Abstract: An interface for aligning a current collector with a tote in a battery system is provided. A pin can be located on one of the current collector or the tote. A receptacle can be located on one of the current collector or the tote. The receptacle can include an opening having a first size in a first direction that is greater than or equal to a second size of the opening in a second direction. The opening can be configured to align the current collector with the tote via the pin inserted into the receptacle.

Abstract: A carrier may include a base with several cell bores, with each cell bore designed to carry a battery cell. The carrier may include several walls, with each wall having one or more surfaces that conform to a shape or surface of the battery cell. For example, a surface of the wall may include an arc with a shape that corresponds to that of a cylindrical battery cell. One of the walls may include opposing surfaces, each of which conform to the shape of multiple battery cells. Also, each cell bore may include a ledge to seat a battery. Additionally, a carrier may include several ribs that provide a vent or channel to direct a gas. In addition to battery cells, carriers may also carry cooling tubes designed to cool the battery cells.

Abstract: An interwoven voltage sense harness of a battery is provided. A battery system can include cells arranged in an array. The battery system can include a harness. The harness can include a circuit electrically insulated by a material. The harness can extend along a side of the cells. The harness can include a trace. The trace can be electrically coupled to the circuit. The trace can contact each of the cells to measure voltage of the cells. At least one aspect is directed to a method. The method can include providing a battery system comprising a plurality of cells arranged in an array and a harness.

Abstract: A battery module may include features to support and protect components thereof from external stress and from certain electrical conditions. In particular, a battery module can be provided with components that direct forces away from electrical connection regions, such as at terminals of a battery cell. Such forces can be directed toward other structures that do not define electrical connection regions. A battery module can also be provided with features, such as a series busbar that electrically connects sets of battery cells, that enhance protections from certain electrical conditions. An assembly for such a battery module can provide guidance to align and secure assembled components and to retain them with a potting material during assembly.

Abstract: A battery module may include features to support and protect components thereof from external stress and from certain electrical conditions. In particular, a battery module can be provided with components that direct forces away from electrical connection regions, such as at terminals of a battery cell. Such forces can be directed toward other structures that do not define electrical connection regions. A battery module can also be provided with features, such as a series busbar that electrically connects sets of battery cells, that enhance protections from certain electrical conditions. An assembly for such a battery module can provide guidance to align and secure assembled components and to retain them with a potting material during assembly.

Abstract: A battery module may include features to support and protect components thereof from external stress and from certain electrical conditions. In particular, a battery module can be provided with components that direct forces away from electrical connection regions, such as at terminals of a battery cell. Such forces can be directed toward other structures that do not define electrical connection regions. A battery module can also be provided with features, such as a series busbar that electrically connects sets of battery cells, that enhance protections from certain electrical conditions. An assembly for such a battery module can provide guidance to align and secure assembled components and to retain them with a potting material during assembly.

Abstract: A battery module may include features to support and protect components thereof from external stress and from certain electrical conditions. In particular, a battery module can be provided with components that direct forces away from electrical connection regions, such as at terminals of a battery cell. Such forces can be directed toward other structures that do not define electrical connection regions. A battery module can also be provided with features, such as a series busbar that electrically connects sets of battery cells, that enhance protections from certain electrical conditions. An assembly for such a battery module can provide guidance to align and secure assembled components and to retain them with a potting material during assembly.

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: An apparatus can include a first wall and a second wall, the second wall having an aperture. The apparatus can include an opening defined by the first wall and the second wall, the opening configured to receive a thermistor. The aperture can be configured to receive a retention member of the thermistor to dispose the thermistor in a battery module.

Abstract: A current collector can include an electrically conductive layer. The electrically conductive layer can be configured to electrically couple to a first battery cell and a second battery cell with an interstitial area between the first battery cell and the second battery cell. The current collector can include an isolation layer. The isolation layer can define an aperture. The aperture can form a path through the isolation layer to the interstitial area.

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: Aspects of the subject technology relate to an inverted battery enclosure, such as an inverted battery enclosure for a battery pack for a vehicle. The inverted battery enclosure may include a lid, and one or more battery cells and/or battery subassemblies attached to an interior surface of the lid. A gap may be provided, within the enclosure, between the battery cells and a bottom of the enclosure. One or more impact absorption features may be provided along a sidewall of the lid.

Abstract: A current collector assembly (CCA) with an insulative structure is provided. A battery system can include the current collector assembly formed from the insulative structure. The current collector assembly can include a conductor layer at least partially encapsulated by the insulative structure. The current collector assembly can include a conductor array cut from the conductor layer. A first portion of the conductor array can contact a positive terminal of a first group of battery cells, and a second portion of the conductor array can contact a negative terminal of a second group of battery cells. The rib can be formed from the insulative structure of the current collector assembly.

Abstract: An interwoven voltage sense harness of a battery is provided. A battery system can include cells arranged in an array. The battery system can include a harness. The harness can include a circuit electrically insulated by a material. The harness can extend along a side of the cells. The harness can include a trace. The trace can be electrically coupled to the circuit. The trace can contact each of the cells to measure voltage of the cells. At least one aspect is directed to a method. The method can include providing a battery system comprising a plurality of cells arranged in an array and a harness.

Abstract: One aspect is an insert molded friction torque device with a rotatable shaft, a friction element mounted over the rotatable shaft in an interference fit, a rigid enclosure structure at least partially enclosing the friction elements, and a single-piece molded housing enclosing the friction element and at least partially enclosing the rigid enclosure structure such that a first portion of the housing is between the friction elements and the rigid enclosure structure within the rigid enclosure structure and a second portion of the housing is outside the rigid enclosure structure.

Abstract: A current collector assembly (CCA) with an insulative structure is provided. A battery system can include the current collector assembly formed from the insulative structure. The current collector assembly can include a conductor layer at least partially encapsulated by the insulative structure. The current collector assembly can include a conductor array cut from the conductor layer. A first portion of the conductor array can contact a positive terminal of a first group of battery cells, and a second portion of the conductor array can contact a negative terminal of a second group of battery cells. The rib can be formed from the insulative structure of the current collector assembly.

Abstract: An intercellular support structure of a battery system is provided. The battery system includes cells arranged in an array and a first support structure with a first material to hold a first portion of a first group of cells with a first spacing between the first group of cells. The battery system includes a second support structure, adjacent to the first support structure, which can include a second material to hold, and can provide a second spacing between, a second portion of the first group of cells and a first portion of a second group of cells. The battery system can include a third support structure, adjacent to the second support structure and opposite to the first support structure, which can include the first material to hold a second portion of the second group of cells with the first spacing between the second portion of the second group of cells.

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 current collector can include an electrically conductive layer. The electrically conductive layer can be configured to electrically couple to a first battery cell and a second battery cell with an interstitial area between the first battery cell and the second battery cell. The current collector can include an isolation layer. The isolation layer can define an aperture. The aperture can form a path through the isolation layer to the interstitial area.

Abstract: A cell carrier for a battery module, a battery module, and a method for assembling a battery module. The battery module includes a plurality of pairs of battery cells and the cell carrier. The cell carrier includes a plurality of recesses, each including a first recess portion including a first sidewall portion and a first bottom portion, and a second recess portion including a second sidewall portion and a second bottom portion. The first bottom portion and the second bottom portion of each recess include a shared cutout. For each pair of battery cells, a first end of a first battery cell is coupled to the first recess portion and a first end of a second battery cell is coupled to the second recess portion of a respective recess.