IP Library › Granted Patent US 12671152

Granted Patent B2

US 12671152 · App. 18/176,762 · Granted Jun 30, 2026

Cell stack-to-cell stack connections for traction battery packs

Inventors: Alex Revels (Canton, MI); Brock Dunlap (Dearborn, MI); Deanna Marie Winton Hoffman (Ann Arbor, MI); Michael E. Reibling (Sterling Heights, MI)

Assignee: FORD GLOBAL TECHNOLOGIES, LLC

H01M50/547 H01M50/342 H01M50/505 H01M50/566 H01M50/567 H01M2220/20

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Quick Facts

Patent No.: US 12671152
App. No.: 18/176,762
Granted: Jun 30, 2026
Kind: B2

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

Electrical connection systems are provided for electrically connecting cell stacks of a traction battery pack. Exemplary electrical connections systems may include a first high voltage terminal of a first cell stack and a second high voltage terminal of a second cell stack. The first high voltage terminal may be mounted to a first cross-member beam of the first cell stack, and the second high voltage terminal may be mounted to a second cross-member beam of the second cell stack. The first high voltage terminal may be arranged and coupled to the second high voltage terminal to electrically connect the first cell stack and the second cell stack.

Claims (40)

1 . A traction battery pack, comprising:

a first cell stack including a first cross-member beam;

a first high voltage terminal mounted to the first cross-member beam;

a second cell stack including a second cross-member beam;

a second high voltage terminal mounted to the second cross-member beam;

the first cross-member beam and the second cross-member beam are immediately adjacent and form a cross-member assembly disposed between the first cell stack and the second cell stack; and

wherein the first high voltage terminal and the second high voltage terminal are directly joined to one another at the cross-member assembly to electrically connect the first cell stack and the second cell stack.

2 . The traction battery pack as recited in claim 1 , wherein a mechanical fastener couples the first high voltage terminal to the second high voltage terminal.

3 . The traction battery pack as recited in claim 2 , wherein the first high voltage terminal includes a first electrical contact portion and the second high voltage terminal includes a second electrical contact portion arranged side-by-side to the first electrical contact portion along a vertical axis, and further wherein the mechanical fastener extends along the vertical axis to couple the first high voltage terminal to the second high voltage terminal.

4 . The traction battery pack as recited in claim 2 , wherein the first high voltage terminal includes a first electrical contact portion and the second high voltage terminal includes a second electrical contact portion arranged side-by-side to the first electrical contact portion along a horizontal axis, and further wherein the mechanical fastener extends along the horizontal axis to couple the first high voltage terminal to the second high voltage terminal.

5 . The traction battery pack as recited in claim 1 , wherein a weld bead or a bus bar couples the first high voltage terminal to the second high voltage terminal.

6 . The traction battery pack as recited in claim 1 , wherein the first high voltage terminal includes a male portion configured to engage a female portion of the second high voltage terminal to electrically connect the first cell stack and the second cell stack.

7 . The traction battery pack as recited in claim 6 , wherein the female portion includes a first arm, a second arm, and a slot extending between the first arm and the second arm, and further wherein the male portion is received within the slot to electrically connect the first cell stack and the second cell stack.

8 . The traction battery pack as recited in claim 1 , comprising a venting passageway disposed between the first cross-member beam and the second cross-member beam, wherein an enclosure cover provides a vertically upper side of the venting passageway, and an enclosure tray or a heat exchanger plate provides a vertically lower side of the venting passageway.

9 . The traction battery pack as recited in claim 8 , wherein a vent opening formed through the first cross-member beam establishes a venting path between the first cell stack and the venting passageway.

10 . The traction battery pack as recited in claim 1 , wherein the first cell stack includes a plurality of battery cells supported between the first cross-member beam and a third cross-member beam, and the second cell stack includes another plurality of battery cells supported between the second cross-member beam and a fourth cross-member beam.

11 . The traction battery pack as recited in claim 1 , wherein the first high voltage terminal includes a base portion mounted to the first cross-member beam and an electrical contact portion that extends at a transverse angle away from the base portion.

12 . The traction battery pack as recited in claim 1 , wherein the first high voltage terminal includes a first electrical contact portion having a first aperture and the second high voltage terminal includes a second electrical contact portion having a second aperture that is coaxially aligned with the first aperture.

13 . The traction battery pack as recited in claim 1 , wherein the first cross-member beam and the second cross-member beam each include a beam body and a reinforcement section that extends inside the beam body.

14 . The traction battery pack as recited in claim 13 , wherein the reinforcement section includes a pultrusion.

15 . The traction battery pack as recited in claim 13 , wherein the beam body includes a cell tab opening sized to receive a tab terminal of a battery cell of the first cell stack or the second cell stack.

16 . The traction battery pack as recited in claim 10 , wherein the plurality of battery cells of the first cell stack are stacked horizontally between the first cross-member beam and the third cross-member beam and longitudinally between a first compression plate and a second compression plate.

17 . A traction battery pack, comprising:

a first cell stack;

a second cell stack;

a cross-member assembly arranged between the first cell stack and the second cell stack and including a first cross-member beam of the first cell stack and a second cross-member beam of the second cell stack; and

an electrical connection system located at the cross-member assembly and configured to electrically connect the first cell stack and the second cell stack, the electrical connection system including:

a first high voltage terminal mounted to the first cross-member beam, a second high voltage terminal mounted to the second cross-member beam, and a mechanical fastener that joins the first high voltage terminal and the second high voltage terminal by extending through coaxially aligned apertures of the first and second high voltage terminals to directly join them at the cross-member assembly.

18 . The traction battery pack as recited in claim 17 , wherein the mechanical fastener includes a weld bead, wherein the weld bead joins a bus bar to the first high voltage terminal and the second high voltage terminal.

19 . The traction battery pack as recited in claim 17 , wherein the mechanical fastener includes a bolt and nut assembly.

20 . A traction battery pack, comprising:

a first cell stack including a first plurality of battery cells;

a second cell stack including a second plurality of battery cells;

the first cross-member beam includes a first plurality of cell tab openings sized to receive tab terminals of the first plurality of battery cells, and the second cross-member beam includes a second plurality of cell tab openings sized to receive tab terminals of the second plurality of battery cells; and

an electrical connection system located at the cross-member assembly and configured to electrically connect the first cell stack and the second cell stack, the electrical connection system including:

a first high voltage terminal mounted to a first surface of the first cross-member beam, the first surface facing toward the second cross-member beam;

a second high voltage terminal mounted to a second surface of the second cross-member beam, the second surface facing toward the first cross-member beam;

wherein a first aperture of the first high voltage terminal is coaxially aligned with a second aperture of the second high voltage terminal when the first and second cross-member beams are arranged immediately adjacent one another to establish the cross-member assembly; and

a bolt and nut assembly extending through the coaxially aligned first and second apertures along a fastening axis to directly join the first high voltage terminal and the second high voltage terminal at the cross-member assembly and establish an electrical connection between the first cell stack and the second cell stack.