Abstract: An electrical conduction assembly comprising a flexible layer, an interface being associated with and electrically coupled to a terminal of an external electrical element, and a circuit trace coupled to the flexible layer and to the interface. The circuit trace includes a fuse as part of the trace, and the fuse is associated with the interface. Also disclosed is a battery including the electrical conduction assembly. Further disclosed is a bus bar holder for a battery. The bus bar holder includes a lead-in structure coupled with a main body on a first side. The lead in structure includes a first lead-in wall to be disposed between a first plurality of battery cells and a second lead-in wall orthogonal to the first lead-in wall. The bus bar holder can also include a plurality of pockets, each or which includes a respective aperture and a respective recess.

Abstract: A battery system includes an electrochemical cell. The electrochemical cell includes a cover having an opening therein. The electrochemical cell also includes an aluminum terminal pad disposed proximate an outer surface of the cover, and having a pad opening aligned with the opening in the cover. The pad opening includes a tapered surface such that the pad opening has a larger cross-sectional width proximate an upper surface of the aluminum terminal pad than proximate a lower surface of the aluminum terminal pad opposite the upper surface and facing the outer surface of the cover. The electrochemical cell also includes a rivet having a body portion extending through the opening in the cover, a head portion disposed in the pad opening of the aluminum terminal pad, and a shoulder extending between the body portion and the head portion.

Abstract: The present disclosure provides a battery pack for a hybrid vehicle. The battery pack includes: multiple battery cells, a housing, a first end plate, a second end plate, a bearing plate and an upper cover, wherein the housing is provided with a bottom portion and side walls extending from the periphery of the bottom portion and forming an upper portion opening; the housing is configured for accommodating the multiple battery cells and the two end plates, when the multiple battery cells are sequentially arranged and mounted into the housing, the first end plate and the second end plate are located at two end sides of the sequentially arranged multiple battery cells to laterally fix the multiple battery cells; the bearing plate is mounted above the top portions of the multiple battery cells; and the upper cover is mounted above the housing to cover the upper portion opening of the housing.

Abstract: The present disclosure includes a battery module having a stack of electrochemical cells that includes terminals, a housing that receives the stack of electrochemical cells, and a bus bar carrier disposed over the stack of electrochemical cells such that bus bars disposed on the bus bar carrier interface with the terminals of the stack of electrochemical cells.

Abstract: Disclosed is a lead acid battery including a housing having an exterior. The battery also includes a lead terminal extending through the housing to the exterior of the housing. A coating covers the lead terminal such that there is no exposed lead exterior to the housing.

Abstract: The present disclosure relates to a battery module having a housing and a stack of battery cells disposed in a receptacle area of the housing, where each battery cell has a top having a battery cell terminal and a bottom, where the top of the battery cells face outwardly away from the receptacle area. The battery module includes an integrated sensing and bus bar subassembly positioned against the stack of battery cells and has a carrier, a bus bar integrated onto the carrier, and a biasing member integrated onto the carrier. The bus bar electrically couples battery cells in an electrical arrangement, and the biasing member is between the top of each battery cell and the carrier, where the biasing member has a first material, more compliant than a second material of the carrier, and the biasing member biases the stack of battery cells inwardly toward the housing.

Abstract: A battery system includes a housing configured to receive a battery cell, where the battery cell is configured to output thermal energy as a byproduct of electrical energy generation and/or consumption, a wall of the housing positioned proximate to the battery cell, and a plurality of fins extending from the wall, where the plurality of fins is configured to absorb thermal energy from the battery cell and dissipate the thermal energy to air, or a heat sink, or both, and where a fin of the plurality of fins comprises a channel configured to facilitate a flow of the air between the fin of the plurality of fins and an adjacent fin of the plurality of fins.

Abstract: Disclosed is a battery having a conductive terminal extending beyond a surface of a battery cover, the conductive terminal having an internal portion and an external surface, wherein the internal portion comprises lead and external surface comprises a non-lead conductive material. Further disclosed is a method for producing such a battery.

Abstract: A method for bonding components of a lithium ion battery module includes positioning an energy absorbing insert adjacent to a first thermoplastic layer of the lithium ion battery module and to a second thermoplastic layer of the lithium ion battery module. Energy is applied to the energy absorbing insert to melt the energy absorbing insert and thereby fuse the first thermoplastic layer to the second thermoplastic layer. The first thermoplastic layer is a transmissive or semi-transmissive layer configured to allow the energy the pass through the first thermoplastic layer for absorption by the energy absorbing insert.

Abstract: Disclosed is a non-lead conductive cap for a battery terminal and battery. The battery may comprise a battery housing and a positive and negative terminal, the positive and negative terminal being accessible through the battery housing; wherein the positive and negative terminal further comprise an electrically conductive cap mounted on both the positive and negative terminal, wherein the electrically conductive cap does not comprise lead.

Abstract: Disclosed is a battery having a conductive terminal extending beyond a surface of a battery cover, the conductive terminal having an internal portion and an external surface, wherein the internal portion comprises lead and external surface comprises a non-lead conductive material. Further disclosed is a method for producing such a battery.

Abstract: A battery module includes a housing including a first interior surface, a second interior surface opposite the first interior surface, and a cell assembly disposed within an interior space of the housing between the first and second interior surfaces. The cell assembly includes a plurality of prismatic battery cells arranged in a cell stack that includes a first end, and a second end opposite the first end. A wall is disposed between the first end of the cell stack and one of the interior surfaces of the housing. The wall includes a first surface in contact with the first end of the cell stack and a second surface opposite the first surface.

Abstract: The present disclosure includes a battery module having a stack of electrochemical cells that includes terminals, a housing that receives the stack of electrochemical cells, and a bus bar carrier disposed over the stack of electrochemical cells such that bus bars disposed on the bus bar carrier interface with the terminals of the stack of electrochemical cells.

Abstract: An overcharge protection device cover assembly for use with a battery cell housing. The battery cell housing has a first terminal and a second terminal, the overcharge protection device cover assembly including a first terminal pad having a first length. The first terminal pad is contactable with the first terminal of the battery cell housing. The assembly also includes a second terminal pad having a second length that is greater than the first length. The second terminal pad is contactable with the second terminal of the battery cell housing. A reversal device of the assembly is deflectable toward the first and second terminal pads. A conductive element of the assembly is positioned between the reversal device and the first and second terminal pads.

Abstract: The present disclosure includes a lithium-ion battery module that has a housing and a plurality of lithium-ion battery cells disposed in the housing. Each of the plurality of lithium-ion battery cells includes a first terminal with a first polarity, a second terminal with a second polarity opposite to the first polarity, an overcharge protection assembly, and a casing electrically coupled to the first terminal such that the casing has the first polarity, where the casing has an electrically conductive material. The lithium-ion battery module also includes a vent of the overcharge protection assembly electrically coupled to the casing and a conductive component of the overcharge protection assembly electrically coupled to the second terminal, and the vent is configured to contact the conductive component to cause a short circuit and to vent a gas from the casing into the housing when a pressure in the casing reaches a threshold value.

Abstract: A battery module includes a plurality of battery cells disposed in at least two rows. The battery cells in adjacent rows are offset from each other. Each of the plurality of battery cells includes a cover and a first terminal that extends from the cover outward. The first terminal is configured to be coupled to a second terminal on an adjacent battery cell. The plurality of battery cells are electrically coupled to each other in a zigzag pattern via the first and second terminals.

Abstract: Disclosed is a non-lead conductive cap for a battery terminal and battery. The battery may comprise a battery housing and a positive and negative terminal, the positive and negative terminal being accessible through the battery housing; wherein the positive and negative terminal further comprise an electrically conductive cap mounted on both the positive and negative terminal, wherein the electrically conductive cap does not comprise lead.

Abstract: The present disclosure relates to a stacked cell manufacturing scheme for battery modules. A disclosed method of manufacturing a battery module includes assembling a plurality of prismatic battery cells of the battery module into a cell stack. The method includes compressing the cell stack using an actuating clamping mechanism, inserting the cell stack into a housing of the battery module with the actuating clamping mechanism engaged with and compressing the cell stack, and removing the actuating clamping mechanism from the cell stack. The housing of battery module maintains a compression of the cell stack above a predetermined threshold in the battery module after removing the actuating clamping mechanism.

Abstract: The present disclosure includes a battery module having a stack of electrochemical cells that includes terminals, a housing that receives the stack of electrochemical cells, and a bus bar carrier disposed over the stack of electrochemical cells such that bus bars disposed on the bus bar carrier interface with the terminals of the stack of electrochemical cells. The bus bar carrier includes opposing first and second guide extensions, the stack of electrochemical cells is disposed between the opposing first and second guide extensions, and the opposing first and second guide extensions physically contact a first outer electrochemical cell and a second outer electrochemical cell, respectively, of the stack of electrochemical cells to guide the terminals of the stack of electrochemical cells toward corresponding ones of the bus bars disposed on the bus bar carrier.