Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into one or more rows. Each of the plurality of battery cells may include a first terminal and a second terminal, and the plurality of battery cells may include a subset of battery cells with the first terminal oriented in a same direction in the battery pack. The battery pack may also include a busbar configured to conduct electrical energy to and from at least the subset of battery cells. The busbar may include a plurality of cutouts positioned over the first terminals of the subset of battery cells, and a plurality of tabs that springably contact the respective first terminal. A method of building a battery pack with a busbar connection is also presented.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into at least a first row and a second row. The first row may be parallel to the second row. The battery pack may also include a coolant loop with at least one channel through which liquid can flow. The coolant tube may run between the first row and the second row. The battery pack may additionally include a thermal pad comprising a first side and a second side. The first side of the thermal pad may be shaped to conform to the coolant loop and the second side of the thermal pad may be shaped to conform to curvatures of the first row.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged in on or more rows, a coolant loop, and a molded insert that encompasses the plurality of cells and the coolant loop such that the plurality of cells and the coolant loop are fixed relative to each other. The molded insert may cover a large portion of the coolant loop and/or the individual battery cells of the battery pack. An injection mold can be used as a fixture to hold the individual battery cells in place relative to the coolant loop, and the molded insert can be injected around the battery and coolant loop assembly.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into one or more rows. Each of the plurality of battery cells may include a first terminal and a second terminal, and the plurality of battery cells may include a subset of battery cells with the first terminal oriented in a same direction in the battery pack. The battery pack may also include a busbar configured to conduct electrical energy to and from at least the subset of battery cells. The busbar may include a plurality of cutouts positioned over the first terminals of the subset of battery cells, and a plurality of tabs that springably contact the respective first terminal. A method of building a battery pack with a busbar connection is also presented.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into at least a first row and a second row. The first row may be parallel to the second row. The battery pack may also include a coolant loop with at least one channel through which liquid can flow. The coolant tube may run between the first row and the second row. The battery pack may additionally include a thermal pad comprising a first side and a second side. The first side of the thermal pad may be shaped to conform to the coolant loop and the second side of the thermal pad may be shaped to conform to curvatures of the first row.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into one or more rows. Each of the plurality of battery cells may include a first terminal and a second terminal, and the plurality of battery cells may include a subset of battery cells with the first terminal oriented in a same direction in the battery pack. The battery pack may also include a busbar configured to conduct electrical energy to and from at least the subset of battery cells. The busbar may include a plurality of cutouts positioned over the first terminals of the subset of battery cells, and a plurality of tabs that springably contact the respective first terminal. A method of building a battery pack with a busbar connection is also presented.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into at least a first row and a second row. The first row may be parallel to the second row. The battery pack may also include a coolant loop with at least one channel through which liquid can flow. The coolant tube may run between the first row and the second row. The battery pack may additionally include a thermal pad comprising a first side and a second side. The first side of the thermal pad may be shaped to conform to the coolant loop and the second side of the thermal pad may be shaped to conform to curvatures of the first row.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged in on or more rows, a coolant loop, and a molded insert that encompasses the plurality of cells and the coolant loop such that the plurality of cells and the coolant loop are fixed relative to each other. The molded insert may cover a large portion of the coolant loop and/or the individual battery cells of the battery pack. An injection mold can be used as a fixture to hold the individual battery cells in place relative to the coolant loop, and the molded insert can be injected around the battery and coolant loop assembly.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into at least a first row and a second row. The first row may be parallel to the second row. The battery pack may also include a coolant loop with at least one channel through which liquid can flow. The coolant tube may run between the first row and the second row. The battery pack may additionally include a thermal pad comprising a first side and a second side. The first side of the thermal pad may be shaped to conform to the coolant loop and the second side of the thermal pad may be shaped to conform to curvatures of the first row.

Abstract: A battery pack for an electric vehicle may include a plurality of battery cells arranged into one or more rows. Each of the plurality of battery cells may include a first terminal and a second terminal, and the plurality of battery cells may include a subset of battery cells with the first terminal oriented in a same direction in the battery pack. The battery pack may also include a busbar configured to conduct electrical energy to and from at least the subset of battery cells. The busbar may include a plurality of cutouts positioned over the first terminals of the subset of battery cells, and a plurality of tabs that springably contact the respective first terminal. A method of building a battery pack with a busbar connection is also presented.