TECHNICAL FIELD

The present technology relates to battery structures and systems. More specifically, the present technology relates to methods of configuring and coupling batteries within a pack.

BACKGROUND

Battery placement within a battery pack may be performed with many considerations. For example, battery configurations with compact placement of battery cells may provide increased energy density by allowing more battery cells within the pack. However, tight cell placement may impact heat dissipation from the cells.

SUMMARY

Battery packs according to some embodiments of the present technology may include a first beam and a second beam. The battery packs may include a plurality of cell blocks disposed between the first beam and the second beam. Each cell block of the plurality of cell blocks may include at least two battery cells. The plurality of cell blocks may include a first cell block characterized by a first side surface proximate the first beam, a second side surface, a third side surface proximate the second beam, and a fourth side surface opposite the second side surface. The plurality of cell blocks may also include a second cell block adjacent the first cell block, the second cell block characterized by a first side surface proximate the first beam, a second side surface, a third side surface proximate the second beam, and a fourth side surface opposite the third side surface. The battery packs may include a first interface material thermally coupling the first side surface of the first cell block with the first longitudinal beam. The battery packs may also include a second interface material thermally coupling the third side surface of the second cell block with the second beam.

In some embodiments, the battery packs may also include a lateral wall extending from the first beam to the second beam between the first cell block and the second cell block. The battery packs may include an insulative material extending about the first cell block along at least one of the second side surface of the first cell block, the third side surface of the first cell block, and the fourth side surface of the first cell block. The battery packs may include the insulative material extending about the second cell block along at least one of the first side surface of the second cell block, the second side surface of the second cell block, and the fourth side surface of the second cell block. The insulative material may be characterized by a thermal conductivity less than 0.5 W/m·K. The first interface material and the second interface material may be characterized by a thermal conductivity greater than 0.5 W/m·K. The first cell block may be laterally offset towards the first beam from a center longitudinal axis between the first beam and the second beam, and the second cell block may be laterally offset towards the second beam from the center longitudinal axis.

Embodiments of the present technology may also encompass battery packs including a first cell block including a first battery cell. The first cell block may be characterized by a first side surface, a second side surface, a third side surface opposite the first side surface, and a fourth side surface opposite the second side surface. The battery packs may include a second cell block adjacent the first cell block along the third side surface of the first cell block. The second cell block may include a second battery cell, and the second cell block may be characterized by a first side surface, a second side surface, a third side surface opposite the first side surface, and a fourth side surface opposite the second side surface. The battery packs may include a third cell block adjacent the second cell block along the third side surface of the second cell block. The third cell block may include a third battery cell, and the third cell block may be characterized by a first side surface, a second side surface, a third side surface opposite the first side surface, and a fourth side surface opposite the second side surface. The battery packs may also include a bypass busbar extending from the first cell block to the third cell block. The bypass busbar may electrically couple the first battery cell with the third battery cell. The bypass busbar may extend across the second cell block and may be electrically isolated from the second battery cell.

In some embodiments, the bypass busbar may extend through a first bulkhead separating the first cell block from the second cell block and may extend through a second bulkhead separating the second cell block from the third cell block. The battery packs may also include a gasket positioned in an aperture of each of the first bulkhead and the second bulkhead through which the bypass busbar extends. The gaskets may isolate the bypass busbar from the first bulkhead and the second bulkhead. The second cell block may include at least two second battery cells electrically coupled together with an internal busbar at cell terminals of the at least two second battery cells proximate the second side surface of the second cell block. The bypass busbar may electrically couple a terminal of the first battery cell and a terminal of the third battery cell. The terminal of the first battery cell and the terminal of the third battery cell may each be proximate the respective second surface of the first cell block and the third cell block. The bypass busbar may extend across the second cell block along a substantially similar plane as the internal busbar at a location distal the second surface of the second cell block from the internal busbar.

The bypass busbar may include a bypass section. The bypass busbar may include a first terminal section positioned at a first end of the bypass section and coupled with the terminal of the first battery cell. The bypass busbar may include a second terminal section positioned at a second end of the bypass section opposite the first end and coupled with the terminal of the third battery cell. The first terminal section and the second terminal section may extend by arcuate portions of the first terminal section and the second terminal section from a first plane to a second plane vertically offset from the first plane. The arcuate portions of the first terminal section and the second terminal section may define an arc of about 180°. The bypass section may extend across the cell terminals of the at least two second battery cells of the second cell block.

In some embodiments the bypass busbar may include a bypass section. The bypass busbar may include a first terminal section positioned at a first end of the bypass section and coupled with the terminal of the first battery cell. The bypass busbar may include a second terminal section positioned at a second end of the bypass section opposite the first end and coupled with the terminal of the third battery cell. The bypass section may extend along a plane substantially orthogonal to a plane across the first terminal section and the second terminal section. An insulation material may be positioned along the second side surface of the second cell block, and the insulation material may be positioned between the second cell block and the bypass section of the bypass busbar. The bypass section of the bypass busbar may extend through bulkheads separating the second cell block from the first cell block and the third cell block. The bulkheads may extend laterally beyond the second side surface of the second cell block.

The battery packs may also include a first beam positioned along the second side surfaces of each of the first cell block, the second cell block, and the third cell block. The battery packs may include a second beam positioned along the fourth side surfaces of each of the first cell block, the second cell block, and the third cell block. The battery packs may include a first thermal interface material coupling the second side surface of the first cell block with the first beam. The battery packs may include a second thermal interface material coupling the fourth side surface of the second cell block with the second beam. The battery packs may also include a third thermal interface material coupling the second side surface of the third cell block with the first beam. The first cell block and the third cell block may each be laterally offset towards the first beam from an axis between the first beam and the second beam. The axis may be parallel to the first beam and the second beam and centered between the first beam and the second beam. The second cell block may be laterally offset towards the second beam from the axis.

Such technology may provide numerous benefits over conventional technology. For example, the present systems may reduce heat transfer between adjacent cells during operating and abuse conditions. Additionally, the present systems may improve component insulation to reduce or limit additional conduction paths between cells. These and other embodiments, along with many of their advantages and features, are described in more detail in conjunction with the below description and attached figures.

