Modular Battery System and Components

Abstract

A battery cell connector for a battery module includes a pair of cantilevered arms and base portions that are linked at the base portion by a bridge. An interconnect board for connecting a plurality of battery cells includes a circuit board and a plurality of battery cell connectors. A battery block system includes a battery block that has a tray and a plurality of battery cells, and an interconnect board in mating relationships with the tray. A battery system includes first and second bus bars, a first and second pluralities of battery cells, and an interconnect board having a plurality of battery cell connectors linking the first and second plurality of battery cells.

1 . A battery block system, comprising:
 a) a tray for supporting a plurality of battery cells of a battery block, the first plurality of battery cells assembled within the tray, wherein first terminals of the plurality of battery cells are aligned in a first plane at a first end of the battery block and second terminals of each of the plurality of battery cells are aligned in a second plane; and   b) an interconnect board in mating relationship with the tray, the interconnect board including a plurality of battery cell connectors, each battery cell connector including a pair of terminals on opposite sides of the interconnect board that are in electrical communication with each other.   
     
     
         2 . The battery block system of  claim 1 , further including an interconnect board housing in mating relation to the interconnect board, the interconnect board housing also being in mateable relation to the tray at the first and second planes, whereby battery cells of a second battery block system can be connected in series to the battery cells of the battery block system through the battery cell connectors of the interconnect board. 
     
     
         3 . The battery block system of  claim 2 , further comprising a second battery block of a second tray for supporting battery cells of a second battery block at the interconnect board, wherein the battery cells of the first battery block are connected to the battery cells of the second battery block in series through the battery cell connectors. 
     
     
         4 . The battery block system of  claim 3 , further including a first bus bar connected to the first battery block opposite the interconnect board, the first bus bar connecting the plurality of battery cells of the first battery block in parallel at one of the first and second terminals, the first bus bar including a first battery system terminal. 
     
     
         5 . The battery block system of  claim 4 , further including a second bus bar connected to the second battery block opposite the interconnect board, the second bus bar connecting the plurality of battery cells of the second battery block in parallel at one of the first and second terminals, the second bus bar including a second battery system terminal. 
     
     
         6 . The battery block system of  claim 5 , wherein the interconnect board is a first interconnect board, and further including a third battery block and a second interconnect board interposed between the second and third battery blocks. 
     
     
         7 . The battery block system of  claim 1 , wherein at least a portion of the battery cell connectors include,
 a) a pair of cantilevered arms in spaced relation to each other, each arm having a base portion and a cantilevered portion, each base portion defining an edge portion, each cantilevered portion extending from its base portion, the cantilevered portions being splayed away from each other with distance from their respective base portions; and   b) a bridge linking the arms at the base of each arm, and supporting the arms in spaced relation to each other at the edge portion of each base portion, the base portions and the bridge together defining a U-shape in a plane that is transverse to a major longitudinal axis of at least one arm.   
     
     
         8 . The battery block system of  claim 1 , wherein the interconnect board further includes a circuit board including an electrically-conductive channel, wherein at least a portion of the battery cell connectors are in electrical communication with each other in parallel through the electrically-conductive channel. 
     
     
         9 . The battery block system of  claim 8 , wherein the circuit board includes at least one fusable link between at least a subset of the plurality of battery cell connectors. 
     
     
         10 . The battery block system of  claim 9 , wherein the at least one fusible link electrically isolates a battery cell in response to conducting a current greater than a threshold current. 
     
     
         11 . The battery block system of  claim 1 , further including an electrical circuit at, or in electrical communication with, the circuit board, that balances battery cells connected to the battery cell connectors. 
     
     
         12 . The battery block system of  claim 1 , further including an electrical circuit at, or in electrical communication with, the circuit board, that indicates voltage of at least a subset of the battery cells, wherein the electrical circuit is connected to the circuit board through a busbar having a voltage monitoring tab. 
     
     
         13 . The battery block system of  claim 1 , wherein the circuit board includes at least two terminals at least one of which is at an end of the circuit board. 
     
     
         14 . The battery block system of  claim 13 , further including a temperature circuit at, or in electrical communication with, the circuit board, wherein the temperature circuit indicates the temperature of a at least one of the battery cells. 
     
     
         15 . The battery block system of  claim 14 , wherein the temperature circuit is remote from the circuit board. 
     
     
         16 . The battery block system of  claim 15 , wherein the circuit board includes a terminal connection that is connected only to the temperature circuit. 
     
     
         17 . A battery system comprising:
 a) a first bus bar;   b) a first tray for supporting a plurality of battery cells connected in parallel to the first bus bar at respective first terminals of the battery cells;   c) a second bus bar;   d) a second tray for supporting a second plurality of battery cells connected in parallel to the second bus bar at respective first terminals of the second plurality of the battery cells, each of the battery cells of the first plurality of cells being connected in series to a respective battery cell of the second plurality of battery cells, thereby enabling electrical current flow between the first and second bus bars via plural series connections between the first and second pluralities of battery cells; and;   e) an interconnect board having a plurality of battery cell connectors that provides electrical connection between at least one pair of battery cells of the first and second pluralities of battery cells, the interconnect board further including an electrically-conductive channel connecting the plurality of battery cell connectors.   
     
     
         18 . The battery system of  claim 17 , wherein the bus bar includes a base plate component, and at least one cantilevered arm extending from the base plate. 
     
     
         19 . The battery system of  claim 18 , wherein the base plate and cantilevered arm are formed of a continuous material. 
     
     
         20 . The battery system of  claim 19 , wherein the cantilevered arm extends away from a plane defined by the base plate component. 
     
     
         21 . The battery system of  claim 20 , further including a spring plate between the base plate component and busbar, and wherein the spring plate defines spring tabs that abut, and provide, at least in part, a spring constant to the cantilevered arms. 
     
     
         22 . The battery system of  claim 17 , wherein at least a portion of the battery cell connectors include,
 a) a pair of cantilevered arms in spaced relation to each other, each arm having a base portion and a cantilevered portion, each base portion defining an edge portion, each cantilevered portion extending from its base portion, the cantilevered portions being splayed away from each other with distance from their respective base portions; and   b) a bridge linking the arms at the base of each arm, and supporting the arms in spaced relation to each other at the edge portion of each base portion, the base portions and the bridge together defining a U-shape in a plane that is transverse to a major longitudinal axis of at least one arm.   
     
     
         23 . The battery system of  claim 17 , wherein the interconnect board is a first interconnect board, and further including:
 a) a third plurality of battery cells interposed between the second plurality of battery and the second busbar; and   b) a second interconnect board connecting to each of the battery cells of the second plurality of battery cells in series with each of the battery cells of the third plurality of battery cells via a plurality of battery cell connectors, the second interconnect board including a second electrically-conductive channel connecting the plurality of battery cell connectors.   
     
     
         24 . A battery block system, comprising:
 a) a battery block that includes a tray for supporting a plurality of battery cells, the plurality of battery cells assembled within the tray, wherein first terminals of the plurality of battery cells are aligned in a first plane at a first end of the battery block and second terminals of each of the plurality of battery cells are aligned in a second plane at a second end of the battery block; and   b) two interconnector busbars.