CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from and the benefit of U.S. Provisional Application Serial No. 62/529,659, entitled "MODULAR HOUSING FOR BATTERY SYSTEMS", filed July 7, 2017, and which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND

[0002] The present disclosure relates generally to the field of batteries and battery modules. More specifically, the present disclosure relates batteries and in particular to a battery housing and method that allow multiple modular battery cells to be configured into and operate together as a unitary battery module without the need for a separate housing.

[0003] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0004] As technology continues to evolve, there is a need to provide improved power sources, particularly battery modules, for various applications including vehicles, stationary storage systems, and so forth. For example, battery assemblies typically include a plurality of battery cells within a battery housing. One type of battery assembly, for example, includes a plurality of prismatic battery cells, such as lithium ion (Li-ion) prismatic battery cells. To operate together as a battery assembly, the battery cells must be held together or configured into a functional unit. This is typically accomplished in one of two ways: first, the battery cells may be complete discrete units that are arranged within a battery housing; or second, the battery cells may be arranged within a mono-block battery housing that is designed for a fixed configuration in which the battery cells are manufactured as a combined unit.

[0005] However, both of these configurations require additional materials, components, and manufacturing steps because they require a battery housing to contain the battery cells. Additionally, the battery housing retains the battery cells in a fixed configuration that cannot be modified to suit a particular requirement, such as when the battery assembly is to be used in a constrained space or area with non- traditional shape (that is, an area that is not rectangular, box-shaped, or the like). Thus, a new housing must be designed and manufactured each time a new configuration is needed.

SUMMARY

[0006] A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0007] The present disclosure relates to a modular battery cell. The modular battery cell includes a housing, the housing having a first engagement element and a second engagement element. The first and second engagement elements are couplable with corresponding engagement elements of at least one other modular battery cell when the at least one other modular battery cell is positioned adjacent to the modular battery cell.

[0008] The present disclosure also relates to a battery assembly having a plurality of modular battery cells. Each modular battery cell of the plurality of modular battery cells includes a housing having a first engagement element and a second engagement element. The first engagement element of each of the plurality of modular battery cells is coupled to one of the first engagement element or the second engagement element of at least one adjacent modular battery cell. [0009] The present disclosure further relates to a battery assembly including a plurality of modular battery cells, and a coupling plate coupled to each of the plurality of modular battery cells. The coupling plate fixes the plurality of modular battery into a predetermined configuration.

DRAWINGS

[0010] Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

[0011] FIG. 1 is an overhead perspective view of an embodiment of a modular battery cell, the modular battery cell having a housing with engagement elements, in accordance with an aspect of the present disclosure;

[0012] FIG. 2 is an expanded overhead view of an example configuration of a plurality of the modular battery cells of FIG. 1, in accordance with an aspect of the present disclosure;

[0013] FIG. 3 is an overhead perspective view of another example configuration of a plurality of the modular battery cells of FIG. 1, in accordance with an aspect of the present disclosure;

[0014] FIG. 4 is an overhead perspective view of another example configuration of a plurality of the modular battery cells of FIG. 1, in accordance with an aspect of the present disclosure;

[0015] FIG. 5 is an expanded overhead view of a coupling mechanism between the modular battery cells of FIG. 4, in accordance with an aspect of the present disclosure;

[0016] FIGS. 6 and 7 are perspective views of another embodiment of a modular battery cell, the modular battery cell having a housing with engagement elements, in accordance with an aspect of the present disclosure; [0017] FIG. 8 is a close-up view of the engagement elements of the modular battery cells of FIGS. 6 and 7, in accordance with an aspect of the present disclosure;

[0018] FIG. 9 is an overhead view of an example configuration of the modular battery cells of FIGS. 6 and 7, in accordance with an aspect of the present disclosure;

[0019] FIG. 10 is an overhead view of another example configuration of the modular battery cells of FIGS. 6 and 7, in accordance with an aspect of the present disclosure;

[0020] FIGS. 11 and 12 are perspective views of a battery module including modular battery cells and a connecting plate, in accordance with an aspect of the present disclosure;

[0021] FIG. 13 is a side elevation view of an embodiment of a connecting plate and corresponding modular battery cells, in accordance with an aspect of the present disclosure; and

[0022] FIG. 14 is a side elevation view of another embodiment of a connecting plate and corresponding modular battery cells, in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

[0023] One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business- related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. [0024] Referring now to FIGS. 1-5 a first battery assembly 10 is shown. In particular, the battery assembly 10 includes a plurality of modular battery cells 12A, 12B, 12C . . . 12N (where "N" is any number of modular battery cells, all of which are collectively referred to herein using the reference numeral 12) that are configured to be coupled to each other such that they are operable together as a single battery module. In accordance with certain embodiments, the battery cells are lithium ion battery cells. However, other battery cell chemistries are also contemplated.

[0025] FIG. 1 shows a first embodiment of a modular battery cell 12A that includes a first embodiment of engagement elements 14 that are configured to couple with corresponding engagement elements 14 of one or more other modular battery cells 12, e.g., modular battery cell 12B, when the other modular battery cells 12B is positioned adjacent to the modular battery cell 12 A. It should be noted that a "modular battery cell," as disused herein, is distinct from a "battery module." For example, a modular individual battery cell as described herein is configured to be used in combination with other individual battery cells in a modular fashion to produce a battery module. For clarity, such configurations are referred to herein as "battery assemblies," which denotes a similar configuration to a "battery module," and which includes multiple modular battery cells.

[0026] Each modular battery cell 12 includes a housing 16 (which may also be referred to as a casing), at least a portion of which includes (e.g., forms) the engagement elements 14. The modular battery cell 12 includes an electrode assembly (not shown) within the housing 16, which includes at least an anode, a cathode, and a separator. In one embodiment, the housing 16 includes a first edge portion 18 at a first end of the housing 16, a second edge portion 20 at a second end of the housing 16 opposite the first edge portion 18, a third edge portion 22 at a top surface of the housing 16 between the first 18 and second 20 edge portions, and a fourth edge portion 24 at a bottom surface (e.g., a base) of the housing 16 between the first 18 and second 20 edge portions and opposite the third edge portion 22.

[0027] The housing 16 further includes a first face 26 and a second face 28 opposite the first face 26, each of the first 26 and second 28 faces being bordered by the first 18, second 20, third 22, and fourth 24 edge portions. The housing 16 has a width W defined by a width of either the first face 26 or the second face 28, a height H defined by a height of the either of the first edge portion 18 or the second edge portion 20 (or by a height of either the first face 26 or the second face 28), and a thickness T defined by a thickness of the first 18, second 20, third 22, or fourth 24 edge portion.

[0028] Each of the first 18 and second 20 edge portions, and at last least a portion of each of the first 26 and second 28 faces, of the housing 16 include (e.g., define) the engagement elements 14. In one embodiment, the housing 16 includes a first engagement element 14A and a second engagement element 14B. In one embodiment, each engagement element 14 generally includes a protruding portion 30 and a receiving portion 32. Further, each of the first edge portion 18 and the second edge portion 20 of the housing 16 includes at least a portion of an engagement element 14 (e.g., a corresponding pair of the protruding portion 30 and the receiving portion 32) that extends along the height of the first edge portion 18 and second edge portion 20, respectively. In one embodiment, the first engagement element 14A includes: a first protruding portion 3 OA extending along the height (e.g., such as the entirety of the height or only a portion) of the first edge portion 18 (from the third edge portion 22 to the fourth edge portion 24) in a direction that is crosswise (e.g., orthogonal) to the plane in which the first face 26 lies; a first receiving portion 32A on the second face 28 proximate the first edge portion 18 and extending along an entirety of the height of the first edge portion 18 (from the third edge portion 22 to the fourth edge portion 24); and a second protruding portion 30B extending along the height (e.g., such as the entirety of the height or only a portion) of the first edge portion 18 (from the third edge portion 22 to the fourth edge portion 24) in a direction that is crosswise (e.g., orthogonal) to the plane in which the second face 28 lies, and immediately adjacent to the first receiving portion 32A.

[0029] The first protruding portion 30A is linear, or at least substantially linear, and extends from the first edge portion 18 along a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the first face 26 lies. Put another way, the first protruding portion 30A extends from the surface of the first face 26 in a direction that is crosswise to the plane in which the first face 26 lies, or in a direction parallel to, or at least substantially parallel to, the plane, or within the plane, in which the first edge portion 18 lies. The first protruding portion 30A thus extends beyond the first face 26 by a first distance. At least a portion of the first protruding portion 30A and the first edge portion 18 together define a continuous surface. The first protruding portion 3 OA also has an outer width, which is measured from the surface of the first edge portion 18. In some embodiments, the first protruding portion 30A may have a varying width (that is, be tapered). The widths of the first protruding portion 30A may be gradually changing, e.g., tapered, or the first protruding portion 30A may include one or more steps or abrupt width changes.

[0030] In one embodiment shown in FIGS. 1-5, the first receiving portion 32A is linear, or at least substantially linear, and is a recess within the second face 28 of the housing 16, and the first receiving portion 32A has a depth (a second distance) measured from the second face 28. The first receiving portion 32A has an inner width that is configured to snugly or securely receive the first protruding portion 3 OA of an adjacent housing 16. That is, the inner width of the first receiving portion 32A is only slightly greater than the outer width of the first protruding portion 30A. In this way, adjacent housings 16 may be at least partially secured together by a friction fit between the protruding portion 30 of one housing 16 and the receiving portion 32 of an adjacent housing 16. In some embodiments, the first receiving portion 32A may have a varying width (that is, be tapered) from the depth to the surface of the second face 28. The widths of the first receiving portion 32 A may be gradually changing, as in a taper, or the first receiving portion 32A may include one or more steps or abrupt width changes. The varying widths of the first receiving portion 32A correspond to the varying widths of the first protruding portion 30A, such that the first receiving portion 32A is configured to snugly or securely receive the first protruding portion 30A.

[0031] The second protruding portion 30B is linear, or at least substantially linear, and extends from the first edge portion 18 along a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the second face 28 lies. Put another way, the second protruding portion 30B extends from the surface of the second face 28 in a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the second face 28 lies, or in a direction parallel to, or at least substantially parallel to, the plane, or within the plane, in which the first edge portion 18 lies. The second protruding portion 30B extends in a direction opposite the direction in which the first protruding portion 30B extends. The second protruding portion 30B thus extends beyond the second face 28 by a third distance. As the second protruding portion 30B is immediately adjacent to the first receiving portion 32A, the second protruding portion 30B extends from the depth of the first receiving portion 32A by a fourth distance. The fourth distance is greater than both the depth of the first receiving portion 32A and the third distance. Optionally, the first distance of the first protruding portion 30A and the depth of the first receiving portion 32A may be chosen such that the first distance is greater than the depth, thereby allowing for a gap or space 34 between adjacent housings 16 (for example, between the first face 26 of a first housing 16 and a second face 28 of an adjacent second housing 16, as shown in FIG. 2). The width of the gap 34 is the difference between the first distance of the first protruding portion 3 OA and the depth of the first receiving portion 32A. This gap 34 allows for heat dissipation from the housings 16. Further, the size of the gaps 34 may be chosen to facilitate active or passive cooling, electrical isolation between housings 16, and/or thermal isolation between housings 16.

[0032] In the embodiment shown in FIGS. 1-5, the second engagement element 14B includes: a third protruding portion 30C extending along the height (e.g., along only a portion or along the entirety of the height) of the second edge portion 20 (from the third edge portion 22 to the fourth edge portion 24) in a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the first face 26 lies; a second receiving portion 32B on the second face 28 proximate the second edge portion 20 and extending along the height of the second edge portion 20 (from the third edge portion 22 to the fourth edge portion 24); and a fourth protruding portion 30D extending along the height (e.g., extending along only a portion of the height or along an entirety of the height) of the second edge portion 20 (from the third edge portion 22 to the fourth edge portion 24) in a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the second face 28 lies, and immediately adjacent to the second receiving portion 32B.

[0033] The third protruding portion 30C is linear, or at least substantially linear, and extends from the second edge portion 20 along a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the first face 26 lies. Put another way, the third protruding portion 30C extends from the surface of the first face 26 in a direction that is crosswise to the plane in which the first face 26 lies, or in a direction parallel to, or at least substantially parallel to, the plane, or within the plane, in which the second edge portion 20 lies. The third protruding portion 30C thus extends beyond the first face 26 by the first distance, for example by the same distance as the distance by which the first protruding portion 30A extends beyond the first face 26. At least a portion of the third protruding portion 30C and the second edge portion 20 may together define a continuous surface. The third protruding portion 30C also has an outer width, which is measured from the surface of the second edge portion 20. In some embodiments, the third protruding portion 30C may have a varying width, e.g., tapered. The widths of the third protruding portion 30C may be gradually changing, as in a taper, or the third protruding portion 30C may include one or more steps or abrupt width changes.

[0034] The second receiving portion 32B is linear, or at least substantially linear, and is a recess within the second face 28 of the housing 16, and the second receiving portion 32B has the same depth (the second distance) as the first receiving portion 32B, measured from the second face 28. The second receiving portion 32B has an inner width that is configured to snugly or securely receive the third protruding portion 30C of an adjacent housing 16. That is, the inner width of the second receiving portion 32B is only slightly greater than the outer width of the third protruding portion 30C. In this way, adjacent housings 16 may be at least partially secured together by a friction fit between the protruding portion 30 of one housing 16 and the receiving portion 32 of an adjacent housing 16. In some embodiments, the second receiving portion 32B may have a varying width (that is, be tapered) from the depth to the surface of the second face 28. The widths of the second receiving portion 32B may be gradually changing, as in a taper, or the second receiving portion 32B may include one or more steps or abrupt width changes. The varying widths of the second receiving portion 32B correspond to the varying widths of the third protruding portion 30C, such that the second receiving portion 32B is configured to snugly or securely receive the third protruding portion 30C.

[0035] The fourth protruding portion 30D is linear, or at least substantially linear, and extends from the second edge portion 20 along a direction that is orthogonal to, or at least substantially orthogonal to, the plane in which the second face 28 lies. Put another way, the fourth protruding portion 30D extends from the surface of the second face 28 in a direction that is orthogonal to, or at least substantially orthogonal to, the plane in which the second face 28 lies, or in a direction parallel to, or at least substantially parallel to, the plane, or within the plane, in which the first edge portion 18 lies. The fourth protruding portion 30D extends in a direction opposite the direction in which the third protruding portion 30C extends. The fourth protruding portion 30D thus extends beyond the second face 28 by the third distance, for example by the same distance than the distance by which the second protruding portion 30B extends beyond the second face 28. As the fourth protruding portion 30D is immediately adjacent to the second receiving portion 32B, the fourth protruding portion 30D extends from the depth of the second receiving portion 32B by the fourth distance. The fourth distance is greater than both the depth of the second receiving portion 32B and the third distance. Optionally, the first distance of the third protruding portion 30C and the depth of the second receiving portion 32B may be chosen such that the first distance is greater than the depth, thereby allowing for a gap or space 34 between adjacent housings 16. The width of the gap 34 is the difference between the first distance of the third protruding portion 30C and the depth of the second receiving portion 32B. This gap 34 allows for heat dissipation from the housings 16. Further, the size of the gaps 34 may be chosen to facilitate active or passive cooling, electrical isolation between housings 16, and/or thermal isolation between housings 16.

[0036] Thus, in one embodiment, receiving portions 30A and 30B form grooves that couple with the corresponding tabs formed by protruding portions 30A and 30C. Although the engagement elements 14 of the housing 16 are discussed above as having the same size, configuration, and measurements, it will be understood that the engagement element 14 at the first edge portion 18 may have a different size, configuration, and/or measurements than the engagement element at the second edge portion 20. Also, the sizes, configurations, and measurements of the engagement elements 14 discussed herein are not intended to be limiting, but instead are examples of engagement elements 14 that may be used.

[0037] Referring now to FIGS. 3 and 4, a plurality of the modular battery cells 12 may be arranged in a variety of configurations using the first embodiment of the engagement elements 14 to produce different versions of the battery assembly 10. In the embodiment of FIG. 3, a plurality of the modular battery cells 12 (battery cells 12A-12N) may be in a linear arrangement, with the first face 26 of the first housing 16A being in contact with or separated by a gap 34 from the second face 28 of an adjacent second housing 16B. In certain embodiments, the housings 16 may be coupled to each other by welding, laser welding, adhesives, chemical or thermal bonding, or the like. Thus, the first edge portions 18 of the housings 16 form a first side of the battery assembly 10 and the second edge portions 20 of the housings 16 form a second side of the battery assembly 10. Likewise, the third edge portions 22 of the housings 16 form a third side of the battery assembly 10, the fourth edge portions 24 of the housings 16 for a fourth side of the battery assembly 10, the first face 26 of a first housing 16A in the linear arrangement forms the first end of the battery assembly 10, and the second face 28 of a last housing 16N in the linear arrangement forms the second end of the battery assembly 10. However, it will be understood that more or fewer than the number of modular battery cells 12 shown in FIG. 3 may be used. Further, battery module arrangements other than those shown may be used.

[0038] In the illustrated embodiment of FIG. 4, a plurality of the modular battery cells 12 are in a linear arrangement in which the second edge portion(s) 20 of one or more housings 16 are in contact with the first edge portion(s) 18 of one or more adjacent housings 16. As shown in FIG. 4, the second edge portion 20 of each of the first housing 16A and the second housing 16B are in contact with the first edge portion 18 of each of the third housing 16C and the fourth housing 16D. The second edge portion 20 of each of the third 16C and fourth 16D housings are in contact with the first edge portion 18 of each of a fifth housing 16E and a sixth housing 16F. The housings 16 may be coupled to each other by welding, laser welding, adhesives, chemical or thermal bonding, or the like. In one embodiment, two housings 16 are coupled to each other such that the first face 26 of a first housing is in contact with or separated by the gap 34 from the second face 28 of an adjacent second housing.

[0039] The coupling or attachment of housings 16 for the embodiment of FIG. 4 is shown in more detail in FIG. 5. The first 16A and second 16B housings are coupled to another set of two housings 16C, 16D such that the second edge portions 20 of the first set of housings 16A, 16B are in contact with the first edge portions 18 of the second set of housings 16C, 16D. Thus, the first edge portions 18 of two of the housings 16A, 16B form a first end of the battery assembly 10 and the second edge portions 20 of the fifth 16E and sixth 16F housings form a second end of the battery assembly 10. Likewise, the third edge portions 22 of all of the housings 16A-16D form a third side of the battery assembly 10, the fourth edge portions 24 of all of the housings 16A-16D form a fourth side of the battery assembly 10, the first face 26 of the first housing 16A, the second face 28 of the third housing 16C, and the first face 26 of the fifth housing 16E in the linear arrangement form the first side of the battery assembly 10, and the second face 28 of the second housing 16B, the first face 16 of the fourth housing 16D, and the second face 28 of the sixth housing 16F in the linear arrangement forms the second side of the battery assembly 10. However, it will be understood that more or fewer than the number of modular battery cells 10 shown in FIG. 4 may be used. Further, battery module arrangements other than those shown may be used.

[0040] Referring now to FIGS. 6-10, another embodiment of the battery assembly 10 is shown. In particular, the battery assembly 10 includes a plurality of the modular battery cells 12 that are configured to be coupled to each other such that they are operable together as a single battery module. FIGS. 6 and 7 depict another embodiment of the modular battery cell 12 that includes another embodiment of the engagement elements 14 that are configured to engage with engagement elements 14 of one or more adjacent battery cells 12. The modular battery cells 12 of FIGS. 6-10 are substantially similar to the modular battery cells of FIGS. 1-5, except for the configuration of the engagement elements 14.

[0041] Referring now to FIGS. 6-10, each of the first 18 and second 20 edge portions of the housing 16 define or include the engagement elements 14 (e.g., the first engagement element 14A and the second engagement element 14B). In the illustrated embodiment of FIGS. 6-10, each engagement element 14 includes a locking portion 36 and a receiving portion 38. Further, each of the first edge portion 18 and the second edge portion 20 of the housing 16 includes at least a portion of a corresponding engagement element 14 (a set or pair of the locking portion 36 and the receiving portion 38) that extends (fully or partially) along the height of the first edge portion 18 and second edge portion 20, respectively. By way of example, the illustrated first engagement element 14A includes: a first locking portion 36A extending from the first edge portion 18 along an entirety of the height of the first edge portion 18 (from the third edge portion 22 to the fourth edge portion 24) proximate the second face 28; and a first receiving portion 38A on the first edge portion 18 proximate the first face 26 and extending along an entirety of the height of the first edge portion 18 (from the third edge portion 22 to the fourth edge portion 24).

[0042] The first locking portion 36A is linear, or at least substantially linear, and extends from the first edge portion 18 along a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the second face 28 lies. The first locking portion 36A thus extends beyond the second face 28 by a fifth distance. The first locking portion 36A also includes a lip or other protrusion 40 that extends from the first locking portion 36A in a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the first locking portion 36A lies. Put another way, the lip 40 extends toward the second edge portion 20 of the housing 16. The lip 40 may extend along the entirety of the height of the first locking portion 36A (or the height of the first edge portion 18), or it may include one or more discrete protrusions along the height of the first locking portion 36A (or the height of the first edge portion 18). [0043] In one embodiment, the first receiving portion 38A is linear, or at least substantially linear, and defines a recess or groove within at least a portion of the first edge portion 18 of the housing 16. In another embodiment, the engagement element 14 further includes a first spacing portion 42 A, and the first receiving portion 38 A defines a recess or groove within the first spacing portion 42A and does not extend into the first edge portion 18 of the housing 16. The first receiving portion 38A has a depth (a sixth distance), measured from an outer surface of either the first edge portion 18 or the first spacing portion 42 A. The first receiving portion 38A has an inner width that is configured to snugly or securely receive the first locking portion 36A of an adjacent housing 16. Due to the configuration of the locking portion 36 and receiving portion 38, adjacent housings 16 may be at least partially secured together by a friction fit between the protruding portion 30 of one housing 16 and the receiving portion 32 of an adjacent housing 16. Put another way, the housings 16 may be snapped together or slidingly coupled together, as shown in FIG. 8.

[0044] In one embodiment, the second engagement element 14B includes: a second locking portion 36B extending, fully or partially, from the second edge portion 20 along the height of the second edge portion 20 (from the third edge portion 22 to the fourth edge portion 24) proximate the first face 26; and a second receiving portion 38B on the second edge portion 20 proximate the second face 28 and extending, fully or partially, along the height of the second edge portion 20 (from the third edge portion 22 to the fourth edge portion 24).

[0045] The second locking portion 36B is linear, or at least substantially linear, and extends from the second edge portion 20 along a direction that is crosswise to (e.g., orthogonal to, or at least substantially orthogonal to) the plane in which the first face 26 lies. The second locking portion 36B thus extends beyond the first face 26 by the fifth distance, which in some embodiments may be the same distance as the distance by which the first locking portion 36A extends beyond the second face 28. The second locking portion 36B also includes a lip or other protrusion 40 that extends from the second locking portion 36B in a direction that is orthogonal to, or at least substantially orthogonal to, the plane in which the second locking portion 36B lies. Put another way, the lip 40 extends toward the first edge portion 18 of the housing 16. The lip 40 may extend along the entirety of the height of the second locking portion 36B (or the height of the second edge portion 20), or it may include one or more discrete protrusions along the height of the second locking portion 36B (or the height of the second edge portion 20).

[0046] The second receiving portion 38B may be linear, or at least substantially linear, and defines a recess or groove within at least a portion of the second edge portion 20 of the housing 16. In another embodiment, the engagement element 14 further includes a second spacing portion 42B, and the second receiving portion 38B defines a recess or groove within the second spacing portion 42B and does not extend into the second edge portion 20 of the housing 16. The second receiving portion 38B has a depth (the sixth distance) measured from an outer surface of either the second edge portion 20 or the second spacing portion 42B, for example the same depth as that of the first receiving portion 38A. The second receiving portion 38B has an inner width that is configured to snugly or securely receive the second locking portion 36B of an adjacent housing 16. Due to the configuration of the locking portion 36 and receiving portion 38, adjacent housings 16 may be at least partially secured together by a friction fit between the protruding portion 30 of one housing 16 and the receiving portion 32 of an adjacent housing 16. Put another way, the housings 16 may be snapped together, as shown in FIG. 8. When the housings 16 are snapped together, the engagement elements 14 may be arranged such that the gap or space 34 is defined between the first 26 and/or second 28 surfaces of adjacent housings 16, as discussed above regarding FIGS. 1-5.

[0047] Referring now to FIGS. 9 and 10, example configurations of a plurality of the modular battery cells 12 arranged as another embodiment of the battery assembly 10 are shown. The holes shown on the third edge portion 22 of each housing 16 correspond to locations of the positive terminal 44 (which is proximate the first edge portion 18) and the negative terminal 46 (which is proximate the second edge portion 20). In the illustrated embodiment of the battery assembly 10 shown in FIG. 9, the housings 16 of two modular battery cells 12 are coupled together such that the first face 26 of the first housing 16A is in contact with or separated by the gap 34 from the second face 28 of the adjacent second housing 16B. In this configuration, the positive terminals 44 are on the same side of the battery assembly 10 and the negative terminals 46 are on the same side of the battery assembly 10. Such an arrangement facilitates production of a parallel electrical connection. Further, the first edge portions 18 of the housings 16 define a first end of the battery assembly 10, the second edge portions 20 of the housings 16 define a second end of the battery assembly 10, the second face 28 of the first housing 16A defines a first side of the battery assembly 10, and the first face 26 of the second housing 16B defines a second side of the battery assembly 10.

[0048] In the illustrated embodiment of the battery assembly 10 shown in FIG. 10, the housings 16 of two modular battery cells 12 are coupled together such that the first face 26 of the first housing 16A is in contact with or separated by the gap 34 from the first face 26 of the adjacent second housing 16B. The first edge portion 18 of the first housing 16A and the second edge portion 20 of the second housing 16B define a first end of the battery assembly 10, the second edge portion 20 of the first housing 16A and the first edge portion 18 of the second housing 16B define a second end of the battery assembly 10. Further, the second face 28 of the first housing 16A defines a first side of the battery assembly 10 and the second face 28 of the second housing 16B defines a second side of the battery assembly 10. In this configuration, the negative terminal 46 of the first housing 16A is on the same side of the battery assembly 10 as the positive terminal 44 of the second housing 16B. Such an arrangement facilitates production of a serial electrical connection. Likewise, the positive terminal 44 of the first housing 16A is on the same side of the battery assembly 10 as the negative terminal 46 of the second housing 16B. However, it will be understood that more modular battery cells 12 than those shown may be used. Further, although the engagement elements 14 of the housing 16 are discussed above as having the same size, configuration, and measurements, it will be understood that the engagement element 14 at the first edge portion 18 may have a different size, configuration, and/or measurements than the engagement element at the second edge portion 20. Also, the sizes, configurations, and measurements of the engagement elements 14 discussed herein are not intended to be limiting, but instead are examples of engagement elements 14 that may be used. [0049] Referring now to FIGS. 11-14, a third battery assembly 10 is shown. In particular, the battery assembly 10 includes a plurality of the modular battery cells 12 that are configured to be coupled to each other by one or more coupling plates 48 such that the modular battery cells 12 are operable together as a single battery module. A plurality of modular battery cells 12 are locked or fixed in a particular battery module configuration by the coupling plate(s) 48 attached to the plurality of modular battery cells 12.

[0050] Each modular battery cell 12 includes a corresponding embodiment of the housing 16, at least a portion of which forms the engagement elements 14. The modular battery cells 12 of FIGS. 11-14 are substantially similar to the modular battery cells of FIGS. 1-5, except for the configuration of the engagement elements 14.

[0051] Each of the first 18 and second 20 edge portions of the housing 16 include the engagement elements 14. In one embodiment, the housing 16 includes an embodiment of the first engagement element 14A and an embodiment of the second engagement element 14B. In general, the first 18 and/or the second 20 edge portion of each housing 16 in the battery assembly 10 includes one or more engagement elements 14 that are configured to interact with one or more engagement elements 50 of the one or more coupling plates 48. The coupling plate(s) 48 perform substantially the same function as a battery module housing of currently known battery assemblies, but require less space, fewer materials, and less manufacturing complexity.

[0052] In the illustrated embodiment of FIG. 12, the coupling plate 48 is attached to the first 18 and/or second 20 edge portion of each housing 16. The plurality of modular battery cells 12 are arranged in a linear configuration, such that the first end portion 18 of one housing 16 is adjacent to the second end portion 20 of the adjacent housing 16. Thus, both a first end and a second end of the battery assembly 10 are made up of first 18 and second 20 edge portions. The coupling plate 48 may be affixed to the first end and/or the second end of the battery assembly 10, such as by welding, laser welding, adhesives, chemical or thermal bonding, or the like. In certain embodiments, the housings 16 are spaced from each other such that a gap or space 34 is created between adjacent housings 16, and coupling plate(s) 48 lock the housings 16 in a fixed configuration, thereby preserving these gaps 34.

[0053] The manner in which the coupling plate 48 couples to the engagement elements 14 of the modular battery cells 12 may be further appreciated with reference to FIG. 13, which is a schematic side elevation view of the modular battery cells 12 and the coupling plate 48. In FIG. 13, each engagement element 14 generally includes a receiving portion 52 (e.g., a recess in the casing of the modular battery cell 12). In particular, the first edge portion 18 and/or the second edge portion 20 of the housing 16 includes one or more receiving portions 52 each having a depth. As the electrode assembly coils of the modular battery cell 12 are located within the housing 16 at each end (that is, proximate each of the first edge portion 18 and the second edge portion 20), the first edge portion 18 and/or the second edge portion 20 optionally may have an increased thickness to accommodate the receiving portions 52 without interference with the electrode assembly coils. In one embodiment, each of the first 18 and second 20 edge portions of the housing 16 include one or more discrete receiving portions 52 along the height of the first 18 and second 20 edge portions, respectively.

[0054] As is shown in greater detail in FIG. 13, each coupling plate 48 includes one or more protruding portions 54 that are sized and configured to be received within the one or more receiving portions 52 on the housing 16. Each protruding portion 54 has as length that is at most the same as, and may be less than, the depth of the corresponding receiving portion 52. Further, each receiving portion 52 has an inner width that is configured to snugly or securely receive the corresponding protruding portion 54. Due to the configuration of the receiving portion 52 and the protruding portion 54, adjacent housings 16 may be at least partially secured together by a friction fit between the protruding portion(s) 54 of the coupling plate(s) 48 and the receiving portion(s) 54 of the housings 16. Put another way, the coupling plate(s) 48 may be snapped to the housings 16. The receiving portions 52 and corresponding protruding portions 54 may be spaced such that the gap 34 is created and maintained between adjacent housings 16 by the attachment of the coupling plate(s) 48 to the housings 16. Further, in one embodiment, the coupling plate(s) 48 are removably coupled to the housings 16 for quick and easy modification of the dimensions of the battery assembly 10 and/or to replace faulty modular battery cells 12.

[0055] Other arrangements between the coupling plate 48 and the engagement elements 14 are possible. For example, in the illustrated embodiment of FIG. 14, each engagement element 14 generally includes a protruding portion 56. In particular, the first edge portion 18 and/or the second edge portion 20 of the housing 16 includes one or more protruding portions 56.

[0056] As is shown in greater detail in FIG. 14, each coupling plate 48 includes one or more receiving portions 58 that are sized and configured to receive a corresponding protruding portion 56 on the housing 16. Each receiving portion 58 has a depth that is at least the same as, and may be more than, the length of the corresponding protruding portion 56. Further, each receiving portion 58 has an inner width that is configured to snugly or securely receive the corresponding protruding portion 58. In one embodiment, the one or more receiving portions 58 may extend through an entirety of the thickness of the coupling plate 48, from a first side of the coupling plate 48 to a second side of the coupling plate 48. Due to the configuration of the receiving portion 58 and the protruding portion 56, adjacent housings 16 may be at least partially secured together by a friction fit between the receiving portion(s) 58 of the coupling plate(s) 48 and the protruding portion(s) 58 of the housings 16. Put another way, the coupling plate(s) 48 may be snapped to the housings 16. The receiving portions 58 and corresponding protruding portions 56 may be spaced such that a gap or space 34 is created and maintained between adjacent housings 16 by the attachment of the coupling plate(s) 48 to the housings 16. Further, in one embodiment, the coupling plate(s) 48 are removably coupled to the housings 16 for quick and easy modification of the dimensions of the battery assembly 10 and/or to replace faulty modular battery cells 12.

[0057] Although the engagement elements 14 of the housing 16 are discussed above as having the same size, configuration, and measurements, it will be understood that the engagement element 14 at the first edge portion 18 may have a different size, configuration, and/or measurements than the engagement element at the second edge portion 20. Also, the sized, configurations, and measurements of the engagement elements 14 discussed herein are not intended to be limiting, but instead are examples of engagement elements 14 that may be used.

[0058] The modular battery cells 12 shown in FIGS. 1 -14 are used to create battery assemblies 10 having reduced weight, reduced cost, reduced number of components (for example, by eliminating the need for a battery module housing), increased recyclability, reduced time to market, greater configurability, chemical robustness, and the like. Further, the battery assemblies 10 are physically robust and capable of meeting shock, vibration, torsional, compressive, tensile, and other load requirements with minimal deformation and without reduction in functionality. The battery assemblies 10 are configurable to application-specific requirements, such as parallel or series configurations, number of modular battery cells 12, stacked or side-by-side configurations, and the like. The housings 16 discussed herein may be composed of one or more polymers that allow for mold-through terminals, hermetically sealed closures, and/or direct assembly of modular battery cells 10 to one another. Additionally, the housing material may facilitate laser welding of cells to one another. Still further, the engagement elements 14 and/or coupling plates 48 discussed herein may also be configured such that auxiliary system components, such as electronics, fans, mounting plates, and the like may be mounted to the coupling plates 48 and/or using the engagement elements 14 and then assembled to the battery assembly 10 without the use of secondary fasteners or components.

[0059] In one embodiment, a modular battery cell 12 includes a housing 16 having a first engagement element 14A and a second engagement element 14B, and the first 14A and second 14B engagement elements being couplable with corresponding engagement elements of at least one other modular battery cell when the at least one modular battery cell is positioned adjacent to the modular battery cell.

[0060] In one aspect of the embodiment, the housing 16 includes: a first edge portion 18; a second edge portion 20 opposite the first edge portion 18; a third edge portion positioned 22 between the first 18 and second 20 edge portions; a fourth edge portion 24 opposite the third edge portion 22 and between the first 18 and second 20 edge portions; a first face 16 bordered by the first 18, second 20, third 22, and fourth 24 edge portions; and a second face 28 opposite the first face 26 and bordered by the first 18, second 20, third 22, and fourth 24 edge portions.

[0061] In one aspect of the embodiment, the first engagement element 14A includes: a first protruding portion 30A; a second protruding portion 30B; and a first receiving portion 32A; and the second engagement element 14B includes: a third protruding portion 30C; a fourth protruding portion 30D; and a second receiving portion 32B.

[0062] In one aspect of the embodiment, at least a portion of the first engagement element 14A is on the first edge portion 18 and at least a portion of the second engagement element 14B is on the second edge portion 20.

[0063] In one aspect of the embodiment, the first edge portion 18 has a height, the first protruding portion 30A extending along an entirety of the height of the first edge portion 18, the first protruding portion 30A extending from the first face 26 in a first direction that is orthogonal to the plane in which the first face 26 lies; the second protruding portion 30B extends along the entirety of the height of the first edge portion 18, the second protruding portion 30B extending from the second face 28 in a second direction that is opposite the first direction and orthogonal to the plane in which the second face 28 lies; and the first receiving portion 32A extends along the entirety of the height of the first edge portion 18, the first receiving portion 32A being on the second face 28 immediately proximate the second protruding portion 30B.

[0064] In one aspect of the embodiment, the first protruding portion 30A extends from the first face 26 by a first distance and the first receiving portion 32B has a depth that is less than the first distance.

[0065] In one aspect of the embodiment, the second edge portion 20 has a height, the third protruding portion 30C extending along an entirety of the height of the second edge portion 20, the third protruding portion 30C extending from the first face 26 in a first direction that is orthogonal to the plane in which the first face 26 lies; the fourth protruding portion 30D extends along the entirety of the height of the second edge portion 20, the fourth protruding portion 30D extending from the second face 28 in a second direction that is opposite the first direction and orthogonal to the plane in which the second face 28 lies; and the second receiving portion 32B extends along the entirety of the height of the second edge portion 20, the second receiving portion 32B being on the second face 28 immediately proximate the fourth protruding portion 30D.

[0066] In one aspect of the embodiment, the third protruding portion 30C extends from the first face 26 by a first distance and the second receiving portion 32B has a depth that is less than the first distance.

[0067] In one aspect of the embodiment, the first engagement element 14A includes: a first locking portion 36A; and a first receiving portion 38A; and the second engagement element 14B includes: a second locking portion 36B; and a second receiving portion 38B.

[0068] In one aspect of the embodiment, the first edge portion 18 has a height, the first locking portion 36A extending from the first edge portion 18 along an entirety of the height of the first edge portion 18 proximate the second face 28; and the first receiving portion 38A is on the first edge portion 18 and extends along the entirety of the height of the first edge portion 18.

[0069] In one aspect of the embodiment, the second edge portion 20 has a height, the second locking portion 26B extending from the second edge portion 20 along an entirety of the height of the second edge portion 20 proximate the first face 26; and the second receiving portion 38B is on the second edge portion 20 and extends along the entirety of the height of the second edge portion 20.

[0070] In one embodiment, a battery assembly 10 includes: a plurality of modular battery cells 12, each modular battery cell 12 including a housing 16 having a first engagement element 14A and a second engagement element 14B, the first engagement element 14A of each of the plurality of modular battery cells 12 being coupled to one of the first engagement element 14A and the second engagement element 14B of at least one adjacent modular battery cell. [0071] In one aspect of the embodiment, the first engagement element 14A includes a first protruding portion 30A, a second protruding portion 30B, and a first receiving portion 32A; and the second engagement element 14B includes a third protruding portion 30C, a fourth protruding portion 30D, and a second receiving portion 32B, the first receiving portion 30A of a first housing 16A of the plurality of modular battery cell 12 being configured to receive a one of the first protruding portion 3 OA and the third receiving portion 30C of a second housing 16B of the plurality of battery cells 12 and the second receiving portion 32B of the first housing 16A being configured to receive another one of the first protruding portion 30A and the third protruding portion 30C of the second housing 16B.

[0072] In one embodiment, a battery assembly 10 includes: a plurality of modular battery cells 12; and a coupling plate 48 coupled to each of the plurality of modular battery cells 12, the coupling plate fixing the plurality of modular battery cells 12 into a predetermined configuration.

[0073] In one aspect of the embodiment, each of the plurality of modular battery cells 12 includes a housing 16, the coupling plate 48 being welded to the housing 16 of each of the plurality of modular battery cells 12.

[0074] In one aspect of the embodiment, each of the plurality of modular battery cells 12 includes a housing 16 having at least one protruding portion 56 and the coupling plate 48 includes at least one receiving portion 58, the at least one protruding portion 56 of each of the plurality of modular battery cells 12 being received by the at least one receiving 58 portion of the coupling plate 48.

[0075] In one aspect of the embodiment, each of the plurality of modular battery cells 12 includes a housing 16 having at least one receiving portion 52 and the coupling plate 48 includes at least one protruding portion 54, the at least one protruding portion 54 of the coupling plate 48 being received by the at least one receiving portion 52 of each of the plurality of modular battery cells 12.

[0076] One or more of the disclosed embodiments, alone or on combination, may provide one or more technical effects including the use of modular battery cells to manufacture of create battery assemblies having reduced weight, reduced cost, reduced number of components (for example, by eliminating the need for a battery module housing), increased recyclability, reduced time to market, greater configurability, chemical robustness, and the like. Further, the battery assemblies are physically robust and capable of meeting shock, vibration, torsional, compressive, tensile, and other load requirements with minimal deformation and without reduction in functionality. The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

[0077] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.