WO2025003928A1

WO2025003928A1 - Serviceable battery module

Info

Publication number: WO2025003928A1
Application number: PCT/IB2024/056239
Authority: WO
Inventors: Jason Robert Degen; Jens BUHLINGER; Nayan D. KHAPEKAR; Kirti R. SINGH; James Everett DAWSON
Original assignee: Eaton Intelligent Power Limited
Priority date: 2023-06-27
Filing date: 2024-06-27
Publication date: 2025-01-02

Abstract

A battery module includes two or more independently replaceable cell banks coupled together in series, in parallel, or both. Each cell bank includes multiple battery cells (e.g., pouch cells, prismatic cells, etc.) mechanically held together using end caps. The battery cells of each cell bank are electrically coupled together in series, parallel, or both at terminals. The terminals are electrically connected together either via adapters or through direct mating.

Description

SERVICEABLE BATTERY MODULE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to Indian Provisional Patent Application Serial No. 202311042934, filed June 27, 2023, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] Conventional battery modules include battery cells that are fixedly attached to a bus bar or other cell interconnect. For example, the battery cells may be connected by laser or ultrasonic welding. When a chemistry change within one of the battery cells affects the operation of the battery module, the entire battery module must be replaced. Improvements are desired.

SUMMARY

[0003] In accordance with aspects of the disclosure, cell banks within a battery module are removably connected together. Accordingly, each cell bank can be independently replaced within the battery module instead of needing to replace the entire battery module. Each cell bank includes one or more battery cells.

[0004] In certain implementations, each cell bank includes multiple battery cells mechanically and electrically connected together. In some examples, the battery cells of the cell bank are electrically connected in parallel. In other examples, the battery cells of the cell bank are electrically connected in series.

[0005] In certain implementations, the individual battery cells of a cell bank are mechanically connected together in a stack. In certain implementations, the battery cells of the cell bank are connected together using end caps.

[0006] A first end cap is disposed at first ends of the battery cells and a second end cap is disposed at second ends of the battery cells. The end caps provide structural stability to the battery cells. Each end cap includes a respective terminal that terminates the battery cells at the respective end. For example, electrodes of the battery cells extend through the end caps and are joined together (e.g., crimped) to the terminals.

[0007] In certain implementations, multiple cell banks can be electrically connected together, e.g., in series. In certain examples, a terminal of one cell bank electrically connects to a terminal of another cell bank. In some implementations, the connection portions are electrically connected together via an adapter (e.g., a spring contact terminal). In other implementations, the connection portions directly engage each other. In certain implementations, each cell bank includes two terminals. In certain examples, the terminals are disposed at different sides of the cell bank.

[0008] In certain implementations, the battery module includes a frame assembly configured to hold the cell banks. The frame assembly defines an open space sized to receive a majority of the cell banks. In certain examples, the frame assembly defines one or more guide slots at opposite sides of the frame housing. Each guide slot is configured to receive a terminal of at least one cell bank. In certain examples, the guide slot receives a first terminal of a first cell bank and a second terminal of a second cell bank. In certain examples, the guide slot also receives a respective adapter (e.g., spring contact terminal) configured to electrically join the first and second terminals.

[0009] In certain examples, the guide slot(s) at a first side of the frame assembly are offset from the guide slot(s) at the second side of the frame assembly. In certain examples, the terminal at the first end of the cell bank is offset from the terminal at the second end of the cell bank.

[0010] In some implementations, the terminals include copper blades. In certain implementations, a biasing arrangement electrically connects the copper blades together. In an example, the biasing arrangement includes an HPLB (high power lock box) terminal offered by Eaton Corporation having operations in Cleveland, Ohio, USA.

[0011] In other implementations, a first terminal of a cell bank includes a male body and a second terminal of the cell bank includes a female body. The male and female bodies are configures so that a male body of one cell bank mates (e.g., mechanically engages and electrically connects) to a female body of another cell bank. In certain examples, the male body is an HPLB male terminal offered by Eaton and the female body is an HPLB female terminal offered by Eaton.

[0012] A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows.

[0014] FIG. 1 illustrates a first example battery cell bank including one or more battery cells mechanically and electrically mounted together as a unit, the battery cell bank having electrode leads of a first type.

[0015] FIG. 2A illustrates one end of the battery cell bank of FIG. 1 in which the battery cell bank includes a single battery cell.

[0016] FIG. 2B illustrates one end of the battery cell bank of FIG. 1 in which the battery cell bank includes a plurality of battery cells.

[0017] FIG. 3 illustrates an example battery module at which multiple battery cell banks are installed at a framework.

[0018] FIG. 4 is an enlarged view of a portion of FIG. 3.

[0019] FIG. 5 shows an example biasing element.

[0020] FIG. 6 illustrates connections between battery cell banks via biasing elements, the battery cell banks being installed at an example framework, the portion of the framework at which the biasing elements are mounted being removed for ease in viewing.

[0021] FIG. 7 illustrates a plurality of biasing elements installed at an example framework.

[0022] FIG. 8 illustrates a second example battery cell bank including one or more battery cells mechanically and electrically mounted together as a unit, the second battery cell bank having terminals connectorizing electrode leads of a second type.

[0023] FIG. 9 illustrates a battery module having direct connections between the terminals of the battery cell banks of FIG. 8.

[0024] FIG. 10 is a perspective view of a portion of the battery module of FIG. 9.

[0025] FIG. 11 is a perspective view of another example battery module having direct connections between the terminals of a third example implementation of a battery cell bank. [0026] FIG. 12 is a perspective view of the third example cell bank of FIG. 11, the cell bank having an end cap and a terminal exploded away from electrode leads at one of the cell bank for ease in viewing.

[0027] FIG. 13 is a cross-sectional view of the assembled cell bank of FIG. 12.

[0028] FIG. 14 is an enlarged view of a portion of FIG. 13.

[0029] FIG. 15 is an enlarged view of a portion of FIG. 13. [0030] FIG. 16 is a perspective view of another example battery module having direct connections between the terminals of a fourth example implementation of a battery cell bank. [0031] FIG. 17 is a perspective view of the fourth example cell bank of FIG. 16, the cell bank having an end cap and a terminal exploded away from electrode leads at one of the cell bank for ease in viewing.

[0032] FIG. 18 is a cross-sectional view of the assembled cell bank of FIG. 17.

[0033] FIG. 19 is an enlarged view of a portion of FIG. 18.

[0034] FIG. 20 is an enlarged view of a portion of FIG. 18.

[0035] FIG. 21 is a perspective view of another example battery module having direct connections between the terminals of a fifth example implementation of a battery cell bank.

[0036] FIG. 22 is a perspective view of the fifth example cell bank of FIG. 21, the cell bank having an end cap and a terminal exploded away from electrode leads at one of the cell bank for ease in viewing.

[0037] FIG. 23 is a cross-sectional view of the assembled cell bank of FIG. 22.

[0038] FIG. 24 is an enlarged view of a portion of FIG. 23.

[0039] FIG. 25 is an enlarged view of a portion of FIG. 23.

DETAILED DESCRIPTION

[0040] Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0041] Referring to FIGS. 3, 9, 11, 16, and 21, two or more cell banks 110, 120, 130, 140, 150 are removably connected together within a battery module 100. In certain implementations, the cell banks 110, 120, 130, 140, 150 are connected together in series. In various implementations, the cell banks 110, 120, 130, 140, 150 can be connected together in series, in parallel, or a combination of the two.

[0042] As will be discussed herein, each cell bank 110, 120, 130, 140, 150 includes one or more individual battery cells 102 connected together as a unit. In some implementations, the battery cells 102 are pouch cells. In other implementations, the battery cells 102 are prismatic cells. Other configurations are possible. Each cell bank 110, 120, 130, 140, 150 can be independently replaced within the battery module 100 without disturbing the other cell banks 110, 120, 130, 140, 150. Accordingly, if a battery cell 102 fails, only the respective cell bank 110, 120, 130, 140, 150 of the battery cell 102 is replaced instead of the entire battery module 100. [0043] Referring to FIGS. 1, 8, 12, 17, and 22, example types of cell banks 110, 120, 130, 140, 150 are shown. In certain implementations, each cell bank 110, 120, 130, 140, 150 has a terminal 106, 126, 128. The terminal 106, 126, 128 terminates an electrode lead 105 of each of the one or more battery cells 102 of the cell bank 110, 120, 130, 140, 150. In certain implementations, the electrode leads 105 include conductive, flexible tabs extending outwardly from the battery cells 102.

[0044] The cell banks 110, 120, 130, 140, 150 are electrically connected together through electrical connection of the terminals 106, 126, 128. The terminals 106, 126, 128 of multiple cell banks 110, 120, 130, 140, 150 can be electrically connected together, e.g., in series, in parallel, or a combination of the two, to electrically connect the cell banks 110, 120, 130, 140, 150. In some implementations, the terminals 106, 126, 128 of a pair of cell banks 110, 120, 130, 140, 150 can be connected together using adapters 108 as will be described in more detail below. In other implementations, the terminals 106, 126, 128 of a pair of cell banks 110, 120, 130, 140, 150 can be electrically connected together through direct mechanical contact.

[0045] At least a portion of at least one terminal 106, 126, 128 is disposed external of an end cap 104, 134, 144, 154. In certain examples, the electrode lead 105 of each battery cell 102 of the cell bank 110, 120, 130, 140, 150 extends through the end cap 104, 134, 144, 154 (e.g., through an aperture 107, 138, 148, 158 defined in the end cap 104, 134, 144, 154) to the terminal 106, 126, 128. The electrode lead 105 is electrically connected to the terminal 106, 126, 128. In certain implementations, the electrode lead 105 is mechanically connected to the terminal 106, 126, 128.

[0046] In certain implementations, an end cap 104, 134, 144, 154 is disposed at the end of the cell bank 110, 120, 130, 140, 150. In certain implementations, the end cap 104, 134, 144, 154 has a body 135, 145, 155 including a main wall extending over an end face of the cells 102 of the cell bank 110, 120, 130, 140, 150. In certain implementations, the main wall of the end cap 134, 144, 154 defines a protrusion 136, 146, 156 extending outwardly from the cell bank 130, 140, 150. The aperture 107, 138, 148, 158 extends through the protrusion 136, 146, 156. In certain examples, the body 135, 145, 155 of the end cap 104, 134, 144, 154 also extends from the main wall over side edges of the battery cells 102 of the cell bank 110, 120, 130, 140, 150.

[0047] The terminal 106, 126, 128 of the cell bank 110, 120, 130, 140, 150 is attached to the electrode lead 105 of each battery cell 102. In certain examples, the terminal 106, 126, 128 include parallel plates 125 between which the electrode leads 105 can be press-fit, crimped, welded, or otherwise secured. In certain examples, the electrode leads 105 are staggered when disposed between the parallel plates 125 so that each lead 105 contacts at least one of the plates 125.

[0048] In certain implementations, the terminals 106, 106A, 106B include clips that fold or otherwise extend around the respective electrodes 105 (e.g., see FIGS. 2A and 2B). In the example shown in FIGS. 2A and 2B, the terminal 106 has a C-shape. Other configurations, such as a U-shape, are possible. In certain examples, a terminal 106 may be crimped about the electrode lead 105 of one or more battery cells 102.

[0049] In certain examples, the electrode leads 105 of the battery cells 102 extend through the end caps 104, 134, 144, 154 and are joined together (e.g., press-fit, crimped, or welded) to the terminals 106, 126, 128. At least a portion of each terminal 106, 126, 128 is disposed external of the end cap 104, 134, 144, 154. In some examples, all of the terminal 106, 126, 128 is disposed external of the end cap. In other examples, a portion of the terminal 106, 126, 128 may extend through the aperture 107, 138, 148, 158. For example, portions of the parallel plates 125 may extend along the aperture 107, 138, 148, 158 within the protrusion 136, 146, 156 (e.g., see FIGS. 14-15, 19-20, and 24-25).

[0050] Overlap between the terminals 106, 126, 128 (e.g., the parallel plates 125) and the protrusion 136, 146, 156 enhances strength and rigidity of the electrical connection (e.g., the flexible tabs of the electrode leads 105) between the battery cells 102 and the terminals 106, 126, 128. In certain examples, the terminal 106, 126, 128 may be integral with the end cap 104, 134, 144, 154 (e.g., overmolded, welded, press-fit, affixed, or otherwise attached). Attachment between the terminals 106, 126, 128 and the end cap 104, 134, 144, 154 protects the electrical connection (e.g., the electrode leads 105) during insertion and removal of the cell bank 110, 120, 130, 140, 150 to and from the battery module 100.

[0051] In some implementations, a terminal 106, 126, 128 is attached to the electrode lead 105 of one or more battery cells 102 after the electrode lead(s) 105 have been inserted through the end cap 104, 134, 144, 154. In other implementations, a terminal 106, 126, 128 is attached to the electrode lead 105 of one or more battery cells 102 prior to installation of the end cap 104, 134, 144, 154. In certain such implementations, the combination of the terminal 106, 126, 128 and the electrode lead(s) 105 can be inserted through the aperture 107, 138, 148, 158 in the end cap 104, 134, 144, 154, respectively. In certain implementations, the terminals 106 are secured to the electrode lead(s) 105 by passing the terminals 106 and electrode leads 105 through the aperture 107, 138, 148, 158 defined in the end cap 104, 134, 144, 154. For example, the aperture 107, 138, 148, 158 may include one or more barbs that press the terminal 106 against the electrode lead(s) 105 (e.g., to crimp the terminal 106 to the electrodes 105). [0052] In still other implementations, the terminal 106, 126, 128 can be mechanically attached to the end cap 104, 134, 144, 154 before the electrode lead(s) 105 are electrically connected to the terminal 106, 126, 128 and before the electrode lead(s) 105 are inserted through the end cap 104, 134, 144, 154. For example, the terminal 106, 126, 128 can be molded, crimped, welded, affixed, fastened, press-fit, heat-staked, or otherwise mechanically connected to the end cap 104, 134, 144, 154 so that a slot or other contact surface of the terminal 106, 126, 128 aligns with the aperture 107, 138, 148, 158 of the end cap 104, 134, 144, 154. Accordingly, an electrode lead 105 can be inserted (e.g., slid) through the end cap 104, 134, 144, 154 and into the terminal 106, 126, 128 in a single step.

[0053] In some implementations, the cell bank 110, 120, 130, 140, 150 may include a single battery cell 102 (e.g., see FIG. 2A). The end cap 104, 134, 144, 154 can be mounted to an end of the cell bank 102 so that the end of the cell bank 102 is disposed within an interior 103 of the end cap 104, 134, 144, 154. An electrode lead 105 of the battery cell 102 extends through the end cap 104, 134, 144, 154 (e.g., through an the aperture 107, 138, 148, 158 defmed in the end cap 104, 134, 144, 154).

[0054] In other implementations, the cell bank 110, 120, 130, 140, 150 includes multiple battery cells 102 stacked together (e.g., see FIGS. 2B, 12, 17, and 22). While two battery cells 102 (102a, 102b) are shown in FIG. 2B, other amounts (e.g., three, four, five, six, etc.) are possible. For example, three battery cells 102 are shown in each cell bank 130, 140, 150 of FIGS. 11-25. Each of the battery cells 102 includes a respective first electrode lead 105. The first electrode leads 105 of all of the battery cells 102 of a cell bank 110, 120, 130, 140, 150 are electrically connected together at the terminal 106, 126, 128. For example, the first electrode leads 105 of the cell bank 110, 120, 130, 140, 150 may be connected together in parallel. In various examples, the first electrode leads 105 of the cell bank 110, 120, 130, 140, 150 may be connected together in parallel, in series, or in a combination of the two.

[0055] In certain implementations, the battery cells 102 are mechanically held together at the end cap 104, 134, 144, 154. Each end cap 104, 134, 144, 154 provides structural stability to the battery cells 102 within a cell bank 110, 120, 130, 140, 150. In certain examples, each end cap 104, 134, 144, 154 defines an interior pocket or cavity 103 in which an end of each battery cell 102 is received (e.g., see FIGS. 2A and 2B). In certain implementations, the end cap 104, 134, 144, 154 is coupled to the battery cells 102 using adhesive. In other implementations, the end cap 104, 134, 144, 154 can be connected to the battery cells 102 by press-fit, crimping, friction-fit with barbs or textured surfaces, or other mechanical connection. [0056] In some examples, the end cap 104 defines a perimeter extending around the stack of battery cells 102 (e.g., see FIG. 10). In other examples, the end cap 104, 134, 144, 154 has a U-shaped cross-section and extends over ends of the battery cells 102 and parts of side edges of the battery cells without extending over major surfaces of the battery cells 102.

[0057] In certain implementations, because the battery cells 102 of a cell bank 110, 120, 130, 140, 150 are stacked within the end cap 104, 134, 144, 154, the electrode leads 105 extending through the cap 104, 134, 144, 154 have different lengths. Accordingly, an electrode lead 105 of a first battery cell 102 may extend beyond an electrode lead 105 of a second battery cell 102 (e.g., see FIG. 2B). This difference in extension length may allow the terminal 106, 126, 128 to electrically contact more of the combined electrode leads 105.

[0058] In some implementations, the apertures 107, 138, 148, 158 of the end caps 104, 134, 144, 154 are aligned along a center longitudinal axis of a main wall of the end cap 104, 134, 144, 154 (e.g., see end cap 154 of FIGS. 21-25). Accordingly, the electrode lead 105 of an inner battery cell 102 of a cell bank 110, 150 may be located closer to the end cap aperture 107, 158 than an outer battery cell 102 of the cell bank 110, 150. In other implementations, the apertures 107, 138, 148, 158 of the end caps 104, 134, 144, 154 may be offset from the center longitudinal axis. For example, the apertures 138, 148 (and hence protrusions 136, 146) of the end caps 134, 144 of FIGS. 11-20 are offset away from center. Offsetting the apertures 138, 148 and protrusions 136, 146 provides space to accommodate the terminals 106, 126, 128.

[0059] In certain implementations, a first end cap 104, 134, 144, 154 is disposed at first axial ends of the battery cells 102 and a second end cap 104, 134, 144, 154 is disposed at second axial ends of the battery cells 102. The first and second end caps 104, 134, 144, 154 cooperate to provide structural stability to the stacked battery cells 102 of the cell bank 110, 120, 130, 140, 150. In certain examples, each cell bank 110, 120, 130, 140, 150 is elongated along a length L (e.g., see FIG. 1) between the first and second axial ends. In certain such implementations, two or more battery cells 102 can be stacked together and mechanically connected together at their axial ends using the end caps 104, 134, 144, 154.

[0060] In certain implementations, each end cap is configured to facilitate alignment and/or attachment between adjacent end caps 104, 134, 144, 154 to hold together the cell banks 110, 120, 130, 140, 150 of a battery module 100. In some implementations, each end cap 134, 144, 154 includes alignment pegs andholes. In some examples, pegs 137, 147, 157 are disposed at one side of an end cap 134, 144, 154 and holes 139, 149, 159 are disposed at the opposite side. The pegs of each end cap 134, 144, 154 are sized to fit into the holes of an adjacent end cap 134, 144, 154 (e.g., see FIGS. 11, 16, and 21). As shown in FIGS. 12, 17, and 22, the pegs and holes of a first end cap 134, 144, 154 ofa battery cell 130, 140, 150 are oppositely disposed to the pegs and holes of an oppositely facing second end cap 134, 144, 154. In certain implementations, the pegs 137, 147, 157 and holes 139, 149, 159 are sized and shaped to provide a friction-fit or press-fit when the pegs are inserted in the corresponding holes.

[0061] In certain implementations, each cell bank 110, 120, 130, 140, 150 includes a first terminal 106A, 126 and a second terminal 106B, 128 (e.g., see FIGS. 1 and 8). For example, in certain implementations, the first terminal 106A, 126 may terminate a positive electrode lead 105 of a battery cell 102 of the cell bank 110, 120, 130, 140, 150 and the second terminal 106B, 128 may terminate a negative electrode lead 105 of the battery cell 102. In certain such examples, when the cell banks 110, 120, 130, 140, 150 are electrically connected in series, the positive terminal of one cell bank 110, 120, 130, 140, 150 may be electrically connected to the negative terminal of another cell bank 110, 120, 130, 140, 150. In some implementations, the first and second terminals are disposed at a common side of the cell bank 110, 120, 130, 140, 150. In other implementations, the first and second terminals are disposed at different (e.g., opposite) ends of the cell bank 110, 120, 130, 140, 150. In certain implementations, the positive terminals 106A are formed at least partially of copper clad aluminum. In certain implementations, the negative terminals 106B are formed at least partially of copper.

[0062] In the examples shown in FIGS. 1 and 8, the battery cells 102 of a cell bank 110, 120 are electrically coupled together in parallel so that first electrode leads 105 of the battery cells 102 are coupled together at one of the first and second ends while second electrode leads 105 of the battery cells 102 are coupled together at the other of the first and second ends. In certain implementations, each cell bank 110, 120 has a first terminal 106, 126, 128 at the first axial end that is electrically connected to the first electrode leads 105. In certain implementations, each cell bank 110, 120 has a second terminal 106, 126, 128 at the second axial end that is electrically connected to the second electrode leads 105. In certain examples, the first terminal is a positive terminal 106A, 126 and the second terminal is a negative terminal 106B, 128.

[0063] Referring now to FIGS. 3 and 9, in certain implementations, multiple cell banks 110, 120 can be electrically connected together (e.g., in series) at a battery module 100. For example, FIG. 3 shows a first cell bank 110A electrically connected to a second cell bank HOB with additional cell banks 110 further electrically connected (e.g., in series). In certain examples, the terminal 106, 126, 128 at one end of one cell bank 110, 120 electrically connects to the terminal 106, 126, 128 at the same end of another cell bank 110, 120 (e.g., an adjacent cell bank 110, 120). In certain implementations, a terminal 106, 126, 128 of a first cell bank 110A electrically connects to a terminal 106, 126, 128 of a second cell bank HOB while another terminal 106, 126, 128 of the second cell bank HOB electrically connects to the terminal 106, 126, 128 of a third cell bank 110, 120 (e.g., see FIGS. 3 and 9). In some implementations, the terminals 106 are electrically connected together via an adapter 108 (e.g., a biasing element). In other implementations, the terminals 126, 128 directly contact each other to establish an electrical connection.

[0064] In certain implementations, the terminals 126, 128 are oriented so that the male terminal 126 slides into the female terminal 128. In some implementations, the terminals 126, 128 are oriented so that a sliding direction DI for connecting the terminals is along the same direction as a sliding direction D2 for connecting the end caps 104, 134, 144, 154 (e.g., see FIG. 22). Such an orientation facilitates assembly of the battery module 100. In other implementations, however, the terminals 126, 128 can be oriented to provide a different sliding connection direction DI of the terminals 126, 128 compared to the sliding direction D2 for the end caps 134, 144, 154 (e.g., see FIG. 12).

[0065] FIGS. 1-7 illustrate portions of a battery module 100 having battery cell terminals 106 coupled together via adapters 108. FIG. 5 illustrates one example implementation of an adapter 108. In FIG. 5, the adapter 108 is a biasing arrangement. The biasing arrangement 108 includes a first biasing element 108A (e.g., a spring contact) and a second biasing element 108B (e.g., a spring contact) facing in opposite directions. In certain examples, each biasing element 108A, 108B defines opposing electrical contact surfaces. In certain implementations, the area of the contact surfaces is selected to satisfy the current transfer requirements between the biasing elements 108A, 108B and the terminals 106. In certain implementations, the contact surfaces of the adapters 108 include silver plating over a copper base. In certain examples, the contact surfaces include a nickel undercoat between the copper and the silver.

[0066] In certain implementations, a first pocket 108C is formed by the first biasing element 108A and a second pocket 108D is formed by the second biasing element 108B. The first pocket 108C is configured to receive the terminal 106 of a first cell bank 110 and the second pocket 108C is configured to receive the terminal 106 of a second cell bank 110. A terminal engages the electrical contact surfaces of the respective biasing element 108A, 108B when received in the pocket 108C, 108D.

[0067] In certain implementations, the first pocket 108C receives a positive terminal 106A and the second pocket 108D receives a negative terminal 106B (e.g., see FIGS. 4 and 6) or vice versa. In certain implementations, the terminals 106 can be slid into the respective pockets 108C, 108D. In some examples, the terminals 106 are slid into the pockets 108C, 108D along a first direction extending vertically along FIG. 5. In other examples, the terminals 106 are slid into the pockets 108C, 108D along a second direction extending into the paper of FIG. 5. For example, the second direction may be orthogonal to the first direction. In other examples, the terminals 106 may be slid into the pockets 108C, 108D at an angle between the first and second directions.

[0068] FIGS. 8-25 illustrate alternative electrode terminals configured in the form of a male terminal 126 and a female terminal 128. In the example shown, the male terminal 126 forms the negative terminal and the female terminal 128 forms the positive terminal. However, the reverse is possible. In certain implementations, the male terminal 126 is sized to fit within the female terminal 128. Accordingly, the male terminal 126 of one cell bank 120, 130, 140, 150 mates (e.g., mechanically engages and electrically connects) to the female terminal 128 of another cell bank 120, 130, 140, 150 to electrically join together both cell banks 120, 130, 140, 150.

[0069] As shown in FIG. 10, in certain implementations, the male terminal 126 includes a plug body 126A from which two parallel terminal plates 126B (e.g., parallel plates 125 of FIGS. 11-25) extend. In such implementations, the electrode leads 105 of the respective cell bank 110, 120, 130, 140, 150 extend between the terminal plates 126B for connection therewith. For example, the electrode leads 105 can be press-fit, crimped, welded, or otherwise connected to the terminal plates 126B. Similarly, the female terminal 128 includes a receiver body 128A from which two parallel terminal plates 128B (e.g., parallel plates 125 of FIGS. 11- 25) extend. In such implementations, the electrode leads 105 of the respective cell bank 110, 120, 130, 140, 150 extend between the terminal plates 128B for connection therewith. In certain examples, the plug body 126A is sized and shaped to fit within the receiver body 128A.

[0070] Referring back to FIG. 3, in certain implementations, the battery module 100 includes a frame assembly at which the cell banks 110, 120, 130, 140, 150 can be removably mounted. In certain implementations, the frame assembly includes one or more side brackets 114 configured to hold the cell banks 110, 120, 130, 140, 150. In certain examples, the cell banks extend between the side brackets 114. In certain examples, the side brackets 114 each define one or more slots or cavities 116. In certain examples, the terminals 106, 126, 128 are disposed at the slots or cavities 116. In some implementations, one or more adapters 108 are disposed at the slots or cavities 116. When a cell bank 110, 120, 130, 140, 150 is mounted at the frame assembly, the terminals 106A, 106B extend into respective slots or cavities 116 to engage the adapters 108. In certain implementations, each slot or cavity 116 is sized to hold an adapter 108, the terminal 106 at one end of one cell bank 110, 120, 130, 140, 150, and the terminal 106 at the same end of another cell bank 110, 120, 130, 140, 150.

[0071] In some implementations, both terminals 106, 126, 128 of a cell bank 110, 120, 130, 140, 150 are disposed at a common side of the cell bank 110, 120, 130, 140, 150. In some such implementations, two adapters 108 can be mounted in each slot or cavity 116 — a first adapter 108 to receive the first terminal 106 and a second adapter 108 to receive the second terminal 106. In certain examples, the first and second terminals 106 are spaced along a depth of the frame assembly. The first adapter 108 is configured to mate the first terminal 106 to a terminal of another cell bank. The second adapter 108 is configured to mate the second terminal 106 to a terminal of yet another cell bank. In other such implementations, each terminal 126, 128 is configured to mate with a respective terminal 128, 126 of a respective cell bank.

[0072] In other implementations, the terminals 106, 126, 128 of a cell bank 110, 120, 130, 140, 150 are disposed at opposite sides. In some such implementations, each slot or cavity holds one adapter 108. In certain implementations, first terminals 106A, 126 of a cell bank 110, 120, 130, 140, 150 are offset from the second terminals 106B, 128 of the cell bank 110, 120, 130, 140, 150 along a height H of the cell bank 110, 120, 130, 140, 150 (e.g., see FIG. 1). The offset allows the second terminal 106B, 128 of a first cell bank 110, 120, 130, 140, 150 to electrically contact the first terminal 106A, 126 of a second cell bank 110, 120, 130, 140, 150, either directly (e.g., see FIG. 10) or via the adapter 108 (e.g., see FIG. 4). For example, in FIG. 4, the offset allows the second terminal 106B of a first cell bank to extend into the second pocket 108B of an adapter 108 while the first terminal 106A of a second cell bank extends into the first pocket 108A. In certain examples, the slots or cavities 116 at the first side bracket 114 are offset from the slots or cavities 116 at the second side bracket 114 (e.g., see FIG. 3) to accommodate the offset of the terminals 106, 126, 128.

[0073] In certain implementations, the frame assembly also includes cooling plates 118 or other cooling structures disposed between the cell banks 110, 120, 130, 140, 150. In certain implementations, the frame assembly includes compression plates 115 that apply a compressing force B on the battery cells 102 of the cell banks 110, 120, 130, 140, 150. For example, when the battery cells 102 include pouch cells, the compression plates 115 apply a compressing force B to inhibit swelling of the pouch cells 102. In certain examples, the compressing force B is applied using one or more biasing springs.

[0074] In certain implementations, the frame assembly includes intermediate electrical circuitry that connects to the first terminal 106, 126, 128 of the first cell bank 110, 120, 130, 140, 150 in the series and the second terminal 106, 126, 128 of the last cell bank 110, 120, 130, 140, 150 in the series. The intermediate electrical circuitry extends to one or more ports or electrical connectors at the frame assembly. An external cable may connect to the port to electrically connect the battery module to equipment to be powered. Alternatively, a cable extending frame the frame assembly may terminate at an electrical connector for plugging into a port of equipment to be powered. In certain implementations, the intermediate electrical circuitry includes one or more sensors to monitor a state of the battery cells 110, 120, 130, 140, 150 during operation. For example, the intermediate electrical circuitry may include one or more temperature sensors for the battery cells and/or one or more voltage sensors. The sensors may alert a user when a battery cell 110, 120, 130, 140, 150 begins to overheat or otherwise fault so that the user may replace the battery cell 110, 120, 130, 140, 150.

[0075] Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.

Claims

What is claimed is:

1. A cell bank extending along a center axis between opposite first and second ends, the cell bank comprising: a plurality of pouch cells extending parallel to the center axis, each pouch cell having a respective first tab at a first end of the pouch cell and a respective second tab at an opposite, second end of the pouch cell; a first end cap disposed at the first end of the cell bank, the first end cap defining a passage therethrough, wherein the first tab of each pouch cell of the plurality of pouch cells extends through the passage of the first end cap; and a first connector arrangement coupled to the first end cap to move with the first end cap, the first connector arrangement including a first terminal electrically terminating the first tab of each pouch cell of the plurality of pouch cells.

2. The cell bank of claim 1, wherein the passage of the first end cap is defined through an axial extension of the first end cap.

3. The cell bank of claim 1, wherein the passage of the first end cap is offset from the center axis of the cell bank.

4. The cell bank of claim 1, wherein the first connector arrangement extends into the passage of the first end cap.

5. The cell bank of claim 1, wherein the first connector arrangement includes parallel plates between which the respective first tabs extend.

6. The cell bank of claim 5, wherein the parallel plates are planar between the passage and the first terminal.

7. The cell bank of claim 5, wherein the parallel plates are bent between the passage and the first terminal.

8. The cell bank of claim 1, further comprising: a second end cap disposed at the second end of the cell bank, the second end cap defining a passage therethrough, wherein the second tab of each pouch cell of the plurality of pouch cells extends through the passage of the second end cap; and a second connector arrangement coupled to the second end cap to move with the second end cap, the second connector arrangement including a second terminal electrically terminating the second tab of each pouch cell of the plurality of pouch cells.

9. The cell bank of claim 8, wherein the second connector arrangement extends into the passage of the second end cap.

10. The cell bank of claim 8, wherein the first connector arrangement is female and the second connector arrangement is male.

11. The cell bank of claim 8, wherein each of the first and second end caps has a U-shaped profile.

12. A battery module comprising: a first cell bank including a plurality of first cell pouches extending between oppositely facing first and second end caps, the first cell pouches being coupled together in parallel, the first cell bank including a female connector arrangement terminating the first cell pouches extending outwardly from the first end cap and a male connector arrangement terminating the first cell pouches extending outwardly from the second end cap; and a second cell bank including a plurality of second cell pouches extending between oppositely facing first and second end caps, the second cell pouches being coupled together in parallel, the second cell bank including a male connector arrangement terminating the second cell pouches extending outwardly from the first end cap and a female connector arrangement terminating the second cell pouches extending outwardly from the second end cap; the first and second end caps being configured to interface with each other.

13. The battery module of claim 12, wherein the first and second end caps snap-fit together.

14. The batery module of claim 12, wherein the first and second end caps each include a plurality of bosses and a plurality of slots sized to fit the bosses.

15. The batery module of claim 12, wherein the first and second cell banks are electrically coupled together in series.

16. A method of assembling a batery module comprising: for a plurality of cell banks, connectorizing an electrode lead of the cell bank with a respective terminal including: sliding the electrode lead through an aperture defined in an end cap of the cell bank so that a portion of the electrode lead is disposed external of the end cap; and attaching the terminal to the external portion of the electrode lead; and electrically connecting the terminals of the cell banks using a reversible mechanical connection.

17. The method of claim 16, wherein connectorizing the electrode lead comprises: clipping the terminal to a portion of the electrode lead; and sliding the terminal and the electrode lead through the aperture defined in the end cap of the cell bank.

18. The method of claim 16, further comprising securing the terminals to the respective end cap.

19. The method of claim 16, wherein electrically connecting the terminals of the cell banks comprises moving pairs of the terminals into direct engagement.

20. The method of claim 16, further comprising connecting the end caps of adjacent ones of the cell banks together through pegs and holes.