Abstract: A battery system for providing electric power to a vehicle includes an assembly having battery cells. The battery system also includes a shear wall that is arranged along a lateral side of the assembly to provide structural support. The shear wall is two-part, including a first element and a second element, both of which may be formed from sheet metal and welded together. The first element has a first flange extending away from the lateral side of the assembly, and the second element has a second flange. The first flange and the second flange are layered together to form an interface. The flanges are welded together at the interface, proximal to the assembly, to form a resulting flange that is thicker than either individual flange and that may be mounted to a frame member. The battery system may also include another shear wall on the opposite lateral side.

Abstract: A battery system for an electric vehicle includes a fixed cover, and a removable cover arranged over battery modules and a high voltage distribution system. The battery system includes a busbar arranged at least partially over a region of the battery modules and under the removable cover. The busbar includes a fixed section and a movable section, or a hinge, such that the busbar can be repositioned out of the way. The support tray includes a link between the fixed and movable sections. Floating fasteners, allowing at least one of radial float and axial float are used to secure the link to the support tray, thereby avoiding safety hazards and reducing the potential for short circuits in high voltage distribution systems or conductors thereof. The floating fasteners include a head, a neck, an engagement section, and a washer, which prevent removal from a component once installed.

Abstract: An apparatus that can define at least one compartment in a battery pack to receive a battery module is disclosed. The apparatus can include a first member that extends from the first side of the battery pack to the second side of the battery pack. The apparatus can include a second member and a third member that together run cross car and extend from the first side to the second side of the battery pack, except with a gap between the second member and the third member.

Abstract: A battery system of a vehicle may include a main battery pack, a secondary battery pack, and one or more secondary contactors. The main battery pack is integrated into the vehicle and includes a first plurality of battery cells, a first DC bus coupled to the first plurality of battery cells, and main contactors coupled to the first DC bus to form a switched DC bus. The secondary battery pack includes a second plurality of battery cells, and a second DC bus coupled to the second plurality of battery cells. The second DC bus of the secondary battery pack is electrically coupled to the switched DC bus of the main battery pack via the secondary contactors. In some embodiments, the main battery pack includes control circuitry configured to communicate with control circuitry of the secondary battery pack to manage or monitor coupling of the battery packs.

Abstract: An electric vehicle battery pack with a thermal shield that protects internal components from, for example, battery ventilation, and in particular allows battery pack electrical components to be placed above venting ends of batteries. The thermal shield is positioned above the venting ends of one or more batteries, and various battery pack electrical components may be placed above the thermal shield. Gases and particulate matter from battery venting are thus intercepted and deflected by the thermal shield, instead of damaging battery pack electrical components. In this manner, various battery pack electrical components may be placed above battery venting ends without risk of damage. This allows for a more compact and versatile arrangement of battery pack components.

Abstract: Electric vehicle battery packs with external side enclosures for containing electrical connectors and other components therein. Each enclosure is sized to support various connectors or other components as desired, and may have a number of openings formed to provide interfaces for connecting various electric vehicle systems to the battery pack. The enclosures may be placed at various locations along one or more sides of the battery pack, and connectors may be routed over an upper surface of a battery pack frame or through a gap formed between the pack frame and cover. Enclosures may be made of any material, including plastic for lower weight applications and metal for improved electromagnetic interference shielding.

Abstract: A laminated busbar assembly includes one or more busbars that are configured to be electrically coupled to a plurality of battery cells, one or more insulative layers arranged adjacent to the one or more busbars, and a steel layer arranged between the one or more busbars and the plurality of battery cells. The steel layer is configured to shield the one or more busbars from a thermal event associated with one or more battery cells of the plurality of battery cells. The thermal event may include a debris, hot gas, sparks, embers, or other emanations. Each of the battery cells each include a respective venting end, where electrical terminals are located, that face the steel layer. The laminated busbar is a stack of layers that can include two busbars that form a DC bus, with insulation arranged between the busbars and between the steel layer and the proximal busbar.

Abstract: A battery module is provided. The battery module comprises a plurality of battery cells. Each battery cell comprises a first electrical terminal and a second electrical terminal. The battery module further comprises at least one bi-metallic busbar, e.g., at least one first busbar. The at least one first busbar comprises a metallic part, e.g., a first aluminum part, electrically coupled to the first electrical terminals of a first group of the plurality of battery cells. The first busbar further comprises another metallic part, e.g., a first copper part. The first copper part comprises a first interface part electrically coupled to the first aluminum part. The first copper part comprises a first terminal part configured to be electrically coupled to a conductor external to the battery module.

Abstract: A cell carrier for a battery module, a battery module including the cell carrier, and a method of assembling a battery module are provided. The cell carrier includes a multi-sided base. The multi-sided base includes a plurality of through-holes arranged in a predetermined pattern. Each through-hole includes an inner sidewall configured to hold one of a plurality of battery cells.

Abstract: A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

Abstract: An interconnect is disclosed that opens a battery circuit when an access cover is removed. The interconnect includes a single installed position, and does not include any throw positions to avoid ambiguity. The interconnect includes a conductive element that closes the battery circuit when the interconnect is installed. The access cover cannot be removed when the interconnect is installed, because the interconnect includes at least one mechanical feature that prevents removal of the access cover. In some instances, the interconnect is integrated into the access cover, such that when the cover is removed, the circuit is opened necessarily during removal. The interconnect interface may include blades, pins, or other electrically conducting elements. The interconnect is arranged in the battery system away from power electronics and other components that may interface to an electrical load, thus providing an added measure of safety when the access cover is off.

Abstract: Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.

Abstract: A battery system includes battery cells arranged and adhered to a carrier. One or more side walls are bonded with adhesive to the battery cells to provide support, and a current collector assembly is also adhered on one axial side of the battery cells. One or more dividers may be included to maintain electrically isolation between the parallel connected battery cell groups. The other axial side of the battery cells is adhered to a cooling plate. A similar structure is bonded with adhesive to the other side of the cooling plate to form a compact battery system. Shear walls, busbars, terminal busbars, and an isolation bracket with a mounted Electronic Control Unit are bonded with adhesive to the assembly to form the battery system. Each adhesive, or type of adhesive, may exhibit specified criteria and requirements such as strength, thermal conductivity, electronic conductivity, curing requirements, or a combination thereof.

Abstract: A battery module is provided. The battery module comprises a plurality of battery cells. Each battery cell comprises a first electrical terminal and a second electrical terminal. The battery module further comprises at least one bi-metallic busbar, e.g., at least one first busbar. The at least one first busbar comprises a metallic part, e.g., a first aluminum part, electrically coupled to the first electrical terminals of a first group of the plurality of battery cells. The first busbar further comprises another metallic part, e.g., a first copper part. The first copper part comprises a first interface part electrically coupled to the first aluminum part. The first copper part comprises a first terminal part configured to be electrically coupled to a conductor external to the battery module.

Abstract: A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

Abstract: An interconnect is disclosed that opens a battery circuit when an access cover is removed. The interconnect includes a single installed position, and does not include any throw positions to avoid ambiguity. The interconnect includes a conductive element that closes the battery circuit when the interconnect is installed. The access cover cannot be removed when the interconnect is installed, because the interconnect includes at least one mechanical feature that prevents removal of the access cover. In some instances, the interconnect is integrated into the access cover, such that when the cover is removed, the circuit is opened necessarily during removal. The interconnect interface may include blades, pins, or other electrically conducting elements. The interconnect is arranged in the battery system away from power electronics and other components that may interface to an electrical load, thus providing an added measure of safety when the access cover is off.

Abstract: Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.

Abstract: Systems and methods are provided to vent a battery pack for an electric vehicle. The battery pack comprises a pack housing subdivided by a crossmember. The crossmember defines a multidirectional vent passage configured to allow venting with a first bay and a second bay. A pressure release valve is arranged on the pack housing and configured to release pressure based on the multidirectional vent passage.

Abstract: Example illustrations are directed to an insulator assembly and methods, e.g., of installing the insulator assembly into a battery pack. An insulator assembly may include an insulator sheet and an insulator sheet standoff coupled to the insulator sheet. The standoff may be configured to allow ventilation associated with the insulator sheet and one or more surfaces of a battery component. Example insulator assemblies may be provided in a battery pack, e.g., for an electric vehicle.

Abstract: A laminated busbar assembly includes one or more busbars that are configured to be electrically coupled to a plurality of battery cells, one or more insulative layers arranged adjacent to the one or more busbars, and a steel layer arranged between the one or more busbars and the plurality of battery cells. The steel layer is configured to shield the one or more busbars from a thermal event associated with one or more battery cells of the plurality of battery cells. The thermal event may include a debris, hot gas, sparks, embers, or other emanations. Each of the battery cells each include a respective venting end, where electrical terminals are located, that face the steel layer. The laminated busbar is a stack of layers that can include two busbars that form a DC bus, with insulation arranged between the busbars and between the steel layer and the proximal busbar.