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: An electrochemical cell includes a cell element and a current collector disposed in a housing that includes a vent. The current collector includes an outer member and an inner member coupled together by one or more flexible arms. The outer member is coupled to the cell element and the inner member is coupled to the vent, such that the flexible arms allow axial movement of the inner member with respect to the outer member when the vent moves from an undeployed position to a deployed position. The housing may include a shoulder that holds the cell element in the housing. The electrochemical cell may also include a coil plate provided at an end of the cell element. The coil plate is coupled to an edge of at least one electrode of the cell element.

Abstract: Present embodiments include a lithium ion battery module and associated lithium ion battery cells. The lithium ion battery cells include a prismatic cell casing enclosing electrochemically active components. The cell thickness, the cell width, the cell length, and the electrochemically active components are such that the lithium ion battery cell has a volumetric energy density between 82 Watt-hours per Liter (Wh/L) and 153 Wh/L, and has a nominal voltage between 2.0 V and 4.2 V.

Abstract: The present disclosure includes an electrochemical cell having a housing configured to house one or more electrodes of the electrochemical cell. The housing includes a wall having an inner surface facing the one or more electrodes. The electrochemical cell also includes a hinged vent stamped on the inner surface of the housing, where the hinged vent includes a fracture portion, a hinge portion on either side of the fracture portion extending substantially parallel to the fracture portion, and connecting portions extending between the fracture portion and the hinge portions. The fracture portion includes a first cross-sectional width through the wall of the housing and the hinge portion includes a second-cross sectional width through the wall of the housing greater than the first cross-sectional width.

Abstract: The present disclosure relates to a battery module that includes a housing having a first protruding shelf along a first perimeter of the housing, a second protruding shelf along a second perimeter of the housing, where the first and second protruding shelves each include an absorptive material configured to absorb a first laser emission. The battery module also includes an electronics compartment cover configured to be coupled to the housing via a first laser weld, and a cell receptacle region cover configured to be coupled to the housing via a second laser weld. The electronics compartment cover has a first transparent material configured to transmit the first laser emission toward the first protruding shelf and the cell receptacle region cover has a second transparent material configured to transmit the first laser emission or a second laser emission toward the second protruding shelf.

Abstract: A battery module includes a battery module housing, a heat exchanger including a plurality of fins disposed in the housing, a first lithium ion battery cell and a second lithium ion battery cell disposed within the battery module housing. The first lithium ion battery cell and the second lithium ion battery cell are separated by a fin of the plurality of fins. The module includes a temperature sensing component coupled to the fin separating the first and second battery cells. Filler material is disposed within the housing and between the battery cells and the fins to mechanically restrain the battery cells within the battery module housing. The filler materials conduct thermal energy between the battery cells and the fin. The filler material covers a free end of the fin and the temperature sensing component. The temperature sensing component is coupled to a conductor extending out of the filler material.

Abstract: A device for aiding in the fracture of a vent of an electrochemical cell includes a main body having a first surface and a plurality of lobes extending out from the first surface of the main body such that an open space is provided between adjacent lobes. Each of the plurality of lobes are configured to make contact with the vent during deployment of the vent such that the vent completely separates from a bottom of the electrochemical cell. The open space provided between adjacent lobes is configured to allow gases from inside the electrochemical cell to pass through during deployment of the vent.

Abstract: A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

Abstract: Present embodiments are directed to a battery module including a venting assembly and a method of manufacturing the battery module. The venting assembly may, in certain embodiments, be designed to vent gases from a plurality of battery cells disposed in a housing of the battery module. Each of the plurality of battery cells may include a battery cell vent. The venting assembly may include a lid designed to be coupled to the housing and disposed over the battery cells in the housing. In some embodiments, the lid includes a vent chamber formed in the lid and designed to receive and direct gases vented from the plurality of battery cells away from the battery module.

Abstract: A system includes a battery cell having a packaging and a coil disposed within the packaging. The battery cell further includes a first terminal electrically coupled to a portion the coil and protruding through an opening in the packaging, wherein the first terminal is hermetically sealed at the opening in the packaging using a compressive force.

Abstract: A lithium ion (Li-ion) battery module includes a container with one or more partitions that define compartments within the container. Each of the compartments is configured to receive and hold a prismatic Li-ion electrochemical cell element, and a cover is configured to be disposed over the container to close the compartments. The container includes a polymer blend including a base polymer and one or more additives blended into the base polymer. The base polymer is electrically nonconductive and the one or more additives are configured to increase a thermal conductivity of the container to promote transfer of heat generated from the electrochemical cell elements through the container.

Abstract: A lithium ion (Li-ion) battery cell includes a prismatic housing that includes four sides formed by side walls coupled to and extending from a bottom portion of the housing. The housing is configured to receive and hold a prismatic Li-ion electrochemical cell element. The housing includes an electrically nonconductive polymeric (e.g., plastic) material. Additionally, a heat sink is overmolded by the polymeric material of the housing, such that the heat sink is retained in an outer portion of the sides of the housing and the heat sink is exposed along the bottom portion of the housing.

Abstract: A lithium ion (Li-ion) battery cell includes a housing. The housing includes side walls coupled to and extending from a first portion of the housing to form an opening in the housing opposite the first portion of the housing. The housing includes an electrically nonconductive polymeric (e.g., plastic) material. An electrochemical cell element is disposed in the housing and immersed in electrolyte that is also disposed in the housing. The Li-ion battery cell also includes a cover including an electrically nonconductive polymeric material. The cover is disposed over the opening in the housing and sealed to the housing via a seal. The seal is configured to resist or prevent ingress of moisture into the housing and to resist or prevent egress of the electrolyte from the housing.

Abstract: A lithium ion (Li-ion) battery module includes a container with one or more partitions that define compartments within the container. Each of the compartments is configured to receive and hold a prismatic Li-ion electrochemical cell element and electrolyte. The Li-ion battery module also includes a cover configured to be disposed over the container to close the compartments. The container includes an electrically nonconductive polymeric material (e.g., plastic) with a nanomaterial applied to the polymeric material. The nanomaterial enhances the impermeability of the container to reduce ingress of moisture into the compartments and to reduce egress of the electrolyte from the compartments.

Abstract: A battery module includes a hermetically sealed battery cell assembly. The battery cell assembly includes a housing and an electrochemical cell disposed in the housing. The battery cell assembly also includes a first battery terminal coupled to and extending away from the electrochemical cell and extending through a first opening in the housing. The first opening in the housing comprises a flange. The battery cell assembly further includes a sealing ring disposed around the flange to exert a compressive force for hermetically sealing the opening.

Abstract: A current collector with improved flexibility and electrical conductivity includes at least one flexible leg coupled to a central portion of the current collector. The flexible leg extends substantially orthogonally to the central portion when a force is applied to the central portion. Specifically, the at least one flexible leg extends at least 16 percent of the outer width when a 1000 Newton loading is applied between the central portion and the outer portion.