Abstract: A battery assembly includes a plurality of battery cells each including a cell tab and a bus bar connected to the cell tabs of adjacent battery cells. The bus bar including a pair of 180 degree bend regions that each define a channel for receiving a respective cell tab and a cut-out region defining an opening having opposing edge portions that allows direct access to the cell tab within the cut-out region. A weld line connects the cell tab to at least one of the opposing edge portions within the cut-out region.

Abstract: A battery assembly includes a plurality of battery cells each including a cell tab and a bus bar connected to the cell tabs of adjacent battery cells. The bus bar including a pair of 180 degree bend regions that each define a channel for receiving a respective cell tab and a cut-out region defining an opening having opposing edge portions that allows direct access to the cell tab within the cut-out region. A weld line connects the cell tab to at least one of the opposing edge portions within the cut-out region.

Abstract: A battery module includes a plurality of battery cells and a flexible bus. Each of the battery cells has a main body, a first terminal disposed on the main body, and a second terminal disposed on the main body. The main body includes active material configured to generate power from an electrochemical reaction. The bus includes an electrical current harness configured to conduct an electrical current through the battery module and a battery management system configured to detect and transmit status information, as well as selectively control a charging and a discharging of at least one of the battery cells.

Abstract: Method and apparatus for thermal management of a battery cell or a battery assembly including a plurality of battery cells. One or more fins are in thermal contact with one or more battery cells. A fluid is caused to flow from a high pressure side of a plenum fluidly coupled to each fin, through a cavity in each fin, and back to a low pressure side of the plenum. The fins are fluidly coupled to the plenum using flexible connections that can accommodate movement of the fins with respect to the plenum.

Abstract: Systems and methods for determining the quality of battery cell tab electrical connections are presented. In certain embodiments, a first electrical current may be supplied between a first tab group and a second tab group of a battery cell group. A first voltage drop may be measured between the first tab group and the second tab group and a measured cell group resistance may be determined based on the measured first voltage drop. The measured cell group resistance may be compared with a reference cell group resistance to determine a quality of an associated battery cell tab electrical connection.

Abstract: A battery module includes a plurality of battery cells and a flexible bus. Each of the battery cells has a main body, a first terminal disposed on the main body, and a second terminal disposed on the main body. The main body includes active material configured to generate power from an electrochemical reaction. The bus includes an electrical current harness configured to conduct an electrical current through the battery module and a battery management system configured to detect and transmit status information, as well as selectively control a charging and a discharging of at least one of the battery cells.

Abstract: A battery module includes a plurality of battery cells and a flexible bus. Each of the battery cells has a main body, a first terminal disposed on the main body, and a second terminal disposed on the main body. The main body includes active material configured to generate power from an electrochemical reaction. The bus includes an electrical current harness configured to conduct an electrical current through the battery module and a battery management system configured to detect and transmit status information, as well as selectively control a charging and a discharging of at least one of the battery cells.

Abstract: An electrical connection includes an electrically conductive first contact member, an electrically conductive second contact member, an interface, and an attachment. The first contact member includes a first contact surface for passing current. The second contact member includes a second contact surface for passing current that directly contacts the first contact surface. The interface includes one of a cold weld and a fused section that physically joins the first contact member and the second contact member, and that forms a primary conductive path between the first contact member and the second contact member. The interface is formed by ultrasonic vibration of the first contact surface relative to the second contact surface. The attachment is separate from the interface and mechanically joins the first contact member and the second contact member. A method for forming the electrical method is also provided.

Abstract: Apparatuses and methods of use are provided that include a battery cell comprising a flexible resistive thermal device. The resistive thermal device includes a flexible conductive circuit that is positioned on or adjacent to the surface of the battery cell. Resistance measured in the conductive circuit is correlated with a temperature of the battery cell thereby allowing control of a cooling system and/or the charging/discharging rates of the battery cell to be adjusted in response to temperature. Flexibility of the resistive thermal device also accommodates dimensional changes in the battery cell.

Abstract: A battery cell assembly includes a ganged plurality of battery cells. The battery cells are electrically connected in series. At least one hinge is disposed between an adjacent pair of the battery cells. The battery cells are configured to be stacked upon a folding of the battery cell assembly at the at least one hinge. A cooling plate assembly for use with the battery cell assembly, and a battery power system having the battery cell assembly interlaced with the cooling plate assembly, is also provided.

Abstract: A battery is provided with solid state cooling means so that it may operate within a predetermined operating temperature range is described. Suitably such a battery may be a high voltage-high current battery intended for use in a vehicle propelled by an electric motor such as a hybrid or electric vehicle. A plurality of thermoelectric assemblies is positioned in thermal contact with the assembled cells and/or modules which comprise the battery. These assemblies may be appropriately powered to pump heat from the battery responsive to a plurality of temperature sensors associated with individual cells or modules so that the battery temperature is maintained within the predetermined temperature range. The thermoelectric assemblies may also be powered to pump heat to the battery to more rapidly increase its temperature to the predetermined operating range under low temperature conditions.

Abstract: A method for measuring electrical resistance of a joint includes supplying a first current between a first end of a first member of the joint and a first end of a second member of the joint. The method also includes measuring a first voltage between a second end of the first member and a second end of the second member. The first ends of the first member and the second member are oriented or situated opposite of the joint from the second ends of the first member and the second member. The method also includes calculating a first joint resistance of the joint from the supplied first current and the measured first voltage.

Abstract: A battery cell assembly includes a ganged plurality of battery cells. The battery cells are electrically connected in series. At least one hinge is disposed between an adjacent pair of the battery cells. The battery cells are configured to be stacked upon a folding of the battery cell assembly at the at least one hinge. A cooling plate assembly for use with the battery cell assembly, and a battery power system having the battery cell assembly interlaced with the cooling plate assembly, is also provided.

Abstract: A battery module includes a plurality of battery cells and a flexible bus. Each of the battery cells has a main body, a first terminal disposed on the main body, and a second terminal disposed on the main body. The main body includes active material configured to generate power from an electrochemical reaction. The bus includes an electrical current harness configured to conduct an electrical current through the battery module and a battery management system configured to detect and transmit status information, as well as selectively control a charging and a discharging of at least one of the battery cells.

Abstract: Method and apparatus for thermal management of a battery cell or a battery assembly including a plurality of battery cells. One or more fins are in thermal contact with one or more battery cells. A fluid is caused to flow from a high pressure side of a plenum fluidly coupled to each fin, through a cavity in each fin, and back to a low pressure side of the plenum. The fins are fluidly coupled to the plenum using flexible connections that can accommodate movement of the fins with respect to the plenum.

Abstract: Apparatuses and methods of use are provided that include a battery cell comprising a flexible resistive thermal device. The resistive thermal device includes a flexible conductive circuit that is positioned on or adjacent to the surface of the battery cell. Resistance measured in the conductive circuit is correlated with a temperature of the battery cell thereby allowing control of a cooling system and/or the charging/discharging rates of the battery cell to be adjusted in response to temperature. Flexibility of the resistive thermal device also accommodates dimensional changes in the battery cell.

Abstract: A method for non-destructive health monitoring of a joined component includes: supplying a first current between a first end of a first member and a first end of a second member of the joined component; measuring a first voltage between a second end of the first member and a second end of the second member, wherein the first ends of the first member and the second member are situated opposite of at least one joint from the second ends of the first member and the second member; calculating a first joint resistance of the at least one joint from the supplied first current and the measured first voltage; comparing the calculated first joint resistance to a predetermined minimum joint resistance; and comparing the calculated first joint resistance to a predetermined maximum joint resistance, wherein the predetermined maximum joint resistance is greater than the predetermined minimum joint resistance.

Abstract: An electrical connection includes an electrically conductive first contact member, an electrically conductive second contact member, an interface, and an attachment. The first contact member includes a first contact surface for passing current. The second contact member includes a second contact surface for passing current that directly contacts the first contact surface. The interface includes one of a cold weld and a fused section that physically joins the first contact member and the second contact member, and that forms a primary conductive path between the first contact member and the second contact member. The interface is formed by ultrasonic vibration of the first contact surface relative to the second contact surface. The attachment is separate from the interface and mechanically joins the first contact member and the second contact member. A method for forming the electrical method is also provided.

Abstract: A method for measuring electrical resistance of a joint includes supplying a first current between a first end of a first member of the joint and a first end of a second member of the joint. The method also includes measuring a first voltage between a second end of the first member and a second end of the second member. The first ends of the first member and the second member are oriented or situated opposite of the joint from the second ends of the first member and the second member. The method also includes calculating a first joint resistance of the joint from the supplied first current and the measured first voltage.

Abstract: A method for non-destructive health monitoring of a joined component includes: supplying a first current between a first end of a first member and a first end of a second member of the joined component; measuring a first voltage between a second end of the first member and a second end of the second member, wherein the first ends of the first member and the second member are situated opposite of at least one joint from the second ends of the first member and the second member; calculating a first joint resistance of the at least one joint from the supplied first current and the measured first voltage; comparing the calculated first joint resistance to a predetermined minimum joint resistance; and comparing the calculated first joint resistance to a predetermined maximum joint resistance, wherein the predetermined maximum joint resistance is greater than the predetermined minimum joint resistance.