Single conductor layer cell-to-cell interconnect for electric vehicle power supply or other power supply
An apparatus includes an interconnect assembly configured to receive and retain multiple batteries. The interconnect assembly includes a retainer configured to receive portions of the batteries, a conductive interconnect layer carried by the retainer, and a terminal bar configured to transport electrical currents to and from the conductive interconnect layer. The conductive interconnect layer includes a conductive layer positioned between first and second insulative layers, where the conductive layer has a first thickness that is less than a thickness of the terminal bar. The conductive layer includes multiple interconnects configured to be coupled to cathodes and anodes of the batteries.
1 . An interconnect assembly configured to receive and retain a plurality of batteries, the interconnect assembly comprising:
a plurality of electrically coupled sub-assemblies, each comprising
a retainer configured to receive portions of the plurality of batteries,
a conductive interconnect layer carried by the retainer and comprising a conductive layer carried between first and second insulative layers, the conductive layer having a plurality of interconnects configured to couple to the plurality of the batteries, and
a terminal bar configured to transport electrical currents to and from the conductive interconnect layer; and
a hot plate electrical conductor electrically coupled to the plurality of sub-assemblies, the hot plate electrical conductor having an opening therein configured to cause a path of least electrical resistance through the plurality of sub-assemblies to pass through a middle portion of the hot plate electrical conductor.
2 . The interconnect assembly of claim 1 , wherein each conductive layer further comprises a plurality of series connectors, each configured to electrically couple the plurality of batteries; and wherein the plurality of interconnects extend from the plurality of series connectors to the plurality of batteries and electrically couple the plurality of series connectors to the plurality of batteries.
3 . The interconnect assembly of claim 2 , wherein each conductive layer further comprises a plurality of balancing conductors, each configured to transport electrical current between the plurality of series connectors.
4 . The interconnect assembly of claim 2 , wherein each of the plurality of series connectors is configured to one of electrically couple two batteries in two adjacent rows of batteries; and electrically couple the plurality of batteries in a plurality of rows of batteries each separated by an offset row of batteries.
5 . The interconnect assembly of claim 1 , wherein the conductive layer comprises a plurality of conductive structures, a first conductive structure thereof comprising a first interconnect from among the plurality of interconnects coupled to cathodes of the plurality of batteries, a second conductive structure of the plurality thereof comprising a second interconnect from among the plurality thereof coupled to anodes of the plurality of batteries, and a third conductive structure of the plurality thereof between the first and second conductive structures and comprising a third interconnect from among the plurality thereof coupled to cathodes of the plurality of batteries.
6 . The interconnect assembly of claim 5 , wherein the plurality of conductive structures are coupled to different sets of parallel-coupled ones of the plurality of batteries; and wherein the plurality of conductive structures are coupled in series with one another.
7 . The interconnect assembly of claim 1 , wherein each terminal bar comprises a terminal connector configured to electrically couple the interconnect assembly to a larger system; and wherein each terminal bar has a plurality of openings therein.
8 . The interconnect assembly of claim 1 , further comprising a coldplate between the plurality of sub-modules and having a plurality of recesses therein to receive additional portions of the plurality of batteries.
9 . The interconnect assembly of claim 1 , further comprising a sensor assembly including a ribbon cable carrying a thermistor and a plurality of voltage contact points, the thermistor configured to sense a temperature in the interconnect assembly; and the plurality of voltage contact points configured to be coupled to conductive tabs of each conductive interconnect layer and receive voltages at the conductive tabs.
10 . The apparatus of claim 9 , wherein each retainer comprises a curved projection configured to push the thermistor into a side of one of the plurality of batteries.
11 . The apparatus of claim 1 , wherein each retainer comprises a plurality of walled structures configured to contact the plurality of batteries; at least some of the plurality of walled structures comprising walls having contact pads extending inward from the walls and configured to contact the batteries.
12 . The apparatus of claim 11 , wherein the contact pads are arranged such that each wall of the plurality of walled structures has a single contact pad.
13 . The interconnect assembly of claim 1 , wherein each terminal bar has an opening therein configured to cause a path of least electrical resistance through the plurality of sub-assemblies to pass through a middle portion of the hot plate electrical conductor.