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, first and second finger portions, a blade portion, and first and second voltage sense members. The first and second voltage sense members are coupled to the first and second finger portions, respectively. The blade portion is disposed between the first and second finger portions such that a first gap is defined between the first finger portion and the blade portion, and a second gap is defined between the second finger portion and the blade portion. The first and second electrical terminals extend through the first and second gaps, respectively, and are coupled to the first and second voltage sense members, respectively.

Abstract: A middle- or large-sized battery module includes two or more unit modules each having one or more plate-shaped battery cells, as unit cells, surrounded by a high-strength sheathing member made of synthetic resin or metal, and separable upper and lower frame members coupled with each other in an assembly-type coupling structure such that the unit modules are vertically mounted in the upper and lower frame members. A sensing unit capable of minimizing the weight and size of battery cells is easily mounted while effectively reinforcing the low mechanical strength of the battery cells and sensing the operation state of the battery cells to a middle- or large-sized battery module. The battery module is manufactured by a simple assembly process without using a plurality of members for mechanical coupling and electrical connection.

Abstract: Disclosed herein is a middle- or large-sized battery pack including a module assembly constructed in a structure in which a plurality of battery modules, each of which includes a plurality of battery cells or unit modules mounted in a module case while the battery cells or unit modules are connected in series to each other, are arranged such that the battery modules are disposed in contact with each other in the lateral direction, and a coolant flow channel is vertically formed, a plurality of support members for supporting opposite sides and the bottom of the module assembly and maintaining the arrangement state of the module assembly, and a pack housing for surrounding the module assembly and the support members.

Abstract: A battery module and a method for assembling the battery module are provided. The battery module includes a first end plate, a second end plate, a frame member, a first battery cell disposed between the first end plate and the frame member, and a second battery cell disposed between the second end plate and the frame member. The battery module further includes a first shoulder bolt having a first head portion, a first shaft portion, a first shoulder portion, and a first threaded portion. The first shoulder bolt is disposed such that the first head portion is disposed against the first end plate and the first shaft portion extends through a first aperture of the first end plate and a first aperture of the frame member, and the first shoulder portion is disposed against the second end plate.

Abstract: A battery pack is provided. The battery pack includes first and second temperature sensors that are disposed in first and second interior spaces, respectively. The first temperature sensor generates a first signal indicative of a first temperature level of the battery cell. The second temperature sensor generates a second signal indicative of a second temperature level of the DC-DC voltage converter. The battery pack further includes a microprocessor that determines a first fan speed percentage value of the electric fan based on the first temperature level, and a second fan speed percentage value of the electric fan based on the second temperature level. The microprocessor selects the first fan speed percentage value if the first fan speed percentage value is greater than the second fan speed percentage value.

Abstract: A battery cell interconnect and voltage sensing assembly having a plastic frame member having a plate portion and a central wall is provided. The central wall defines an interior region. The assembly further includes a first interconnect member that is coupled to the plate portion that is electrically coupled to a first electrical terminal of a first battery cell. The first interconnect member has a spade lug. The assembly further includes a removable wire harness assembly having an adaptor body, a spade clip, and an electrical cable. The spade clip is disposed in an aperture of the adapter member. The spade clip is electrically and physically coupled to the spade lug of the first interconnect member when the adapter member is at least partially disposed in the interior region.

Abstract: Disclosed herein is a battery module including two or more plate-shaped battery cells, as unit cells, constructed in a stacked structure in which electrode terminals of the battery cells are connected in series with each other and the electrode terminal connections are bent such that the battery cells are stacked, and a pair of high-strength cell covers for surrounding the outer surfaces of the battery cells when the cell covers are coupled with each other. The present invention has the effect of easily mounting a sensing unit that is capable of minimizing the weight and size of battery cells while effectively reinforcing the low mechanical strength of the battery cells and sensing the operation state of the battery cells to a battery module.

Abstract: A battery cell assembly having a first battery cell and a cooling fin is provided. The first battery cell has a first housing and first and second electrical terminals. The cooling fin is disposed against the first housing. The cooling fin has a substantially rectangular-shaped plate that extends along a longitudinal axis. The substantially rectangular-shaped plate has a plate portion with a first side and a second side. The first side has a first plurality of recessed regions and a first plurality of flat regions. Each recessed region of the first plurality of recessed regions is disposed between two flat regions of the first plurality of flat regions along the longitudinal axis. The first housing of the first battery cell is disposed against the first side such that the first housing contacts the first plurality of flat regions.

Abstract: A battery pack is provided. The battery pack includes first and second temperature sensors that are disposed in first and second interior spaces, respectively. The first temperature sensor generates a first signal indicative of a first temperature level of the battery cell. The second temperature sensor generates a second signal indicative of a second temperature level of the DC-DC voltage converter. The battery pack further includes a microprocessor that determines a first desired operational speed value of the electric fan based on the first temperature level, and a second desired operational speed value of the electric fan based on the second temperature level. The microprocessor selects the first desired operational speed value if the first desired operational speed value is greater than the second desired operational speed value.

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 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 includes a first battery cell having a first housing and first and second electrical terminals. The first housing has first, second, third and fourth ends. The first and second electrical terminals extend outwardly from the third and fourth ends, respectively. A distance from the second end of the first housing to a second edge of the first electrical terminal is greater than a distance from the first end of the first housing to a first edge of the first electrical terminal. A distance from the second end of the first housing to a second edge of the second electrical terminal is greater than a distance from the first end of the first housing to a first edge of the second electrical terminal. The battery module further includes a cooling fin disposed adjacent to the first battery cell, and a cooling plate coupled to the cooling fin.

Abstract: A battery cell interconnect and voltage sensing assembly is provided. The assembly includes a plastic frame member having a first side and a second side, and first, second, third and fourth elongated apertures extending therethrough. The assembly further includes an elongated interconnect member coupled to the plastic frame member and extends past both the first and third apertures. The elongated interconnect member is coupled to both a first electrical terminal of a first battery cell extending through the first elongated aperture, and a first electrical terminal of a second battery cell extending through the third elongated aperture. The elongated interconnect member has a spade lug coupled to a wire harness assembly.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery module includes a first battery cell having a first housing and first and second electrical terminals. The first housing has first, second, third and fourth ends. The first and second electrical terminals extend outwardly from the third and fourth ends, respectively. A distance from the second end of the first housing to a second edge of the first electrical terminal is greater than a distance from the first end of the first housing to a first edge of the first electrical terminal A distance from the second end of the first housing to a second edge of the second electrical terminal is greater than a distance from the first end of the first housing to a first edge of the second electrical terminal. The battery module further includes a cooling fin disposed adjacent to the first battery cell, and a cooling plate coupled to the cooling fin.

Abstract: A battery cell assembly having a cooling fin with a tube, a substantially rectangular-shaped metal plate, first and second cylindrical coupling members, and first and second O-ring gaskets is provided. The tube has an inlet tube portion and an outlet tube portion. The tube is coupled to a peripheral region of the metal plate. The first cylindrical coupling member has a first aperture extending therethrough, and first and second circumferential grooves. The inlet tube portion is disposed in the first aperture and coupled to the first cylindrical coupling member. The first and second O-ring gaskets are disposed in the first and second circumferential grooves, respectively. The outlet tube portion is disposed in the second aperture and is coupled to the second cylindrical coupling member.

Abstract: A battery cell assembly having a first battery cell and a cooling fin is provided. The first battery cell has a first housing and first and second electrical terminals. The cooling fin is disposed against the first housing. The cooling fin has a substantially rectangular-shaped plate that extends along a longitudinal axis. The substantially rectangular-shaped plate has a plate portion with a first side and a second side. The first side has a first plurality of recessed regions and a first plurality of flat regions. Each recessed region of the first plurality of recessed regions is disposed between two flat regions of the first plurality of flat regions along the longitudinal axis. The first housing of the first battery cell is disposed against the first side such that the first housing contacts the first plurality of flat regions.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.