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 battery module includes a battery module housing, cells disposed in the battery module housing, and spacers disposed between adjacent cells. Each spacer is electrically insulating and includes a body portion having a curvilinear, for example elliptical, outer peripheral shape. The body portion is suspended from the cell housing by hangers, and overlies a central region of a cell housing surface corresponding to large deflection due to cell growth. In addition, the body portion is spaced apart from a periphery of the cell housing surface.

Abstract: A battery pack housing forms a container that receives battery modules. The battery pack housing includes container portion and a cover that closes an open end of the container portion. The container portion includes a base, sidewalls that surround the base, and parallel rails that protrude from the base inner surface. The rails have longitudinally-spaced slots that open facing the cover. In addition, an inner surface of the cover portion includes parallel rails having longitudinally spaced slots that open facing the base. The slots are configured to receive and retain pins provided on side surfaces of the battery module housing. The cooperation between the pins of the battery module housing and the slots of the container portion and cover portion permit modules to be easily and securely located within the battery pack housing, and to be quickly removed from the battery pack housing during maintenance.

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 module includes a battery module housing, cells disposed in the battery module housing, and spacers disposed between adjacent cells. Each spacer is electrically insulating and includes a body portion having a curvilinear, for example elliptical, outer peripheral shape. The body portion is suspended from the cell housing by hangers, and overlies a central region of a cell housing surface corresponding to large deflection due to cell growth. In addition, the body portion is spaced apart from a periphery of the cell housing surface.

Abstract: An electrochemical cell includes an electrode assembly disposed in a cell housing. A first U-shaped current collector is disposed between the cell housing and the electrode assembly, and is electrically connected to a positive electrode portion of the electrode assembly. A second U-shaped current collector is disposed between the cell housing and the electrode assembly, and is electrically connected to a negative electrode portion of the electrode assembly. The first and second current collectors cooperate to surround all sides of the electrode assembly and to retain the electrode assembly in the desired configuration without requiring a separate restraint.

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 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 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 an electrode assembly disposed in a cell housing. A first U-shaped current collector is disposed between the cell housing and the electrode assembly, and is electrically connected to a positive electrode portion of the electrode assembly. A second U-shaped current collector is disposed between the cell housing and the electrode assembly, and is electrically connected to a negative electrode portion of the electrode assembly. The first and second current collectors cooperate to surround all sides of the electrode assembly and to retain the electrode assembly in the desired configuration without requiring a separate restraint.

Abstract: A super cell housing is configured to support cylindrical electrochemical cells in a highly volumetrically efficient arrangement. The super cell housing includes a first tray and a second tray that cooperate to secure the cells therebetween. The first and second trays are identical, and include a base having a cell-facing surface and an opposed outward-facing surface, and a sidewall that surrounds a periphery of the base. A sidewall inner surface has concave contours that each define a portion of a cylindrical surface. The base includes protrusions that extend in a direction normal to the cell-facing surface and are surrounded by the sidewall. Outer surfaces of the protrusions having concave contours that each define a portion of a cylindrical surface. The concave contours of the sidewall and the protrusion cooperate to form cell-receiving openings. At least one of the protrusions includes a through hole that opens at the outward-facing surface.

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: A battery pack housing forms a container that receives battery modules. The battery pack housing includes container portion and a cover that closes an open end of the container portion. The container portion includes a base, sidewalls that surround the base, and parallel rails that protrude from the base inner surface. The rails have longitudinally-spaced slots that open facing the cover. In addition, an inner surface of the cover portion includes parallel rails having longitudinally spaced slots that open facing the base. The slots are configured to receive and retain pins provided on side surfaces of the battery module housing. The cooperation between the pins of the battery module housing and the slots of the container portion and cover portion permit modules to be easily and securely located within the battery pack housing, and to be quickly removed from the battery pack housing during maintenance.