell.

Abstract: A battery cell module includes an enclosure having an electrically non-conductive perimeter and at least one cover formed from a thermally conductive material. The cover has a substantially flat inner surface and sealingly engages the electrically non-conductive perimeter. A plurality of series-interconnected battery cells are placed together into facing contact with each other, an exterior one of the battery cells in facing contact with the inner surface of the cover to facilitate heat transfer therethrough and to provide a desired compression against the series-interconnected battery cells. A first end of the series-interconnected battery cells includes a positive terminal end, and a second end of the series-interconnected battery cells including a negative terminal end, the series-interconnected battery cells the positive and negative terminal ends extending through the electrically non-conductive perimeter.