HOUSING DESIGN

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States Provisional Application, Serial No. 62/632,689, filed Februaiy 20, 2018, entitled, MODULE LEVEL FORMATION AND STANDLOSS ENABLED HOUSING DESIGN, the entire contents of which is hereby incorporated by reference herein in its entirety.

FIELD

[0002] This disclosure relates to a device, system, and method for allowing cells to undergo the formation process within the housing that is used for the finished battery module. In particular, some embodiments include an electrical conduction assembly within the housing that allows the individual voltage of each of the plurality of cells to be individually measured and monitored during the formation process.

BACKGROUND

[0003] Lithium ion batteries (Li-ion batteries or LiBs) are commonly used rechargeable batteries that generally include a plurality of cells arranged within a housing. Energy is produced through an electrochemical reaction in each cell between a negative electrode (anode), a positive electrode (cathode), and an electrolyte that carries ions between the anode and cathode.

[0004] During manufacture, the cells are first filled with an electrolyte and sealed. After sealing, the cells are loaded into large formation pallet to slowly charge, and possibly undergo repeated cycling and aging, as part of the formation process. The formation pallets provide structure for each cell and alignment to the formation fixture. The formation process produces a uniform and stable solid electrolyte interphase on the cell anode.

[0005] Once the formation process is complete, the cells remain in the formation pallet through stand loss, or the reduction in state of charge (SoC) and reduction in electrolyte specific gravity. Typically, manufacturers deliver cells at approximately 50% SoC to maximize cell performance upon receipt by the customer.

[0006] The purchaser, or the original manufacturer, inserts the cells into a housing to create a battery module. However, current battery module designs isolate the cells from external contact points, and therefore make it difficult to access, measure, and/or monitor the individual cell voltages. Thus, cell formation must be achieved prior to their incorporation into the battery module. This method not only increases handling of the cells, which can lead to breakage and injury, but also adds complexity to the

manufacturing process.

[0007] Thus, a need exists for a battery module and method which solve one or more of the foregoing drawbacks.

SUMMARY

[0008] Accordingly, a battery module and method which solve one or more of the foregoing drawbacks is disclosed. The module and method include, among other features, a module level formation and standloss enabled housing design.

[0009] In one embodiment, an electrical conduction assembly for a housing of a battery module includes: an electrically conductive central panel, a first end, a second end opposite the first end, a first edge, and a second edge opposite the first edge; a first plurality of electrically conductive cell contact elements extending from the first edge and a second plurality of electrically conductive cell contact elements extending from the second edge; and a plurality of interconnections, each of the plurality of interconnections having a first end and a second end, the first end being in contact with a corresponding one of the first plurality of electrically conductive cell contact elements and second plurality of electrically conductive cell contact elements, the second end being a free end.

[0010] In one aspect of the embodiment, the electrical conduction assembly is at least partially located within a lid of the housing of the battery module, the second end of each of the plurality of interconnections being located external to the lid.

[0011] In one aspect of the embodiment, each of the plurality of interconnections includes a conduction block in at least one location.

[0012] In one aspect of the embodiment, each of the plurality of interconnections is parallel to the longitudinal axis of the electrically conductive central panel.

[0013] In one embodiment, a housing for a battery module comprises: a plurality of walls and a floor defining a chamber; a lid panel opposite the floor and enclosing the chamber; and an electrical conduction assembly coupled to the lid panel, at least a portion of the electrical conduction assembly extending externally from the housing, the electrical conduction assembly including: an electrically conductive central panel; and a plurality of electrically conductive cell contact elements.

[0014] In one aspect of the embodiment, at least a portion of the electrical conduction assembly is located within the lid panel.

[0015] In one aspect of the embodiment, the electrical conduction assembly further includes a plurality of interconnections each having a first end in contact with one of the plurality of electrically conductive cell contact elements and a second end, the second end being a free end that extends externally from the housing.

[0016] In one aspect of the embodiment, each of the plurality of electrically conductive interconnections includes a conduction block in at least one location.

[0017] In one aspect of the embodiment, the lid panel includes a surface facing the chamber, the surface having a plurality of apertures, each of the plurality of apertures corresponding to at least a portion of one of the plurality of electrically conductive cell contact elements.

[0018] In one embodiment, a battery module comprises: a housing including a plurality of walls, a floor, and a lid, the housing defining a chamber, the lid having a lid panel and an electrical conduction assembly coupled to the lid panel; and a plurality of cells within the chamber, each of the plurality of cells being in electrical communication with the electrical conduction assembly, at least a portion of the electrical conduction assembly extending from the housing such that an individual voltage of each of the plurality of cells is measurable at a location external to the housing.

[0019] In one aspect of the embodiment, at least a portion of the electrical conduction assembly is located within the lid panel.

[0020] In one aspect of the embodiment, the electrical conduction assembly has: an electrically conductive central panel; and a plurality of electrically conductive cell contact elements.

[0021] In one aspect of the embodiment, each of the plurality of cells is in electrical communication with a corresponding one of the plurality of electrically conductive cell contact elements.

[0022] In one aspect of the embodiment, the electrical conduction assembly further has a plurality of interconnections each having a first end in contact with one of the plurality of electrically conductive cell contact elements and a second end, the second end being a free end that extends externally from the housing. [0023] In one aspect of the embodiment, the second end of each of the plurality of interconnections is connectable to a voltage monitoring system.

[0024] In one aspect of the embodiment, the battery module further comprises at least one busbar within the chamber, the at least one busbar being in electrical communication with each of the plurality of cells. In one aspect of the embodiment, the electrical conduction assembly is coupled to the at least one busbar.

[0025] In one embodiment, a method of producing a battery module comprises:

positioning a plurality of cells within a housing, the housing including a lid, the lid having an electrical conduction assembly, the plurality of cells being positioned within the housing such that at least a portion of the electrical conduction assembly is in electrical contact with each of the plurality of cells, the electrical conduction assembly including a plurality of external cell electrical connectors located external from the housing;

connecting a voltage monitoring system to the plurality of external cell electrical connectors; and measuring an individual voltage from each of the plurality of cells while the plurality of cells undergo a formation process.

[0026] In one aspect of the embodiment, the housing further includes at least one external stack electrical connector, the method further comprising: connecting the voltage monitoring system to the at least one external stack electrical connector; and measuring a voltage from all of the plurality of cells while the plurality of cells undergo the formation process.

[0027] In one aspect of the embodiment, the voltage monitoring system is configured to display a real-time voltage of each of the plurality of cells while the plurality of cells undergo the formation process.

[0028] These and other features and advantages of devices, systems, and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.

BRIEF DESCRIPTION OF DRAWINGS

[0029] Various examples of embodiments of the systems, devices, and methods according to this invention will be described in detail, with reference to the following figures, wherein: [0030] FIG. 1 is a perspective view of a battery module in accordance with one or more example of embodiments of a module level formation and standloss enabled housing design as disclosed herein;

[0031] FIG. 2 is a perspective view of a lead frame and lid panel of a housing for use with the battery module shown in FIG. 1;

[0032] FIG. 3 is a perspective view of an assembled lid, including the lead frame and lid panel of FIG. 2, for use with the battery module shown in FIG. 1 ;

[0033] FIG. 4 is a perspective cross-sectional view of the battery module of FIG. 1;

[0034] FIG. 5 is a close-up view of a portion of the view shown in FIG. 4;

[0035] FIG. 6 is a circuit diagram of one or more examples of embodiments of an electrical connection between an electrical conduction assembly, busbars, and battery cells; and

[0036] FIG. 7 illustrates one or more examples of a system for formation of cells within a housing.

[0037] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. For ease of understanding and simplicity, common numbering of elements within the numerous illustrations is utilized when the element is the same in different Figures. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

[0038] Before describing in detail one or more examples of embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to formation of cells of a battery module within a housing.

Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0039] Referring now to FIG. 1, a perspective view of a battery module 10 is shown that is configured to allow for formation and standloss of the cells within the housing of the battery module 10. The battery module 10 generally includes a housing 12, the housing 12 having a plurality of walls 14 and a floor 16 together defining a chamber 18 (chamber 18 is shown in FIG. 4), and a lid 20 that, when the housing 12 is assembled, encloses the chamber 18. As is shown in FIG. 4, a plurality of cells 22 is located within the chamber 18 when the battery module 10 is assembled. The plurality of cells 22 may collectively be referred to as a stack 24 (shown in FIG. 4). When the battery module 10 is assembled, the housing 12 includes an external cell electrical connector 26 for each cell from the plurality of cells 22 and at least one external stack electrical connector 28 for the stack 24 as a whole.

[0040] Referring now to FIGS. 2 and 3, the lid 20 of the housing 12 of the battery module 10 is shown in greater detail. The lid 20 includes a lid panel 30 and an electrical conduction assembly 32 configured to be in electrical communication with each of the plurality of cells 22 located within the chamber 18 of the housing 12. However, it will be understood that although the electrical conduction assembly 32 is discussed herein as being coupled to or within the lid panel 30, the electrical conduction assembly 32 may additionally or alternatively be located at other locations within the housing 12, provided that at least a portion of the electrical conduction assembly 32 is in contact with each cell from the plurality of cells 22.

[0041] In one embodiment, the electrical conduction assembly 32 is manufactured (for example, stamped) as a single piece of conductive material that includes a plurality of leads configured to be in contact with the cells 22 when the battery module 10 is assembled. In one embodiment, the electrical conduction assembly 32 includes an electrically conductive central panel 34, a plurality of electrically conductive cell contact elements 36, and a plurality of interconnections 38 between the central panel 34 and cell contact elements 36. The plurality of cell contact elements 36 serve as the plurality of leads configured to be in contact with at least one of the cathode 40 and the anode 42 of each cell from the plurality of cells 22.

[0042] In one embodiment, the central panel 34 has an elongate rectangular shape with a longitudinal axis 44, a first end 46, a second end 48 opposite the first end 46, a first edge 50, and a second edge 52 opposite the first edge 50. The central panel 34 is configured to extend across all cells 22 in a stack 24 when the battery module 10 is assembled. In the illustrated embodiment shown in the Figures, each of the plurality of cell contact elements 36 are elongate with a longitudinal axis 54 that is orthogonal to the longitudinal axis 44 of the central panel 34. However, it is understood that any number of geometries may be acceptable for accomplishing the purposes provided herein. As non-limiting examples, a linear or curved arrangement may be acceptable.

[0043] In one embodiment, a first plurality of cell contact elements 36 extends from the first edge 50 of the central panel 34 and a second plurality of cell contact elements 36 extends from the second edge 52 of the central panel 34. Further, in one embodiment, cell contact elements 36 extending from opposite sides of the central panel 34 (that is, the first plurality of cell contact elements 36 and the second plurality of cell contact elements 36) are alternating, such that no cell contact element 36 is directly opposite another (for example, as shown in FIGS. 2 and 3). In this embodiment, when the battery module 10 is assembled, either the cathode 40 or the anode 42 of each of the plurality of cells 22 is in contact with a single cell contact element 36. In one non-limiting example, if the stack 24 includes twelve cells 22, cell contact elements 36A-F (the first plurality of cell contact elements 36) are in contact with the anode 42 of each of the first, third, fifth, seventh, ninth, and eleventh cells 22, respectively, and cell contact elements 36G-L (the second plurality of cell contact elements 36) are in contact with the cathode 40 of each of the second, fourth, sixth, eighth, tenth, and twelfth cells 22, respectively (not shown in the figures). However, it will be understood that other configurations are also possible.

[0044] The plurality of interconnections 38 extend parallel to the central panel 34, from the first end 46 toward the second end 48 of the central panel 34. Further, in one embodiment, each interconnection 38 has a first end 56 that is in contract with, or contiguous with, a base of one of the plurality of cell contact elements 36. In one non- limiting example, the first plurality of cell contact elements 36 extending from a first edge 50 of the central panel 34 are indicated in FIG. 2 as 36A-F and the second plurality of cell contact elements 36 extending from a second edge 52 of the central panel 34 opposite the first edge 50 are indicated in FIG. 2 as 36G-L. In this example, a first interconnection 38 extends from the base of cell contact element 36A and ends in a free end extending beyond the first end 46 of the central panel 34. The first interconnection 38 located a first distance from the first edge 50 of the central panel 34 and is parallel to the longitudinal axis 44 of the central panel 34. A second interconnection 38 extends from the base of cell contact element 36B and ends in a second end 58 that is a free end extending beyond the first end 46 of the central panel 34. The second interconnection 38 is located a second distance from the first edge 50 of the central panel 34 and is parallel to the longitudinal axis 44 of the central panel 34, the second distance being less than the first distance.

Each additional interconnection 38, contact element 36 (e.g., contact elements 36C-36F), and second end 58 has a similar configuration to that described in reference to contact elements 36A and 36B. In the illustrated embodiment, each contact element 36 has a corresponding interconnection 38 with a free end 58; for example, contact element 36A corresponds to connection element 38A, contact element 36B corresponds to connection element 38B, contact element 36C corresponds to connection element 38C, and so forth. As shown in FIG. 2, the interconnections 38 extending from cell contact elements 36A-F are parallel to each other. The interconnection 38 extending from cell contact element 36F is closer to the central panel 34 than the interconnection 38 extending from cell contact element 36E, which is closer to the central panel 34 than the interconnection 38 extending from cell contact element 36D, which is closer to the central panel 34 than the interconnection 38 extending from cell contact element 36C, and so on. Further, each of cell contact elements 36A-E is separated from the central panel 34 by at least one interconnection 38, with the greatest number of interconnections 38 separating cell contact element 36A and the least number of interconnections 38 separating cell contact element 36E. In one embodiment, this same configuration exists for the cell contact elements 36G-L and corresponding interconnections 38.

[0045] Further, the interconnection 38 extending from the base of cell contact element 36A and the interconnection 38 extending from the base of cell contact element 36G extend beyond the first end 46 of the central panel 34 to end in a free end, but also extend toward the second end 48 of the central panel 34 such that the interconnections 38 are in contact with all of cell contact elements 36B-F and cell contact elements 36H-L, respectively. Optionally, the free ends of the interconnections 38 and each of the cell contact elements 36 include two right-angle bends to create a step that corresponds to a shape of the lid panel 30. Likewise, one of or each of the first end 46 and the second end 48 optionally includes a tab that is bent at a right angle relative to the plane in which the central panel 34 lies. These right-angle bends help anchor the electrical conduction assembly 32 within the lid panel 30. It will be understood that the electrical conduction assembly 32 shown in FIGS. 2 and 3 has one exemplary configuration, but any suitable configuration may instead be used.

[0046] During assembly of the lid 20, the lid panel 30 (for example, as shown in FIG. 2) may be manufactured by known methods such as injection molding. The lid panel 30 may be composed of non-conductive material(s) such as plastic(s). The electrical conduction assembly 32, which is composed of conductive material(s) such as metal(s), may then be affixed or coupled to the lid panel 30. Alternatively, the electrical conduction assembly 32 may be placed inside a mold and the lid panel 30 may be molded around the electrical conduction assembly 32, such that at least a portion of the electrical conduction assembly 32 is between one or more layers of (or at least partially within) the lid panel 30 to form a single-piece lid 20 in which the lid panel 30 and electrical conduction assembly 32 are integrated.

[0047] As is shown in FIG. 3, the free ends of the interconnections 38 extend beyond at least one surface of the lid 20, such as an edge 60 of the lid panel 30. The housing 12 may also include at least one busbar 62 for the conduction of electricity during power distribution (see FIG. 5). For example, in one embodiment the housing 12 includes a plurality of busbars 62, with one busbar 62 extending between each set of adjacent cells 22 (as shown in FIG. 5). Also, a lower surface 64 of the lid panel 30 (that is, the surface of the lid panel 30 that is facing the chamber 18 and the cells 22 within) may include a plurality of apertures 66, each aperture 66 corresponding to at least a portion of each of the cell contact elements 36 so at least a portion of each cell contact element 36 is exposed from the lid panel 30 to allow electrical conduction from the cells 22 to the electrical conduction assembly 32 and to enable the electrical conduction assembly 32 to be directly coupled to the at least one busbar 62. Once the lid 20 (lid panel 30 and electrical conduction assembly 32) is assembled, a tool such as a punch is used to physically break or create a discontinuity in each of the interconnections 38 to make at least one conduction block 68 in (that is, prevent electrical conduction through) each of the plurality of interconnections 38 so that each cell contact element 36 is in electrical communication with only one interconnection 38 free end (second end 58). Thus, each free end that extends from the lid 20 (as shown in FIG. 3) can be used to measure the individual voltage of a single cell contact element 36, which, in one embodiment, corresponds to a single cell 22. When the battery module 10 is assembled, the free ends of the interconnections 38 are the external cell electrical connectors 26 (for example, as shown in FIG. 1).

[0048] Referring now to FIGS. 4 and 5, the battery module 10 is shown in more detail. Specifically, FIG. 4 shows a cross-sectional view of the battery module 10, with a portion of the stack 24 visible. Each cell 22 includes an anode 42 and a cathode 40. The housing 12 includes a plurality of walls 14 and a floor 16 that define the chamber 18. When the battery module 10 is assembled, the lid 20 is located opposite the floor 16 and encloses the chamber 18 within which the stack 24 is located. At least a portion of the electrical conduction assembly 32 is in electrical communication with the busbars 62. In one embodiment, at least a portion of the electrical conduction assembly 32 is welded or otherwise coupled to each of the busbars 62.

[0049] A circuit diagram of one or more examples of embodiments of the electrical connection between the electrical conduction assembly 32, busbars 62, and three cells 22 is shown in FIG. 6. In this non-limiting example, a first busbar 62A extends between a first cell 22A and a second cell 22B, and a second busbar 62B extends between the second cell 22B and a third cell 22C. The electrical conduction assembly 32 is in electrical communication with (for example, is welded to) each of the busbars 62A, 62B (collectively referred to herein s busbars 62). In this way, the electrical conduction assembly 32 may be used to sense a first voltage, which is a partial voltage of each of the first 22A and second 22B cells, and a second voltage, which is a partial voltage of each of the second 22B and third 22C cells. Although FIG. 6 shows three cells 22, it will be understood that any number of cells may be used. When the battery module 10 is assembled, each cell contact element 36 is in electrical communication with the anode 42 or the cathode 40 of a corresponding one of the plurality of cells 22.

[0050] Referring now to FIG. 7, a system for formation of the cells 22 in the housing 12 is shown. After the battery module 10 is assembled, the battery module 10 may be stored while the cells 22 undergo the formation process (that is, the cells 22 are allowed to form within the housing 12). A voltage monitoring system 70, which may include a voltmeter or multimeter 72, is in electrical communication with the external cell electrical connectors 26 and/or the external stack electrical connectors 28 and used to continuously or periodically measure the individual voltage of each of the plurality of cells 22 and/or the stack 24 as a whole. Further, in one embodiment, the voltage monitoring system 70 includes processing circuitry 74 including a memory 76 and a processor 78, the memory 76 in communication with the processor 78, the memory 76 having instructions 80 that, when executed by the processor 78, configure the processor 78 to perform an automated or semi-automated protocol for cell formation.

[0051] In addition to a traditional processor and memory, processing circuitry 74 may include integrated circuitry for processing and/or control, e.g., one or more processors and/or processor cores and/or FPGAs (Field Programmable Gate Array) and/or ASICs (Application Specific Integrated Circuitry). Processing circuitry 74 may include and/or be connected to and/or be configured for accessing (e.g., writing to and/or reading from) memory 76, which may include any kind of volatile and/or non-volatile memory, e.g., cache and/or buffer memory and/or RAM (Random Access Memory) and/or ROM (Read- Only Memory) and/or optical memory and/or EPROM (Erasable Programmable Read- Only Memory). Such memory 76 may be configured to store code executable by control circuitry and/or other data, e.g., data pertaining to communication, e.g., configuration and/or address data of nodes, etc. Processing circuitry 74 may be configured to control any of the methods described herein and/or to cause such methods to be performed, e.g., by processor 78. Corresponding instructions may be stored in the memory 38, which may be readable and/or readably connected to the processing circuitry 74. In other words, processing circuitry 74 may include a controller, which may comprise a microprocessor and/or microcontroller and/or FPGA (Field-Programmable Gate Array) device and/or ASIC (Application Specific Integrated Circuit) device. It may be considered that processing circuitry 74 includes or may be connected or connectable to memory 76, which may be configured to be accessible for reading and/or writing by the controller and/or processing circuitry 74.

[0052] For example, the processing circuitry 74 may be configured to continuously measure individual voltages of the cells 22 and to determine if the cells 22 are undergoing formation in an acceptable manner. If the processing circuitry 74 determines that one or more measured voltages are unacceptable (for example, are exceed a threshold voltage or differ by more than a predetermined amount from a threshold voltage), the processing circuitry 74 alerts the user through, for example, one or more audible and/or visual signals, such as through a display 82. Likewise, the processing circuitry 74 also enables the user, through, for example, the display 82, to monitor the progress of the formation process and communicates to the user an estimated time of completion of the formation process. For example, the processing circuitry 74 is configured to display a real-time voltage for each of the plurality of cells 22 during and/or after the formation process.

[0053] Aspects of the system described herein may be implemented on a software system running on a computer system or processor. To this end, the methods and system described herein may be implemented in, or in association with, a general-purpose software package or a specific purpose software package. As a specific, non-limiting example, the device could be in communication with a cloud storage database and/or mobile device and/or a computer.

[0054] The software system described herein may include a mixture of different source codes. The system or method herein may be operated by computer-executable instructions, such as but not limited to, program modules, executable on a computer. Examples of program modules include, but are not limited to, routines, programs, objects, components, data structures, and the like which perform particular tasks or implement particular instructions. The software system may also be operable for supporting the transfer of information within a network.

[0055] While the descriptions may include specific devices or computers, it should be understood the system and/or method may be implemented by any suitable device (or devices) having suitable computational means. This may include programmable special purpose computers or general-purpose computers that execute the system according to the relevant instructions. The computer system or portable electronic device can be an embedded system, a personal computer, notebook computer, server computer, mainframe, networked computer, workstation, handheld computer, as well as now known or future developed mobile devices, such as for example, a personal digital assistant, cell phone, smartphone, tablet computer, mobile scanning device, and the like. Other computer system configurations are also contemplated for use with the communication system including, but not limited to, multiprocessor systems, microprocessor-based or programmable electronics, network personal computers, minicomputers, smart watches, and the like. Preferably, the computing system chosen includes a processor suitable for efficient operation of one or more of the various systems or functions or attributes of the communication system described.

[0056] The system or portions thereof may also be linked to a distributed computing environment, where tasks are performed by remote processing devices that are linked through a communication network(s). To this end, the system may be configured or linked to multiple computers in a network including, but not limited to, a local area network, wide area network, wireless network, and the Internet. Therefore, information, content, and data may be transferred within the network or system by wireless means, by hardwire connection, or combinations thereof. Accordingly, the devices described herein communicate according to now known or future developed pathways including, but not limited to, wired, wireless, and fiber-optic channels.

[0057] In one or more examples of embodiments, data may be stored remotely (and retrieved by the application) or may be stored locally on a user’s device in a suitable storage medium. Data storage may be in volatile or non-volatile memory. Data may be stored in appropriate computer-readable medium including read-only memory, random- access memory, CD-ROM, CD-R, CD-RW, magnetic tapes, flash drives, as well as other optical data storage devices. Data may be stored and transmitted by and within the system in any suitable form. Any source code or other language suitable for accomplishing the desired functions described herein may be acceptable for use.

[0058] Furthermore, the computer or computers or portable electronic devices may be operatively or functionally connected to one or more mass storage devices, such as but not limited to, a hosted database or cloud-based storage. The system may also include computer-readable media which may include any computer-readable media or medium that may be used to carry or store desired program code that may be accessed by a computer. The invention can also be embodied as computer-readable code on a computer-readable medium. To this end, the computer-readable medium may be any data storage device that can store data. The computer-readable medium can also be distributed over a network-coupled computer system so that the computer-readable code is stored and executed in a distributed fashion.

[0059] In one or more examples of embodiments, an electrical conduction assembly 32 for a housing 12 of a battery module 10 comprises: an electrically conductive central panel 34 having a longitudinal axis 44, a first end 46, a second end 48 opposite the first end 46, a first edge 50, and a second edge 52 opposite the first edge 50; a first plurality of electrically conductive cell contact elements 36 extending from the first edge 50 and a second plurality of electrically conductive cell contact elements 36 extending from the second edge 52; and a plurality of electrically conductive interconnections 38, each of the plurality of electrically conductive interconnections 38 having a first end 56 and a second end 58, the first end 56 being in contact with a corresponding one of the first plurality of electrically conductive cell contact elements 36 and second plurality of electrically conductive cell contact elements 36, the second end 58 being a free end.

[0060] In one aspect of an embodiment, the electrical conduction assembly 32 is at least partially located within a lid 20 of the housing 12 of the battery module 10, the second end 58 of each of the plurality of electrically conductive interconnections 38 being located external to the lid 20.

[0061] In one aspect of an embodiment, each of the plurality of electrically conductive interconnections 38 includes a conduction block 68 in at least one location.

[0062] In one aspect of an embodiment, each of the plurality of electrically conductive interconnections 38 is parallel to the longitudinal axis 44 of the electrically conductive central panel 34.

[0063] In one or more examples of embodiments, a housing 12 for a battery module 10 comprises: a plurality of walls 14 and a floor 16 defining a chamber 18; a lid panel 30 opposite the floor and enclosing the chamber 18; and an electrical conduction assembly 32 coupled to the lid panel 30, at least a portion of the electrical conduction assembly 32 extending externally from the housing 12, the electrical conduction assembly 32 including: an electrically conductive central panel 34 having a longitudinal axis 44; and a plurality of electrically conductive cell contact elements 36.

[0064] In one aspect of an embodiment, at least a portion of the electrical conduction assembly 32 is located within the lid panel 30.

[0065] In one aspect of an embodiment, the electrical conduction assembly 32 further includes a plurality of electrically conductive interconnections 38 each having a first end 56 in contact with one of the plurality of electrically conductive cell contact elements 36 and a second end 58, the second end 58 being a free end that extends externally from the housing 12.

[0066] In one aspect of an embodiment, each of the plurality of electrically conductive interconnections 38 includes a conduction block 68 in at least one location.

[0067] In one aspect of an embodiment, the lid panel 30 includes a surface facing the chamber 18, the surface having a plurality of apertures 66, each of the plurality of apertures 66 corresponding to at least a portion of one of the plurality of electrically conductive cell contact elements 36.

[0068] In one or more examples of embodiments, a battery module 10 comprises: a housing 12 including a plurality of walls 14, a floor 16, and a lid 20, the housing 12 defining a chamber 18, the lid 20 having a lid panel 30 and an electrical conduction assembly 32 coupled to the lid panel 30; and a plurality of cells 22 within the chamber 18, each of the plurality of cells 22 being in electrical communication with the electrical conduction assembly 32, at least a portion of the electrical conduction assembly 32 extending from the housing 12 such that an individual voltage of each of the plurality of cells 22 is measurable at a location external to the housing 12.

[0069] In one aspect of an embodiment, at least a portion of the electrical conduction assembly 32 is located within the lid panel 30.

[0070] In one aspect of an embodiment, the electrical conduction assembly 32 has: an electrically conductive central panel 34 having a longitudinal axis 44; and a plurality of electrically conductive cell contact elements 36 each having a longitudinal axis 54. In some examples of embodiments, such as illustrated in one or more Figures, the longitudinal axis 54 of each of the plurality of electrically conductive cell contact elements 36 are orthogonal to the longitudinal axis 44 of the electrically conductive central panel 34. However, alternative geometries may be acceptable for accomplishing the purposes provided. For example a linear or curved arrangement may be acceptable.

[0071] In one aspect of an embodiment, each of the plurality of cells 22 is in electrical communication with a corresponding one of the plurality of electrically conductive cell contact elements 36.

[0072] In one aspect of an embodiment, the electrical conduction assembly 32 further has a plurality of electrically conductive interconnections 38 each having a first end 56 in contact with one of the plurality of electrically conductive cell contact elements 36 and a second end 58, the second end 58 being a free end that extends externally from the housing 12.

[0073] In one aspect of an embodiment, the second end 58 of each of the plurality of electrically conductive interconnections 38 is connectable to a voltage monitoring system 70.

[0074] In one aspect of an embodiment, the battery module 10 further comprises at least one busbar 62 within the chamber 18, the at least one busbar 62 being in electrical communication with each of the plurality of cells 22. In one aspect of the embodiment, the electrical conduction assembly 32 is coupled to the at least one busbar 62.

[0075] In one or more examples of embodiments, a method of producing a battery module 10 comprises: positioning a plurality of cells 22 within a housing 12, the housing 12 including a lid 20, the lid 20 having an electrical conduction assembly 32, the plurality of cells 22 being positioned within the housing 12 such that at least a portion of the electrical conduction assembly 32 is in electrical contact with each of the plurality of cells 22, the electrical conduction assembly 32 including a plurality of external cell electrical connectors 26 located external from the housing 12; connecting a voltage monitoring system 70 to the plurality of external cell electrical connectors 26; and measuring an individual voltage from each of the plurality of cells 22 while the plurality of cells 22 undergo a formation process.

[0076] In one aspect of an embodiment, the housing 12 further includes at least one external stack electrical connector 28, the method further comprising: connecting the voltage monitoring system 70 to the at least one external stack electrical connector 28; and measuring a voltage from all of the plurality of cells 22 while the plurality of cells 22 undergo the formation process. [0077] In one aspect of an embodiment, the voltage monitoring system 70 is configured to display a real-time voltage of each of the plurality of cells 22 while the plurality of cells 22 undergo the formation process.

[0078] One or more examples of embodiments of the module level formation and standloss enabled housing design describes herein advantageously provide a device, system, and method for allowing cells to undergo the formation process within the housing that is used for the finished battery module. In particular, some embodiments may include an electrical conduction assembly within the housing that allows the individual voltage of each of the plurality of cells to be individually measured and monitored during the formation process.

[0079] In contrast to currently known battery modules, the external cell electrical connectors 26 allow the individual voltage of each cell 22 to be measured and monitored during the formation process, and at a location external to the housing 12. Further, each of the external cell electrical connectors 26 may be interfaced with an automated or semi- automated protocol for cell formation. The at least one external stack electrical connector 28 allows for the voltage of the stack 24 as a whole (collective voltage) to be measured and monitored, as is known in current battery modules.

[0080] Advantageously, allowing the cells to undergo the formation process (“form”) within the housing negates the requirement of first forming the cells in a formation pallet and then transferring the cells to a housing, which reduces cell handling and exposure to damage, and equipment and labor costs.

[0081] As utilized herein, the terms“approximately,”“about,”“substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0082] As used herein, relational terms, such as“first” and“second,”“top” and“bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. It should be noted that references to relative positions (e.g.,“top” and“bottom”) in this description are also merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

[0083] For the purpose of this disclosure, the term“coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

[0084] It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject maher recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Likewise, one or more method steps may be divided so as to be performed at different locations, and different steps may be included or removed. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

[0085] While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

[0086] 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.