Abstract: A battery assembly includes a battery cell, conductive bus bar, and printed circuit board assembly (PCBA). A cell tab of the battery assembly has a first portion extending from a perimeter edge of a pouch and a second portion arranged orthogonally with respect to the first portion. The bus bar defines a tab slot through which the first portion extends, and has a major surface adjacent to the second portion. The PCBA defines an elongated welding window orthogonal to a longitudinal axis of the PCBA. The PCBA is mounted over the bus bar such that surface area of the second portion is exposed through the welding window, and in turn is welded to the bus bar through and within the welding window. A spring element may be positioned between the carrier frame and the PCBA. A method of making the battery assembly is also provided.

Abstract: A battery cell has positive and negative cell tabs protruding from a first edge and a cell stack-up within a pouch. Anode and cathode foils are connected to the cell tabs proximate the first edge, with the anode foils connected to each other proximate a second edge. An outermost current collector of the anode foils exists with respect to a thickness of the cell stack-up. The cathode foils are connected to the positive cell tab proximate the first edge. The anode foils are connected to each other and the negative cell tab proximate the second edge, such that the outermost current collector forms an internal bus bar between the first and second edges. The battery cell has asymmetrical packaging and symmetrical internal current paths. A system includes a battery pack driving a load, with the battery pack having battery cells constructed as set forth above.

Abstract: A prismatic battery stack includes a first lithium-ion battery cell and a second lithium-ion battery cell. The battery stack also includes a first channel disposed around the first lithium-ion battery cell and the second lithium-ion battery cell. The battery stack includes a second channel disposed around the first lithium-ion battery cell and the second lithium-ion battery cell. The first channel and the second channel serve as heat sinks.

Abstract: A battery module includes a battery cell, a bus bar, and a multilayered cell sense flex circuit having a senseline tab containing a portion of a senseline. The flex circuit determines a battery cell voltage. The bus bar has surface projections, possibly with a variable height and/or width, such that the bus bar penetrates into the tab at least as far as the senseline. Adhesive material may be used on the welded joint. A method of manufacturing the battery module includes forming, in the bus bar, one or more surface projections, e.g., multiple projections having the variable height and/or width, positioning a senseline tab of the flex circuit adjacent to such projections, and joining the tab to the surface projections such that the projections penetrate at least partially into the flex circuit at least as far as the senseline.

Abstract: A battery assembly includes a battery cell, conductive bus bar, and printed circuit board assembly (PCBA). A cell tab of the battery assembly has a first portion extending from a perimeter edge of a pouch and a second portion arranged orthogonally with respect to the first portion. The bus bar defines a tab slot through which the first portion extends, and has a major surface adjacent to the second portion. The PCBA defines an elongated welding window orthogonal to a longitudinal axis of the PCBA. The PCBA is mounted over the bus bar such that surface area of the second portion is exposed through the welding window, and in turn is welded to the bus bar through and within the welding window. A spring element may be positioned between the carrier frame and the PCBA. A method of making the battery assembly is also provided.

Abstract: A battery cell has positive and negative cell tabs protruding from a first edge and a cell stack-up within a pouch. Anode and cathode foils are connected to the cell tabs proximate the first edge, with the anode foils connected to each other proximate a second edge. An outermost current collector of the anode foils exists with respect to a thickness of the cell stack-up. The cathode foils are connected to the positive cell tab proximate the first edge. The anode foils are connected to each other and the negative cell tab proximate the second edge, such that the outermost current collector forms an internal bus bar between the first and second edges. The battery cell has asymmetrical packaging and symmetrical internal current paths. A system includes a battery pack driving a load, with the battery pack having battery cells constructed as set forth above.

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: A method of assembling a power module includes placing a first plurality of cells adjacent to one another to form a first cell layer. A flexible circuit layer is positioned above the first cell layer, the flexible circuit being electrically conductive. A second plurality of cells is positioned adjacent to one another to form a second cell layer aligned with the first cell layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer. The flexible circuit layer is folded along each of a plurality of axes of rotation such that each one of the first plurality of cells faces another one of the second plurality of cells. Each of the first plurality of cells and the second plurality of cells has respective first and second tabs (extending from their respective short ends) which are welded to the flexible circuit layer.

Abstract: A prismatic battery stack includes a first lithium-ion battery cell and a second lithium-ion battery cell. The battery stack also includes a first channel disposed around the first lithium-ion battery cell and the second lithium-ion battery cell. The battery stack includes a second channel disposed around the first lithium-ion battery cell and the second lithium-ion battery cell. The first channel and the second channel serve as heat sinks.

Abstract: A method of assembling a power module includes placing a first plurality of cells adjacent to one another to form a first cell layer. A flexible circuit layer is positioned above the first cell layer, the flexible circuit being electrically conductive. A second plurality of cells is positioned adjacent to one another to form a second cell layer aligned with the first cell layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer. The flexible circuit layer is folded along each of a plurality of axes of rotation such that each one of the first plurality of cells faces another one of the second plurality of cells. Each of the first plurality of cells and the second plurality of cells has respective first and second tabs (extending from their respective short ends) which are welded to the flexible circuit layer.

Abstract: A method and a test fixture for evaluating a junction between an electrical lead trace and a busbar are described, and include an electric power supply disposed to supply electric power to the electrical lead trace and an electric monitoring device disposed to monitor electrical potential across the junction. A mechanical stress-inducing device is disposed to apply mechanical stress proximal to the junction. The electric monitoring device monitors the electrical potential across the junction of the electrical lead trace coincident with the mechanical stress-inducing device applying mechanical stress proximal to the junction when the electric power supply is supplying electric power to the electrical lead trace. Electrical integrity of the junction is evaluated based upon the monitored electrical potential across the junction.

Abstract: A battery module includes a battery cell, a bus bar, and a multilayered cell sense flex circuit having a senseline tab containing a portion of a senseline. The flex circuit determines a battery cell voltage. The bus bar has surface projections, possibly with a variable height and/or width, such that the bus bar penetrates into the tab at least as far as the senseline. Adhesive material may be used on the welded joint. A method of manufacturing the battery module includes forming, in the bus bar, one or more surface projections, e.g., multiple projections having the variable height and/or width, positioning a senseline tab of the flex circuit adjacent to such projections, and joining the tab to the surface projections such that the projections penetrate at least partially into the flex circuit at least as far as the senseline.

Abstract: A battery pack, an integrated device for sensing individual battery voltage in a battery pack and a method of forming an integrated voltage-sensing circuit for use in a battery-powered automobile propulsion system. The integrated voltage-sensing circuit includes a busbar, a terminal pin and a voltage-sensing fuse electrically disposed between the busbar and the terminal pin. The construction of the voltage-sensing circuit is such that it forms an integral structure upon being coupled to the modular housing or related structure that may subsequently be secured to a frame that is used to provide support to each battery cell within the battery pack. In one form, the modular housing and voltage-sensing circuit may be secured to the frame during a frame molding process such that upon completion of the molding, the housing and at least a portion of the voltage-sensing circuit are encapsulated within the frame.

Abstract: A method of joining a first tin-plated electrical component to a second tin-plated electrical component, and components joined to exhibit reduced stress levels at the joined location. The method includes defining a pocket in the second component that is shaped to accept a portion of the first component, placing the portion of the first component substantially within the pocket to define an interfacial region, and using a resistance welder to both form a solid-state diffusion bond along at least a portion of the interfacial region and fill a substantial remainder of the interfacial region with melted tin plating from one or both of the first and second components.

Abstract: A method and a test fixture for evaluating a junction between an electrical lead trace and a busbar are described, and include an electric power supply disposed to supply electric power to the electrical lead trace and an electric monitoring device disposed to monitor electrical potential across the junction. A mechanical stress-inducing device is disposed to apply mechanical stress proximal to the junction. The electric monitoring device monitors the electrical potential across the junction of the electrical lead trace coincident with the mechanical stress-inducing device applying mechanical stress proximal to the junction when the electric power supply is supplying electric power to the electrical lead trace. Electrical integrity of the junction is evaluated based upon the monitored electrical potential across the junction.

Abstract: A battery pack, an integrated device for sensing individual battery voltages in a battery pack and protecting the battery pack in the event of a circuit-breaking event, and a method of forming an integrated voltage-sensing circuit for use in a battery-powered automobile propulsion system. The battery pack includes numerous voltage sensing circuits with patterned sense line trace fuses and an encapsulant formed around each of the fuses. The encapsulant is robust enough to provide environmental isolation of the patterned fuse such that the tendency of the fuse to form short-circuit connections to adjacent circuits is avoided under both normal battery pack operation and after a circuit-breaking episode where the fuse blows.

Abstract: A method of joining a first tin-plated electrical component to a second tin-plated electrical component, and components joined to exhibit reduced stress levels at the joined location. The method includes defining a pocket in the second component that is shaped to accept a portion of the first component, placing the portion of the first component substantially within the pocket to define an interfacial region, and using a resistance welder to both form a solid-state diffusion bond along at least a portion of the interfacial region and fill a substantial remainder of the interfacial region with melted tin plating from one or both of the first and second components.

Abstract: A battery pack, an integrated device for sensing individual battery voltage in a battery pack and a method of forming an integrated voltage-sensing circuit for use in a battery-powered automobile propulsion system. The integrated voltage-sensing circuit includes a busbar, a terminal pin and a voltage-sensing fuse electrically disposed between the busbar and the terminal pin. The construction of the voltage-sensing circuit is such that it forms an integral structure upon being coupled to the modular housing or related structure that may subsequently be secured to a frame that is used to provide support to each battery cell within the battery pack. In one form, the modular housing and voltage-sensing circuit may be secured to the frame during a frame molding process such that upon completion of the molding, the housing and at least a portion of the voltage-sensing circuit are encapsulated within the frame.

Abstract: A battery pack, an integrated device for sensing individual battery voltage in a battery pack and a method of forming an integrated voltage-sensing circuit for use in a battery-powered automobile propulsion system. The integrated voltage-sensing circuit includes a busbar, a terminal pin and a voltage-sensing fuse electrically disposed between the busbar and the terminal pin. The construction of the voltage-sensing circuit is such that it forms an integral structure upon being coupled to the modular housing or related structure that may subsequently be secured to a frame that is used to provide support to each battery cell within the battery pack. In one form, the modular housing and voltage-sensing circuit may be secured to the frame during a frame molding process such that upon completion of the molding, the housing and at least a portion of the voltage-sensing circuit are encapsulated within the frame.