Abstract: An electric vehicle battery pack cover with a fiber reinforced multiple-ply composite body whose bottom surface is coated with a high-hardness, high-melting point, and fire- and abrasion-resistant coating. The coating can be any one or more materials that provide sufficient fire and abrasion resistance to allow the battery pack to contain a battery fire. As examples, the coating can be a nickel layer, a steel layer, a high temperature mineral layer such as a mica layer, or any combination of these materials. The composite body can be any composite body that is both compatible with the fire- and abrasion-resistant coating and provides sufficient strength to act as a battery cover. As examples, the composite body can be made of one or more glass fiber plies, carbon fiber plies, aramid fiber plies, or any combination of any number of these plies, with a crosslinked polymer or other matrix.

Abstract: Aspects of the disclosure relate to a configurable battery pack. The configurable battery pack may include an enclosure that is formed from housing structures that can be selectively chosen to form an enclosure of various sizes, for enclosing various numbers of battery modules and/or battery cells.

Abstract: A current collector assembly includes an electrically conductive layer with several tabs used to electrically couple with one or more battery cells. The tabs may connect to an interconnect of the electrically conductive layer by way of a fuse. Several fuses may include portions of difference sizes. For example, one portion of the fuse may be relatively longer and narrower, while another portion of the fuse may be shorter and wider. The narrower portion may be positioned between insulating layers of the current collector assembly, while the wider portion extends from the insulating layers. The wider portion of the fuse increases the likelihood of the fuse remaining intact when various forces are exerted on the fuse.

Abstract: Aspects of the subject disclosure relate to various features of a battery subassembly, such as a battery module. The battery subassembly may be implemented in an electric vehicle or in a building.

Abstract: A battery system includes a battery frame, a battery module, and a polymeric seat. The battery frame includes a horizontal bottom plate and a plurality of members that extend in a vertical direction from the bottom plate. The battery module includes at least one battery cell enclosed inside body of the battery module. The battery module also includes an attachment surface fixedly attached to the body and one or more supports that extend downward from to the body. The attachment surface is fixedly attached to one or more of plurality of members to generate a force on the one or more supports in a direction of the bottom plate. The polymeric seat is fixedly attached to either the one or more supports or the battery frame and removably contacts the other of the one or more supports or the battery frame. The polymeric seat is compressed in response to the force.

Abstract: A battery system can include a first cell carrier having a first datum. The first datum of the first cell carrier can align with a second datum of a thermal component and at least partially receive a locating feature of a second cell carrier.

Abstract: A system can include a battery subassembly having a flange. The flange can engage a first cross member and a second cross member of a battery pack using a fastener to clamp the battery subassembly with the first cross member and the second cross member.

Abstract: Efficiency of a battery module is achieved using an actively cooled high power electrical interface. The battery module comprises a plurality of battery cells, at least one busbar coupled to the battery cells, a connector electrically coupled to the at least one busbar, and at least one cooling component that is thermally coupled to the first connector. The battery cells may be arranged in two layers, each layer containing a plurality of battery cells connected by a busbar. The connector comprises a contact through which the battery module may be coupled to an external circuit. The at least one cooling component provided cooling for the battery cells and the connectors and may be placed on the surface of the battery module or between layers of battery cells.

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 electrically conductive member can include a first opening and a second opening. The first opening of the electrically conductive member can engage a first member of a cell carrier to at least partially align the electrically conductive member with the cell carrier. The second opening of the electrically conductive member can engage with a second member of the cell carrier for coupling the electrically conductive member with the cell carrier.

Abstract: A drain system is described for allowing fluid to drain from a battery pack while maintaining structural integrity of the battery pack. A frame of the battery pack is comprised of several retaining members in which valves are disposed to allow fluid to exit the battery pack. The valves are positioned such that forces normally experienced while driving a vehicle, such as acceleration, deceleration, and turning forces, cause the fluid to flow toward and through the valves.

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 system having busbars integrated with a tote is provided. The battery system can include a first pin located on a busbar or a tote and a first receptacle on the busbar or the tote. The first receptacle can include a first opening having a first size in a first direction that is greater than or equal to a first size of the first opening in a second direction. A second pin and a second receptacle can be located on the busbar or the tote. The second receptacle can include a second opening having a second size in the first direction that is less than or equal to a second size of the second opening in the second direction to align the busbar with the tote via the first pin inserted into the first receptacle and the second pin inserted into the second receptacle.

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: 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 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: A barrier structure, a battery module including the barrier structure, and a method of assembling the battery module are provided. The barrier structure includes a plurality of first sidewalls oriented in a first direction, and a plurality of second sidewalls oriented in a second direction. The plurality of first sidewalls interlock with the plurality of second sidewalls to form a grid structure comprising a plurality of cells, each having an open-ended top and an open-ended bottom and configured to be arranged around a cylindrical section of at least one of a plurality of battery cells. The battery module includes a plurality of cylindrical battery cells arranged in a predetermined pattern and a barrier structure for separating the battery cells.

Abstract: A battery pack can include a bay having a first bay wall and a second bay wall. The battery pack can include a battery cell having a top portion and a bottom portion. The top portion of the battery cell can face the first bay wall of the bay and the bottom portion of the battery cell can face a second bay wall of the bay.

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.