Abstract: A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

Abstract: A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

Abstract: A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

Abstract: A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

Abstract: A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

Abstract: A battery module includes a lower housing and a plurality of battery cells. The plurality of battery cells are electrically coupled together to produce a voltage. The module also includes an assembly disposed over the battery cells and coupled to the lower housing. The assembly may include a lid and a plurality of bus bar interconnects mounted on the lid. The module also includes a printed circuit board (PCB) assembly disposed on and coupled to the assembly. The PCB assembly may include a PCB. The module also includes a cover disposed over and coupled to the lower housing to hermetically seal the battery module. Also disclosed is a method of manufacturing the battery module.

Abstract: A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

Abstract: A battery module comprising a housing, a venting assembly, a plurality of battery cells disposed in the housing, a printed circuit configured to control operations of the battery module, a vent chamber of the venting assembly, and a lid including the venting assembly. Each of the plurality of battery cells comprises a battery cell vent for venting gases from within the corresponding battery cell upward in a direction of the printed circuit. The vent chamber is disposed between the plurality of battery cells and the printed circuit. The vent chamber is configured to direct the gases vented from the battery cell vent toward an opening for venting the gases from the battery module. The lid is disposed over the plurality of battery cells and holds the printed circuit above the plurality of battery cells.

Abstract: The present disclosure includes a battery module that includes an electrochemical cell having a minor terminal. The battery module also includes a major terminal electrically coupled to the electrochemical cell, wherein the major terminal includes a base and a post extending from the base. Further, the battery module includes an electrical path between the minor terminal of the electrochemical cell and the major terminal of the battery module. The electrical path includes a bus bar having an opening that receives the post of the major terminal and a pocket that retains the base of the major terminal.

Abstract: A battery module includes a housing and battery cells disposed in the housing, each of the battery cells including two terminals. The battery module also includes bus bar cell interconnects including a first material, where each bus bar cell interconnect is configured to electrically couple two adjacent battery cells via an electrical coupling with a first terminal of one of the adjacent battery cells and a second terminal of the other adjacent battery cell, where at least one of the first and second terminals includes the first material. The battery module includes welds, each weld being disposed at a corresponding welding point to directly couple one of the bus bar cell interconnects with the corresponding at least one terminal including the first material. Each welding point is accessible for welding from a position above the battery cells when the interconnects are disposed over the battery cells.

Abstract: A battery module includes a lower housing and a plurality of battery cells. The plurality of battery cells are electrically coupled together to produce a voltage. A lid assembly is disposed over the battery cells and is coupled to the lower housing. The lid assembly includes a lid and a plurality of bus bar interconnects mounted on the lid. A printed circuit board (PCB) assembly is disposed on and coupled to the lid assembly, and the PCB assembly includes a PCB. A cover is disposed over and coupled to the lower housing to hermetically seal the battery module.

Abstract: Present embodiments are directed to a battery module including a venting assembly and a method of manufacturing the battery module. The venting assembly may, in certain embodiments, be designed to vent gases from a plurality of battery cells disposed in a housing of the battery module. Each of the plurality of battery cells may include a battery cell vent. The venting assembly may include a lid designed to be coupled to the housing and disposed over the battery cells in the housing. In some embodiments, the lid includes a vent chamber formed in the lid and designed to receive and direct gases vented from the plurality of battery cells away from the battery module.

Abstract: A battery module including bus bar cell interconnects and a method of manufacture are provided. The battery module may, in certain embodiments, include a housing, a plurality of battery cells disposed in the housing, and a bus bar cell interconnect. The bus bar cell interconnect is designed to electrically couple a first battery cell and a second battery cell. In some embodiments, the bus bar cell interconnect includes a first end electrically coupled with a first terminal of the first battery cell and a second end electrically coupled with a second terminal of the second battery cell. The bus bar cell interconnect also includes a curved portion disposed between the first end and the second end, and the bus bar cell interconnect is designed to distribute stress across the curved portion.

Abstract: A lid assembly for use in a battery module includes a lid with apertures extending through the lid in a vertical direction, where each of the apertures is configured to receive a terminal of a battery cell of the battery module. The lid assembly also includes one or more extensions extending away from the lid in the vertical direction. Each of the one or more extensions is configured to couple the lid to a printed circuit board assembly of the battery module. The lid assembly also includes walls extending away from the lid in the vertical direction. Each of the walls is configured to extend between a first terminal of a first battery cell and a second terminal of a second battery cell.

Abstract: The present disclosure relates to a lithium-ion battery module including a housing having a base, a battery cell in the housing, and a battery module terminal coupled to the battery cell via an electrical pathway, wherein the battery module terminal provides an electrical output when coupled to an electrical load, and wherein the electrical pathway is defined by a first portion, a second portion, and an interconnecting portion connecting the first and second portions. The first portion has a plurality of first conductive components coupled to one another within first connection planes using a first conductive material, and the first connection planes are substantially parallel to the base. The second portion has a plurality of second conductive components coupled to one another within second connection planes using a second conductive material, different from the first conductive material, and the second connection planes are crosswise to the first connection planes.

Abstract: A battery module includes a lower housing and a plurality of battery cells. The plurality of battery cells are electrically coupled together to produce a voltage. A lid assembly is disposed over the battery cells and is coupled to the lower housing. The lid assembly includes a lid and a plurality of bus bar interconnects mounted on the lid. A printed circuit board (PCB) assembly is disposed on and coupled to the lid assembly, and the PCB assembly includes a PCB. A cover is disposed over and coupled to the lower housing to hermetically seal the battery module.

Abstract: A battery system having a bladed fuse connector and a method of operation of the bladed fuse connector are provided. The system may, in certain embodiments, include a printed circuit board (PCB) and a high current interconnect. The high current interconnect may be mounted to and extending upward from the PCB. The battery system may also include a fuse. The fuse may limit an amount of current flowing through the battery system. Additionally, the battery system may include a bladed fuse connector coupled between the high current interconnect and the fuse. The bladed fuse connector may carry a current between the high current interconnect and the fuse. To that end, the bladed fuse connector may include an S-shaped bend between the high current interconnect and the fuse.

Abstract: A method of manufacturing a battery module for use in a vehicle is presented. The method may include disposing battery cells into a lower housing and disposing a lid assembly over the battery cells. The lid assembly may include a lid and bus bar interconnects disposed on the lid. The method may also include disposing a printed circuit board (PCB) assembly onto the lid assembly and electrically coupling portions of the lid assembly, portions of the PCB assembly, and the battery cells to each other.

Abstract: A printed circuit board (PCB) assembly includes a PCB and a high current interconnect mounted on the PCB. The high current interconnect is configured to electrically couple a first high current bladed component, a second high current bladed component, and a trace disposed on the PCB. The high current interconnect includes feet made of a conductive material that are coupled to the PCB. The trace is coupled to the feet via a weld.

Abstract: A battery module includes a housing and battery cells disposed in the housing, each of the battery cells including two terminals. The battery module also includes bus bar cell interconnects including a first material, where each bus bar cell interconnect is configured to electrically couple two adjacent battery cells via an electrical coupling with a first terminal of one of the adjacent battery cells and a second terminal of the other adjacent battery cell, where at least one of the first and second terminals includes the first material. The battery module includes welds, each weld being disposed at a corresponding welding point to directly couple one of the bus bar cell interconnects with the corresponding at least one terminal including the first material. Each welding point is accessible for welding from a position above the battery cells when the interconnects are disposed over the battery cells.