Abstract: A battery module includes an array of electrochemical cells. Each cell includes a cap assembly that supports the cell within the array, and electrically isolates the cell from adjacent cells of the array. The cap assembly includes a first cap disposed on one end of the cell and a second cap disposed on the opposed end of the cell. Each of the first cap and the second cap include a tubular body that has an inner surface that has a shape and dimensions that correspond to the shape and dimensions of the cell outer surface, and a lip that protrudes inward from the inner surface. The lip is disposed at a first end of the body, and a terminal end of the lip defines an opening in the first end of the body.

Abstract: An electrochemical cell has a cell housing and an electrode assembly disposed in the housing. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator. An end of each of the positive and negative electrode plates includes a clear lane that is free of active material and includes an opening. An electrically conductive first inner plate extends through the openings in each positive electrode plate, and an electrically conductive second inner plate extends through openings in each negative electrode plate. The positive clear lanes are sandwiched between, and electrically connected to, the first inner plate and a first outer plate. The negative clear lanes are sandwiched between, and electrically connected to, the second inner plate and a second outer plate. The first outer plate is electrically connected to the housing, and the second outer plate is electrically connected to a terminal.

Abstract: An electrochemical pouch cell includes a stacked or rolled arrangement of electrode plates disposed in a cell housing, and a lead tab that protrudes through the cell housing. The lead tab forms an electrical connection with the electrode plates within the cell and permits transfer of current out of the cell via an opening in a seal joint of the pouch cell housing. The lead tab has a configuration that improves reliability of the seal between the lead tab and the opening.

Abstract: An electrochemical cell includes a prismatic cell housing including a lid plate that closes one end of the housing. The cell also includes a terminal assembly having a simple structure that is supported on the lid plate. The terminal assembly includes the lid plate, a terminal and an adhesive layer that is disposed between and secures the terminal to the lid plate. The terminal assembly includes features that allow the adhesive layer to flow in a controlled and reproducible manner over the entirety of a predetermined area without flowing beyond the predetermined area. The features result from forming a stop line in the predetermined area by applying a surface treatment to the predetermined area. The stop line delineates a desired adhesive later outer boundary and engages the adhesive so as to maintain the adhesive within the predetermined area.

Abstract: An electrochemical cell includes a prismatic cell housing including a lid plate that closes one end of the housing. The cell also includes a terminal assembly having a simple structure that is supported on the lid plate. The terminal assembly includes the lid plate, a terminal and an adhesive layer that is disposed between and secures the terminal to the lid plate. The terminal assembly includes features that allow the adhesive layer to flow in a controlled and reproducible manner over the entirety of a predetermined area without flowing beyond the predetermined area. The features result from forming a stop line in the predetermined area by applying a surface treatment to the predetermined area. The stop line delineates a desired adhesive later outer boundary and engages the adhesive so as to maintain the adhesive within the predetermined area.

Abstract: An electrochemical pouch cell includes a stacked or rolled arrangement of electrode plates disposed in a cell housing, and a lead tab that protrudes through the cell housing. The lead tab forms an electrical connection with the electrode plates within the cell and permits transfer of current out of the cell via an opening in a seal joint of the pouch cell housing. The lead tab has a configuration that improves reliability of the seal between the lead tab and the opening.

Abstract: An electrochemical cell has a prismatic cell housing and an electrode assembly disposed in the cell housing. The cell housing is six-sided and includes a first end, a second end, and a sidewall that extends between the first and second ends. The sidewall includes a pair of major sides joined by a pair of minor sides, where each side of the pair of major sides is larger in area than each side of the pair of minor sides. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator to form an electrode stack. The electrode stack is oriented within the cell housing such that a stack axis that extends parallel to a stacking direction of the positive and negative electrode plates is normal to, and passes through, each side of the pair of minor sides.

Abstract: A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.

Abstract: A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.

Abstract: An electrochemical cell has a cell housing and an electrode assembly disposed in the housing. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator. An end of each of the positive and negative electrode plates includes a clear lane that is free of active material and includes an opening. An electrically conductive first inner plate extends through the openings in each positive electrode plate, and an electrically conductive second inner plate extends through openings in each negative electrode plate. The positive clear lanes are sandwiched between, and electrically connected to, the first inner plate and a first outer plate. The negative clear lanes are sandwiched between, and electrically connected to, the second inner plate and a second outer plate. The first outer plate is electrically connected to the housing, and the second outer plate is electrically connected to a terminal.

Abstract: An electrochemical cell has a prismatic cell housing and an electrode assembly disposed in the cell housing. The cell housing is six-sided and includes a first end, a second end, and a sidewall that extends between the first and second ends. The sidewall includes a pair of major sides joined by a pair of minor sides, where each side of the pair of major sides is larger in area than each side of the pair of minor sides. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator to form an electrode stack. The electrode stack is oriented within the cell housing such that a stack axis that extends parallel to a stacking direction of the positive and negative electrode plates is normal to, and passes through, each side of the pair of minor sides.

Abstract: A battery assembly in one embodiment includes a battery case defining a first plurality of battery compartments and a second plurality of battery compartments, and a thermal plate defined between the first plurality of battery compartments and the second plurality of battery compartments, the thermal plate including a channel divider dividing the thermal plate into an inlet channel portion located between the first plurality of battery compartments and the second plurality of battery compartments, and an outlet channel portion located between the first plurality of battery compartments and the second plurality of battery compartments, wherein the channel divider includes a first divider portion which extends substantially parallel to outer sides of the inlet channel and the outlet channel, and a second divider portion which curves toward the outer side of the inlet channel portion thereby narrowing the inlet channel portion.