Abstract: A battery module includes a first battery cell and a neighboring second battery cell, and an insulating member positioned therebetween. The battery module also includes a battery module enclosure surrounded by an external environment and configured to house each of the first battery cell, the second battery cell, and the insulating member. The battery module additionally includes a battery module cover mounted to the battery module enclosure. The battery module cover includes a vent feature configured to expel high temperature gases from the first battery cell and divert the high temperature gases away from the second battery cell directly to the external environment. The cover is thereby configured to minimize transfer of the high temperature gases from the first battery cell to the second battery cell and control propagation of a thermal runaway event in the battery module.

Abstract: Presented are finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals.

Abstract: Presented are finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals.

Abstract: A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.

Abstract: Assemblies and methods are provided for manufacturing a battery. A number of cells each have tabs for coupling the cell in the battery assembly. A housing has an opening through which each tab extends. The tabs are folded to overlie an outer surface of the housing. A bus bar is disposed on an opposite side of the tabs from the housing, with a coupling joint between the bus bar and the cells. The coupling joint may comprise a weld.

Abstract: A method of manufacturing an interconnect board (ICB) assembly for a battery module, the ICB assembly having a printed circuit board assembly (PCBA) and a carrier frame, includes depositing solder paste onto a printed circuit board (PCB) and/or a flexible printed circuit (flex circuit). The flex circuit has a conductive foil substrate coated with insulating material, and defines tabular flying leads radially-projecting from the flex circuit's periphery. The method may include positioning the PCB adjacent to the flex circuit such that the PCB and flex circuit are in direct contact along a flex interface surface of the PCB, and integrally joining the PCB and flex circuit along the interface surface to form the PCBA. The PCBA connects to the carrier frame to construct the ICB assembly. The battery module may be manufactured by connecting the ICB assembly to battery cells of the battery module.

Abstract: Configurations for a power module having a flexible circuit assembly and corresponding method. The flexible circuit assembly has at least one electrically conductive portion. A first plurality of cells is placed adjacent to one another to form a first cell layer, the first cell layer being positioned on a first side of the flexible circuit assembly. Each of the first plurality of cells has a respective cell body with at least four respective edges. The first plurality of cells has respective cell tabs, including a respective first tab and a respective second tab both extending from one of the at least four respective edges. The flexible circuit assembly is configured to be aligned with the first cell layer such that a voltage sensing circuit joint is concurrently completed when the respective cell tabs of the first cell layer are joined to respective captured portions of the flexible circuit assembly.

Abstract: An interconnect board (ICB) assembly is used with a battery module and a battery controller. The ICB assembly includes a printed circuit board assembly (PCBA) integrally formed from a printed circuit board (PCB) and a flex circuit. The PCB has a component surface populated with electronic components which measure and report parameters of the battery module to the battery controller. The flex circuit is constructed of conductive foil, and defines tabular flying leads that project from a periphery of the flex circuit. A window may be present in the flex circuit. A carrier frame has a support surface flanked by busbars. The PCBA is seated on the support surface, with the flying leads conductively joined to a corresponding busbar. A battery system includes the battery controller and the ICB assembly.

Abstract: A connection assembly includes a busbar defining a first hole, and a circuit board defining a second hole that aligns with the first hole. A battery pack assembly includes the connection assembly. The connection assembly includes a pin having a first body portion and a second body portion. The first body portion is disposed in the first hole and the second body portion is disposed in the second hole. The first body portion defines a first eyelet to allow the first body portion to flex as the first body portion engages the busbar inside the first hole. The second body portion defines a second eyelet to allow the second body portion to flex as the second body portion engages the circuit board inside the second hole. A method of assembling the battery pack assembly includes a first material molded to the busbar to form a frame attached to the busbar.

Abstract: A thermal interface member may comprise a substrate having a first surface and an opposite second surface, an electrically conductive layer disposed on the first surface of the substrate, and an electrically resistive layer disposed on the first surface of the substrate. The substrate may comprise a compliant electrically insulating and thermally conductive material including a polymeric matrix phase and a dispersed phase of thermally conductive particles. The conductive layer may be patterned into a first electrode and a second electrode spaced apart from the first electrode on the first surface of the substrate. The resistive layer may be in electrical contact with the first and second electrodes of the conductive layer and may comprise a resistive material having a positive resistance temperature coefficient and a resistance that increases with an increase in temperature.

Abstract: Assemblies and methods are provided for manufacturing a battery. A number of cells each have tabs for coupling the cell in the battery assembly. A housing has an opening through which each tab extends. The tabs are folded to overlie an outer surface of the housing. A bus bar is disposed on an opposite side of the tabs from the housing, with a coupling joint between the bus bar and the cells. The coupling joint may comprise a weld.

Abstract: A battery module includes a housing and multiple battery cells. The housing may have a positive battery module terminal and a negative battery module terminal. The battery cells may be mounted in the housing. Each battery cell may have a positive battery cell terminal and a negative battery cell terminal disposed on opposing battery cell ends. The positive battery cell terminal and the negative battery cell terminal of each battery cell may be offset from a plane perpendicular to the opposing battery cell ends and passing through a center of the battery cell. The battery cells may be arranged as multiple groups with a common side. The positive and negative battery cell terminals on the common side may alternate about the plane in every other group. The groups may be electrically connected in series between the positive battery module terminal and the negative battery module terminal.

Abstract: A lithium ion battery pouch cell is disclosed that includes a copper-free negative terminal tab in which at least a joining region of an exterior portion of the negative terminal tab is aluminum or nickel-coated aluminum. In this way, the negative terminal tab of the lithium ion battery pouch cell may be welded to a common aluminum bus bar along with a positive terminal tab of another lithium ion battery pouch cell, or the negative terminal tab and the positive terminal tab of the two lithium ion battery pouch cells may be directly welded together in the absence of a common bus bar. Because the negative terminal tab does not include copper, the difficulties inherent in welding aluminum and copper, such as the formation of brittle Al—Cu intermetallic compounds, can be avoided. Lithium ion battery packs that include the disclosed lithium ion battery pouch cell are also disclosed.

Abstract: A thin, conformable electrochemical device according to various aspects of the present disclosure includes an electrically-insulating housing, a plurality of current collectors, a plurality of electrochemical cells, and positive and terminals. The housing includes first and second film portions that cooperate to at least partially define an interior region. The current collector and electrochemical cells are disposed within the interior region. The electrochemical cells are electrically connected to one another via the current collectors. The plurality of electrochemical cells includes a first electrochemical cell and a second electrochemical cell. Each electrochemical cell includes a positive electrode, a negative electrode, and a separator. The positive and negative terminals are electrically connected to the electrochemical cells.

Abstract: A battery pack assembly includes a battery cell and a first plate. A body of the battery cell includes a first tab and a second tab. The first plate includes a first edge and a second edge opposing each other. The first plate defines a slot having a first portion and a second portion adjoining with each other. The first portion of the slot is defined through the first edge of the first plate such that the slot is open at the first edge. The first portion of the slot tapers toward the second portion. The first tab is disposed in the first portion of the slot at the first edge in an initial position. The first tab is disposed in the second portion of the slot in a final position to couple the battery cell and the first plate together.

Abstract: A connection assembly includes a busbar defining a first hole, and a circuit board defining a second hole that aligns with the first hole. A battery pack assembly includes the connection assembly. The connection assembly includes a pin having a first body portion and a second body portion. The first body portion is disposed in the first hole and the second body portion is disposed in the second hole. The first body portion defines a first eyelet to allow the first body portion to flex as the first body portion engages the busbar inside the first hole. The second body portion defines a second eyelet to allow the second body portion to flex as the second body portion engages the circuit board inside the second hole. A method of assembling the battery pack assembly includes a first material molded to the busbar to form a frame attached to the busbar.

Abstract: A method of manufacturing an interconnect board (ICB) assembly for a battery module, the ICB assembly having a printed circuit board assembly (PCBA) and a carrier frame, includes depositing solder paste onto a printed circuit board (PCB) and/or a flexible printed circuit (flex circuit). The flex circuit has a conductive foil substrate coated with insulating material, and defines tabular flying leads radially-projecting from the flex circuit's periphery. The method may include positioning the PCB adjacent to the flex circuit such that the PCB and flex circuit are in direct contact along a flex interface surface of the PCB, and integrally joining the PCB and flex circuit along the interface surface to form the PCBA. The PCBA connects to the carrier frame to construct the ICB assembly. The battery module may be manufactured by connecting the ICB assembly to battery cells of the battery module.

Abstract: An interconnect board (ICB) assembly is used with a battery module and a battery controller. The ICB assembly includes a printed circuit board assembly (PCBA) integrally formed from a printed circuit board (PCB) and a flex circuit. The PCB has a component surface populated with electronic components which measure and report parameters of the battery module to the battery controller. The flex circuit is constructed of conductive foil, and defines tabular flying leads that project from a periphery of the flex circuit. A window may be present in the flex circuit. A carrier frame has a support surface flanked by busbars. The PCBA is seated on the support surface, with the flying leads conductively joined to a corresponding busbar. A battery system includes the battery controller and the ICB assembly.

Abstract: A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.

Abstract: A thermal interface member may comprise a substrate having a first surface and an opposite second surface, an electrically conductive layer disposed on the first surface of the substrate, and an electrically resistive layer disposed on the first surface of the substrate. The substrate may comprise a compliant electrically insulating and thermally conductive material including a polymeric matrix phase and a dispersed phase of thermally conductive particles. The conductive layer may be patterned into a first electrode and a second electrode spaced apart from the first electrode on the first surface of the substrate. The resistive layer may be in electrical contact with the first and second electrodes of the conductive layer and may comprise a resistive material having a positive resistance temperature coefficient and a resistance that increases with an increase in temperature.