Abstract: A battery module having first and second cylindrical battery cells is provided. The module includes a laminated busbar assembly having a bottom isolation layer, a first busbar layer, an intermediate isolation layer, and a second busbar layer. The bottom isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough and exposes a portion of the negative electrode of the first battery cell. The first busbar layer has a first aperture that receives the positive electrode of the first battery cell therethrough. A portion of the first busbar layer electrically contacts the negative electrode of the first battery cell. The intermediate isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough. The second busbar layer electrically contacts the positive electrode of the first battery cell.

Abstract: A battery system includes a battery module that utilizes the first and second retention housings to hold a battery cell retention frame therein that can be either air cooled or fluid cooled. In particular, the first and second retention housings have an inlet port and an outlet port, respectively, for routing fluid through the battery cell retention frame for cooling cylindrical battery cells thereon. Alternately, the battery cell retention frame can be air cooled for cooling the cylindrical battery cells. Also, the first and second retention housings provide improved structural integrity to the battery module.

Abstract: A battery module having first and second cylindrical battery cells is provided. The module includes a laminated busbar assembly having a bottom isolation layer, a first busbar layer, an intermediate isolation layer, and a second busbar layer. The bottom isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough and exposes a portion of the negative electrode of the first battery cell. The first busbar layer has a first aperture that receives the positive electrode of the first battery cell therethrough. A portion of the first busbar layer electrically contacts the negative electrode of the first battery cell. The intermediate isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough. The second busbar layer electrically contacts the positive electrode of the first battery cell.

Abstract: A battery system includes a battery module that utilizes the first and second retention housings to hold a battery cell retention frame therein that can be either air cooled or fluid cooled. In particular, the first and second retention housings have an inlet port and an outlet port, respectively, for routing fluid through the battery cell retention frame for cooling cylindrical battery cells thereon. Alternately, the battery cell retention frame can be air cooled for cooling the cylindrical battery cells. Also, the first and second retention housings provide improved structural integrity to the battery module.

Abstract: A battery system includes a battery module that utilizes the first and second retention housings to hold a battery cell retention frame therein that can be either air cooled or fluid cooled. In particular, the first and second retention housings have an inlet port and an outlet port, respectively, for routing fluid through the battery cell retention frame for cooling cylindrical battery cells thereon. Alternately, the battery cell retention frame can be air cooled for cooling the cylindrical battery cells. Also, the first and second retention housings provide improved structural integrity to the battery module.

Abstract: A battery system includes a battery module that utilizes the first and second retention housings to hold a battery cell retention frame therein that can be either air cooled or fluid cooled. In particular, the first and second retention housings have an inlet port and an outlet port, respectively, for routing fluid through the battery cell retention frame for cooling cylindrical battery cells thereon. Alternately, the battery cell retention frame can be air cooled for cooling the cylindrical battery cells. Also, the first and second retention housings provide improved structural integrity to the battery module.

Abstract: A battery module having first and second cylindrical battery cells is provided. The module includes a laminated busbar assembly having a bottom isolation layer, a first busbar layer, an intermediate isolation layer, and a second busbar layer. The bottom isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough and exposes a portion of the negative electrode of the first battery cell. The first busbar layer has a first aperture that receives the positive electrode of the first battery cell therethrough. A portion of the first busbar layer electrically contacts the negative electrode of the first battery cell. The intermediate isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough. The second busbar layer electrically contacts the positive electrode of the first battery cell.

Abstract: A battery module having first and second cylindrical battery cells is provided. The module includes a laminated busbar assembly having a bottom isolation layer, a busbar layer, a top isolation layer. A first aperture of the bottom isolation layer receives a positive electrode of the first battery cell therethrough and exposes a portion of the negative electrode of the first battery cell. The second aperture of the bottom isolation layer receives the positive electrode of the second battery cell therethrough and exposes a portion of the negative electrode of the second battery cell. The busbar layer has a first layer portion that contacts the negative electrode of the first battery cell and the negative electrode of the second battery cell, and a second layer portion that contacts the positive electrode of the first battery cell and the positive electrode of the second battery cell.

Abstract: A battery system includes a battery module that utilizes the first and second retention housings to hold a battery cell retention frame therein that can be either air cooled or fluid cooled. In particular, the first and second retention housings have an inlet port and an outlet port, respectively, for routing fluid through the battery cell retention frame for cooling cylindrical battery cells thereon. Alternately, the battery cell retention frame can be air cooled for cooling the cylindrical battery cells. Also, the first and second retention housings provide improved structural integrity to the battery module.

Abstract: A battery cell retention frame includes a central cooling plate member having first and second manifold portions and first and second intermediate walls coupled to the first and second manifold portions. The first and second intermediate walls define an internal cooling channel therebetween that fluidly communicates with the first and second manifold portions. The battery cell retention frame includes first and second exterior plates that are coupled to the first and second manifold portions, respectively. The first and second intermediate walls have first and second outer surfaces, respectively, disposed opposite to one another. The battery cell retention frame includes first and second thermally conductive layers that are disposed on the first and second outer surfaces, respectively.

Abstract: A terminal busbar includes a first busbar portion having a coupling plate, and a second busbar portion having a top plate portion, and a fusible member coupled to and between the coupling plate and the top plate portion. The fusible member has a first portion with a groove or an aperture disposed therein. The terminal busbar further includes an overmolded thermoplastic layer encapsulating the first portion of the fusible member and the groove or the aperture. A thickness of the overmolded thermoplastic layer both above and underneath the fusible member is greater than a thickness of the fusible member to prevent secondary arcing.

Abstract: A battery module having first and second battery cells is provided. The battery module includes a first frame member having a first substantially rectangular ring-shaped outer plastic frame and a first heat exchanger. The first heat exchanger has first and second thermally conductive plates that are coupled together and define a first flow path portion extending therethrough. The first battery cell is disposed on and against a first side of the first thermally conductive plate. The second battery cell is disposed on and against the first side of the first thermally conductive plate. The second battery cell is further disposed proximate to the first battery cell.

Abstract: A terminal busbar includes a first busbar portion having a coupling plate, and a second busbar portion having a top plate portion, and a fusible member coupled to and between the coupling plate and the top plate portion. The fusible member has a first portion with a groove or an aperture disposed therein. The terminal busbar further includes an overmolded thermoplastic layer encapsulating the first portion of the fusible member and the groove or the aperture. A thickness of the overmolded thermoplastic layer both above and underneath the fusible member is greater than a thickness of the fusible member to prevent secondary arcing.

Abstract: A battery module having first and second battery cells, a u-shaped frame member, a thermally conductive layer, a top cover plate, and first and second side cover plates is provided. The u-shaped frame member has a bottom wall and first and second side walls coupled to the bottom wall that extend upwardly from the bottom wall. The u-shaped frame member defines an interior space that holds the first and second battery cells therein. The first and second battery cells are disposed directly on the thermally conductive layer. The top cover plate is coupled to the first and second side walls to enclose a top open region of the u-shaped frame member. The first side cover plate that is coupled to the top cover plate and the bottom wall to enclose a first side open region of the u-shaped frame member.

Abstract: A battery system includes a first metallic end plate. A first side of the first metallic end plate has first and second slanted surfaces and a first groove. The battery system further includes a first pouch battery cell having a first pouch housing with a first end portion and a second end portion. The first end portion has a first extension portion and first and second slanted end surfaces. The first pouch battery cell is coupled to the first metallic end plate such that the first extension portion of the first pouch battery cell is disposed in the first groove of the first metallic end plate, and the first and second slanted end surfaces of the first pouch battery cell are disposed on and against first and second thermally conductive adhesive portions, respectively, on the first and second slanted surfaces, respectively, of the first metallic end plate.

Abstract: A battery module having first and second battery cells, a u-shaped frame member, a thermally conductive layer, a top cover plate, and first and second side cover plates is provided. The u-shaped frame member has a bottom wall and first and second side walls coupled to the bottom wall that extend upwardly from the bottom wall. The u-shaped frame member defines an interior space that holds the first and second battery cells therein. The first and second battery cells are disposed directly on the thermally conductive layer. The top cover plate is coupled to the first and second side walls to enclose a top open region of the u-shaped frame member. The first side cover plate that is coupled to the top cover plate and the bottom wall to enclose a first side open region of the u-shaped frame member.

Abstract: A thermally conductive base member and a method of assembly are provided. The thermally conductive base member includes first and second metal base members, and a top plate. The first metal base member has a first bottom plate, first and second female coupling portions, and first and second rib portions. The second metal base member has a second bottom plate, a first male coupling portion, and first and second rib portions. The first male coupling portion is disposed in and coupled to the first female coupling portion. The top plate is coupled to a top surface of the first female coupling portion, a top surface of the second female coupling portion, and the first and second rib portions of the first metal base member such that a first flow channel is defined between the first and second rib portions of the first metal base member and the top plate.

Abstract: A battery system having a thermally conductive base member, a thermal interface member, and a battery module is provided. The thermal interface member is disposed on the thermally conductive base member and has first and second arcuate-shaped surfaces and a first groove. The battery module has a first pouch-type battery cell with a first outer housing having a first end portion with a first extension portion and first and second arcuate-shaped end surfaces. The first pouch-type battery cell is disposed directly on the thermal interface member such that the first extension portion is disposed in the first groove of the thermal interface member, and the first and second arcuate-shaped end surfaces are disposed directly on and against the first and second arcuate-shaped surfaces, respectively, of the thermal interface member.

Abstract: A battery pack having a battery pack housing defining an interior region is provided. The housing further includes an inlet aperture and an outlet aperture communicating with the interior region. The battery pack further includes a battery module that is disposed in the interior region of the battery pack housing proximate to the inlet aperture. The battery module has a first battery cell, a heat exchanger, and first and second end plates. The first battery cell and the heat exchanger are disposed against one another, and are further disposed between the first and second end plates. The heat exchanger defines a first flow path portion therethrough. The first end plate has a first end portion that extends longitudinally past the first end of the first battery cell, and a second end portion that extends longitudinally past the second end of the first battery cell.

Abstract: A battery module and a method are provided. The battery module includes a first battery cell having a first electrical terminal, a second battery cell having a second electrical terminal, and an interconnect assembly having a plate portion, a first finger portion, and a first voltage sense member. The first voltage sense member is coupled to the first finger portion. The first electrical terminal has a first terminal portion disposed directly on and coupled to a first voltage sense wall of the first voltage sense member. The second electrical terminal has a first terminal portion disposed on and coupled to the first terminal portion of the first electrical terminal such that the first terminal portion of the first electrical terminal is sandwiched between the first voltage sense wall of the first voltage sense member and the first terminal portion of the second electrical terminal.