Abstract: A battery pack (1) includes a housing (2) and an array of electrochemical cells (80) disposed in the housing (2). The housing (2) includes a container (3) and a lid (30) that closes an open end of the container (3). The container (3) has a base (4), a sidewall (8) that surrounds the base (4), and a spring plate (110) disposed inside the sidewall (8) between the cells (80) and the sidewall (8). The spring plate (110) is free standing within the container (3) and applies a spring force to the cell array that restrains the cells (80) along an axis normal to the surface of the spring plates (110). The lid (30) includes inwardly-protruding pins (50, 60) that further restrain the cells (80) within the housing (2).

Abstract: A battery pack includes a housing and electrochemical cells disposed in the housing. The housing includes a container and a lid that closes an open end of the container. The container has a base, an outer wall the surrounds the base, and a first and a second inner wall disposed inside the outer wall. The first inner wall extends between, and is fixed to, a first portion and a third portion of the outer wall, and is spaced apart from a second portion and a fourth portion of the outer wall. The second inner wall extends between the first portion and the third portion, and is disposed between the first inner wall and the fourth portion. The second inner wall is movable relative to the outer wall such that spacing of the second inner wall from the first inner wall can be changed.

Abstract: An electrochemical cell includes a cell housing and an electrode assembly disposed in the cell housing. The electrode assembly includes an electrode pair that is arranged to form a winding having a polygonal spiral wound shape in which a radius of the corner portions of each turn of the winding is constant, regardless of the number of turns. In addition, a length of the linear portions of one turn of the winding is different than a length of the linear portions of another turn of the winding. Since each turn of the winding includes the corner portions having a desired radius, the volumetric efficiency of the electrode assembly including the winding within a cell housing is improved relative to some cells that use conventional windings. An apparatus and method of forming a polygonal spiral wound winding are disclosed.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A battery module includes module first and second terminals of opposing polarity. The module houses an array of electrochemical cells and includes a first bus bar that electrically connects the cell first terminals of at least a subset of the cells to the module first terminal, and a second bus bar that electrically connects the cell second terminals of the subset of the cells to the module second terminal. A first electrical connector electrically connects the first bus bar to a cell first terminal of each cell of the subset of the cells. The first electrical connector has a first current carrying capacity. A second electrical connector electrically connects the second bus bar to a cell second terminal of each cell of the subset of the cells. The second electrical connector has a second current carrying capacity. The first current carrying capacity is different than the second current carrying capacity.

Abstract: A battery module includes an array of electrochemical cells, and a frame configured to support the cells within the battery module, the fame encircling the array in such a way as to overlie the cell sidewall of each cell and expose the cell first end and the cell second end of each cell. The frame is surrounded by a spacer. The spacer includes a first wall portions that faces the cell first ends, and a second wall portion that faces the cell second ends. The first and second wall portions include grooves that serve as coolant fluid passages. The frame is disposed in the spacer interior space in such a way that each of the cell first ends and each of the cell second ends are exposed to the fluid passages of the first wall portion and the second wall portion.

Abstract: A battery module includes a module terminal, electrochemical cells and a bus bar that electrically connects at least a subset of the cells to the module terminal. The bus bar includes an electrically conductive substrate and an insulation layer disposed between the substrates and ends of the cells. The substrate includes primary connection through holes, each primary connection through hole having a second diameter and being aligned with the first end of a unique one of the cells. The insulation layer includes secondary connection through holes. Each secondary connection through hole has a third diameter and is concentric with a corresponding one of the primary through holes. The third diameter is less than the second diameter, and an electrical connector extends between the substrate and the cell terminal and provides an electrical connection between the substrate and the cell terminal.

Abstract: A battery pack including a battery pack housing, and a battery module disposed in the battery pack housing, Tire pack housing is sealed and flooded with a dielectric fluid. The battery module includes a module housing that is fluid permeable and includes a fluid passageway, and electrochemical cells disposed in the module housing in such a way that terminals of the cells are exposed to fluid disposed in the fluid passageway. The battery pack includes a thermal management system having an inlet plenum assembly disposed at a first end of the battery module, an outlet plenum assembly disposed at a second end of the battery module, and a fluid pump that directs fluid to the inlet plenum assembly via a fluid delivery line and receives fluid from the outlet plenum assembly via a fluid return line.

Abstract: A battery pack (1) includes a housing (2) and an array (40) of electrochemical cells (80) disposed in the housing (2). The housing (2) includes a container (3) and a lid (30) that closes an open end of the container (3). The container (3) has a base (4), a sidewall (8) that surrounds the base (4), and a spring plate (110) disposed inside the side wall (8) between the cells (80) and the sidewall (8). The spring plate (110) is free standing within the container (3) and applies a spring force to the cell array (40) that restrains the cells (80) along an axis normal to the surface of the spring plates (110). The lid (30) includes inwardly-protruding pins (50, 60) that further restrain the cells (80) within the housing (2).

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A battery pack(1) includes a housing (2) and an array of electrochemical cells (80) disposed in the housing (2). The housing (2) includes a container (3) and a lid (30) that closes an open end of the container (3). The container (3) has a base (4), a sidewall (8) that surrounds the base (4), and a spring plate (110) disposed inside the sidewall (8) between the cells (80) and the sidewall (8). The spring plate (110) is free standing within the container (3) and applies a spring force to the cell array that restrains the cells (80) along an axis normal to the surface of the spring plates (110). The lid (30) includes inwardly-protruding pins (50, 60) that further restrain the cells (80) within the housing (2).

Abstract: A battery pack includes a housing and electrochemical cells disposed in the housing. The housing includes a container and a lid that closes an open end of the container. The container has a base, an outer wall the surrounds the base, and a first and a second inner wall disposed inside the outer wall. The first inner wall extends between, and is fixed to, a first portion and a third portion of the outer wall, and is spaced apart from a second portion and a fourth portion of the outer wall. The second inner wall extends between the first portion and the third portion, and is disposed between the first inner wall and the fourth portion. The second inner wall is movable relative to the outer wall such that spacing of the second inner wall from the first inner wall can be changed.

Abstract: A battery pack includes a two-dimensional or three-dimensional array of battery cells, each cell having a polygonal (i.e, rectangular) shape and a “three side-and-one side” terminal configuration. In some embodiments, the terminal configuration allows the cells to be electrically connected in any configuration, series, parallel, or series parallel simply by changing the orientation of the cell relative to adjacent cells and applying pressure to maintain contact. For a rectangular cell shape, this is achieved by providing three like charged terminals (such as positive) on three respective sides of the cell and one oppositely charged terminal (such as negative) on a fourth side of the cell while maintaining a neutral charge on both of the end surfaces of the cell.

Abstract: A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.

Abstract: A battery pack (1) includes a housing (2) and an array (40) of electrochemical cells (80) disposed in the housing (2). The housing (2) includes a container (3) and a lid (30) that closes an open end of the container (3). The container (3) has a base (4), a sidewall (8) that surrounds the base (4), and a spring plate (110) disposed inside the side wall (8) between the cells (80) and the sidewall (8). The spring plate (110) is free standing within the container (3) and applies a spring force to the cell array (40) that restrains the cells (80) along an axis normal to the surface of the spring plates (110). The lid (30) includes inwardly-protruding pins (50, 60) that further restrain the cells (80) within the housing (2).

Abstract: A vehicle battery system includes a battery housing and a plurality of straps. The battery housing is configured to house a battery for powering the vehicle. Each of the plurality of straps is configured to extend about the battery housing, and includes a first end portion and a second end portion that are configured to be attached to the vehicle. The plurality of straps is configured such that upon application of a shock load to the battery housing along a first axis, the plurality of straps deforms prior to deformation of the battery housing.

Abstract: A electrode assembly includes an electrode pair having a positive electrode and a negative electrode that are arranged crosswise and each z-folded while being cross-woven together in a continuous manner. The electrode assembly includes an electrode stack in which portions of the positive electrode are stacked along a stack axis so as to alternate with portions of the negative electrode.

Abstract: An electrochemical cell includes a cell housing and an electrode assembly disposed in the cell housing. The electrode assembly includes an electrode pair that is arranged to form a winding having a polygonal spiral wound shape in which a radius of the corner portions of each turn of the winding is constant, regardless of the number of turns. In addition, a length of the linear portions of one turn of the winding is different than a length of the linear portions of another turn of the winding. Since each turn of the winding includes the corner portions having a desired radius, the volumetric efficiency of the electrode assembly including the winding within a cell housing is improved relative to some cells that use conventional windings. An apparatus and method of forming a polygonal spiral wound winding are disclosed.

Abstract: An electrochemical cell includes a cell housing and an electrode assembly disposed in the cell housing. The electrode assembly includes an electrode pair that is arranged to form a winding having a polygonal spiral wound shape in which a radius of the corner portions of each turn of the winding is constant, regardless of the number of turns. In addition, a length of the linear portions of one turn of the winding is different than a length of the linear portions of another turn of the winding. Since each turn of the winding includes the corner portions having a desired radius, the volumetric efficiency of the electrode assembly including the winding within a cell housing is improved relative to some cells that use conventional windings. An apparatus and method of forming a polygonal spiral wound winding are disclosed.