Abstract: Described herein are battery packs comprising thermal sensor modules and electric vehicles using these packs. In some examples, a battery pack comprises a set of battery modules positioned within the enclosed cavity formed, in part, by a set of side walls. The thermal sensor module is positioned within a thermal sensor module opening in the set of side walls and comprises a thermal sensor module housing a thermal sleeve, and a temperature sensor positioned within and thermally coupled with the thermal sleeve. The thermal sleeve physically contacts and is thermally coupled with at least one battery cell of the set of battery modules. The thermal sensor module may comprise a thermal sensor module spring configured to urge the thermal sleeve towards the battery cell. One or more retention tab may retain the thermal module in the thermal sensor module opening during fabrication of the battery modules.

Abstract: Described herein are battery modules and methods of fabricating thereof. In some examples, a battery module comprises an enclosure, separated into two enclosure portions and a thermal portion, positioned between the two enclosure portions. Two enclosure portions are in part defined by side walls, which can be tapered. The thermal portion comprises two thermal walls, which are operable as the bottoms of the two enclosure portions and form a thermal cavity between these thermal walls. In some examples, the enclosure is a monolithically cast component. Alternatively, the enclosure can be partially cast with one thermal wall welded thereafter to a cast subassembly. The battery module also comprises two sets of batteries, each positioned into a corresponding enclosure portion. Each battery set is interconnected with an interconnecting assembly, positioned between the battery set and the corresponding cover, for this enclosure portion.