System for arranging and coupling battery cells in a battery module

Abstract

A battery module includes a plurality of battery cells disposed in at least two rows. The battery cells in adjacent rows are offset from each other. Each of the plurality of battery cells includes a cover and a first terminal that extends from the cover outward. The first terminal is configured to be coupled to a second terminal on an adjacent battery cell. The plurality of battery cells are electrically coupled to each other in a zigzag pattern via the first and second terminals.

1 . A battery module, comprising:
 a plurality of battery cells electrically coupled between a first terminal connection and a second terminal connection of the battery module and disposed in a first row, a second row, and a third row, wherein the second row is disposed between and adjacent to the first and third rows, and wherein the battery cells in the second row are offset relative to the battery cells in the first and third rows;   wherein the plurality of battery cells comprises a first end battery cell electrically coupled to the first terminal connection, a second end battery cell electrically coupled to the second terminal connection, and intermediate battery cells electrically coupled to each other between the first and second end battery cells;
 wherein each intermediate battery cell in the first row is electrically coupled to an adjacent battery cell in the first row and to a battery cell in the second row, each intermediate battery cell in the second row is electrically coupled to a battery cell in the first row and to a battery cell in the third row, and each intermediate battery cell in the third row is electrically coupled to a battery cell in the second row and to an adjacent battery cell in the third row. 
   
     
     
         2 . The battery module of  claim 1 , wherein each of the plurality of battery cells comprises a cover and an integrally formed first terminal that extends from the cover outward, wherein the first terminal is configured to be coupled to a second terminal on an adjacent battery cell or to a terminal connection of the battery module. 
     
     
         3 . The battery module of  claim 1 , wherein the plurality of battery cells are cylindrical battery cells. 
     
     
         4 . The battery module of  claim 1 , wherein the plurality of battery cells comprise a total of twelve battery cells with four battery cells in each of the first, second, and third rows. 
     
     
         5 . The battery module of  claim 1 , wherein the plurality of battery cells comprises a total of thirteen battery cells with four battery cells in the first row, five battery cells in the second row, and four battery cells in the third row. 
     
     
         6 . The battery module of  claim 1 , wherein each of the plurality of battery cells comprises:
 a housing having a central longitudinal axis;   a cover coupled to the housing;   a first flange integrally formed with the cover and configured to act as a first terminal for the battery cell, wherein the first flange comprises a first portion that extends generally parallel to the central longitudinal axis of the housing, and a second portion that extends outwardly beyond the housing in a direction perpendicular to the central longitudinal axis of the housing; and   a second terminal extending from the cover and electrically isolated from the first flange.   
     
     
         7 . The battery module of  claim 1 , wherein the first end battery cell and the second end battery cell are disposed in the same row. 
     
     
         8 . The battery module of  claim 1 , wherein the first end battery cell is disposed in the second row and the second end battery cell is disposed in the first row or the third row. 
     
     
         9 . The battery module of  claim 1 , comprising a tray with alignment features configured to align the plurality of battery cells and bus bars for electrically coupling the battery cells in a desired orientation relative to each other. 
     
     
         10 . The battery module of  claim 9 , wherein the tray comprises apertures formed therethrough, wherein the apertures are configured to expose a connection point between the bus bars and the battery cells to facilitate assembly of the battery module. 
     
     
         11 . The battery module of  claim 1 , comprising a lower structure configured to hold the plurality of battery cells therein, wherein the lower structure comprises a chamber for receiving gases vented from one or more of the plurality of battery cells. 
     
     
         12 . The battery module of  claim 1 , wherein at least one of the first terminal connection and the second terminal connection comprise a connection between the plurality of battery cells in the battery module and another plurality of battery cells disposed in an adjacent battery module. 
     
     
         13 . A battery module, comprising:
 a plurality of battery cells disposed in at least two rows, wherein the battery cells in adjacent rows are offset from one another;   wherein each of the plurality of battery cells comprises a cover, a first terminal, and a second terminal, wherein the first terminal extends from the cover outward in a direction perpendicular to a longitudinal axis of the battery cell and is coupled to a second terminal on an adjacent battery cell;   wherein the plurality of battery cells are oriented such that the first terminals corresponding to each pair of adjacent battery cells that are coupled together are offset by an angle of either approximately 60 degrees or approximately 120 degrees.   
     
     
         14 . The battery module of  claim 13 , wherein the first terminal of each of the plurality of battery cells is integrally formed with the corresponding cover. 
     
     
         15 . The battery module of  claim 13 , wherein the plurality of battery cells comprises twelve battery cells electrically coupled together. 
     
     
         16 . The battery module of  claim 13 , wherein the plurality of battery cells comprises thirteen battery cells electrically coupled together. 
     
     
         17 . The battery module of  claim 13 , wherein the plurality of battery cells are disposed in two rows and the first terminals corresponding to every pair of adjacent battery cells that are coupled together are offset by an angle of approximately 60 degrees. 
     
     
         18 . The battery module of  claim 13 , wherein the plurality of battery cells are disposed in three rows comprising a first row, a second row, and a third row. 
     
     
         19 . The battery module of  claim 18 , wherein the battery cells disposed in the first row are electrically coupled between battery cells in the first row and the second row, the battery cells disposed in the second row are electrically coupled between battery cells in the first row and the third row, and the battery cells disposed in the third row are electrically coupled between battery cells in the second row and the third row. 
     
     
         20 . The battery module of  claim 13 , wherein the plurality of battery cells comprises a first end battery cell at one end and a second end battery cell at an opposite end, wherein the first and second end battery cells are configured to be coupled to terminal connections of the battery module. 
     
     
         21 . The battery module of  claim 20 , wherein the terminal connections of the battery module comprise connections to battery cells disposed in adjacent battery modules within a battery system. 
     
     
         22 . A battery module, comprising:
 a plurality of battery cells disposed in at least two rows, wherein the battery cells in adjacent rows are offset from each other;   wherein each of the plurality of battery cells comprises a cover, a first terminal, and a second terminal, wherein the first terminal extends from the cover outward to be coupled to a second terminal on an adjacent battery cell;   wherein the plurality of battery cells are electrically coupled to each other in a zigzag pattern via the first and second terminals.   
     
     
         23 . The battery module of  claim 22 , wherein the plurality of battery cells are disposed in two rows, and wherein the plurality of battery cells are electrically coupled in a zigzag pattern that alternates between a battery cell in a first row and a battery cell in a second row. 
     
     
         24 . The battery module of  claim 22 , wherein the plurality of battery cells are disposed in three rows, and wherein the plurality of battery cells are electrically coupled in a zigzag pattern such that:
 a battery cell in a first row is coupled between an adjacent battery cell in the first row and a battery cell in the second row;   a battery cell in the second row is coupled between a battery cell in the first row and a battery cell in the third row; and   a battery cell in the third row is coupled between a battery cell in the second row and an adjacent battery cell in the third row.   
     
     
         25 . The battery module of  claim 22 , wherein the first terminal of each of the plurality of battery cells comprises a flange integrally formed with the cover. 
     
     
         26 . The battery module of  claim 25 , wherein the flange comprises a first portion that extends generally parallel to the central longitudinal axis of the housing, and a second portion that extends outwardly beyond the housing in a direction perpendicular to the central longitudinal axis of the housing. 
     
     
         27 . The battery module of  claim 22 , wherein the plurality of battery cells comprises twelve or thirteen cylindrical battery cells.