CIRCUITRY HARNESS AND PASS THROUGH FOR LEAD WIRES OF A BATTERY MODULE

1 . A battery module, comprising:

a housing;

electrochemical cells disposed in the housing and electrically coupled together via a plurality of bus bars;

two or more sensors in electrical communication with the plurality of bus bars and two or more leads respectively coupled with the two or more sensors and extending away from the two or more sensors;

a bundle mechanism that bundles the two or more leads together in a bundle;

a pass through opening of the housing sized and positioned to accommodate the bundle of two or more leads and the bundle mechanism passing therethrough from a first side of the housing proximate which the plurality of bus bars is disposed to a second side of the housing; and

a printed circuit board (PCB) disposed on the second side of the housing and configured to receive the bundle of two or more leads.

2 . The battery module of claim 1 , wherein the electrochemical cells are prismatic electrochemical cells, lithium-ion (Li-ion) electrochemical cells, or a combination thereof.

3 . The battery module of claim 1 , comprising a bus bar carrier on which the plurality of bus bars is disposed, wherein the first side of the housing comprises an opening configured to receive the bus bar carrier such that the bus bar carrier is disposed over the electrochemical cells and enables electrical communication between terminals of the electrochemical cells and the plurality of bus bars.

4 . The battery module of claim 3 , wherein a first face of the bus bar carrier faces the electrochemical cells, and wherein the plurality of bus bars is disposed on a second face of the bus bar carrier opposite to the first face.

5 . The battery module of claim 4 , wherein the bus bar carrier comprises retaining features disposed on the second face of the bus bar carrier, wherein the retaining features are configured to retain the two or more leads proximate to the second face of the bus bar carrier, and wherein the retaining features are positioned such that the retaining features guide the two or more leads from the two or more sensors toward the pass through opening.

6 . The battery module of claim 3 , wherein a face of the bus bar carrier faces the electrochemical cells and the plurality of bus bars is disposed on the face.

7 . The battery module of claim 1 , wherein the pass through opening is disposed through the first side of the housing, through the second side of the housing, or both.

8 . The battery module of claim 1 , wherein the bundle mechanism comprises a hollow tube that receives the two or more leads.

9 . The battery module of claim 1 , wherein the first side and the second side are substantially orthogonal to one another.

10 . The battery module of claim 1 , wherein at least one of the two or more sensors is a voltage sensor, wherein at least one of the two or more sensors is a temperature sensor, or a combination thereof.

11 . The battery module of claim 1 , wherein at least one of the two or more sensors is configured to sense a first operating condition through a minor bus bar of the plurality of bus bars, wherein at least one of the two or more sensors is configured to sense a second operating condition through a major bus bar of the plurality of bus bars, or a combination thereof.

12 . A battery module, comprising:

a bus bar carrier;

a plurality of bus bars mounted on the bus bar carrier and configured to electrically couple electrochemical cells of the battery module;

a plurality of sensors in electrical communication with the plurality of bus bars;

a printed circuit board (PCB);

a plurality of sensor leads extending from the plurality of sensors and toward the PCB;

a housing comprising a first side, a second side substantially orthogonal to the first side, and a pass through opening in the first side, the second side, or both; and

a harness configured to retain the plurality of sensor leads in a bundle that extends through the pass through opening and toward the PCB.

13 . The battery module of claim 12 , comprising the electrochemical cells, wherein the electrochemical cells are prismatic electrochemical cells, lithium-ion (Li-ion) electrochemical cells, or a combination thereof.

14 . The battery module of claim 12 , wherein the first side is an open side or comprises an opening configured to receive the bus bar carrier.

15 . The battery module of claim 12 , wherein the bus bar carrier comprises a first face that faces the electrochemical cells and a second face opposite to the first face, wherein the plurality of bus bars is disposed on the second face.

16 . The battery module of claim 12 , wherein the bus bar carrier comprises snap-in retaining features disposed on the bus bar carrier, configured to retain the plurality of sensor leads proximate to the bus bar carrier, and configured to define a path from the plurality of sensors and toward the pass through opening.

17 . The battery module of claim 12 , wherein the harness comprises a hollow tube configured to receive the plurality of sensor leads.

18 . A battery module, comprising:

a plastic housing;

a plurality of electrochemical cells stacked on an inside of the plastic housing such that a plurality of terminals extends from the plurality of electrochemical cells into an opening in a first side of the plastic housing;

a bus bar carrier disposed in the opening of the first side of the plastic housing such that a first surface of the bus bar carrier faces the plurality of electrochemical cells, wherein the bus bar carrier comprises the first surface and a second surface opposite to the first surface;

a plurality of bus bars disposed on the second surface of the bus bar carrier and configured to interface with the plurality of terminals to electrically couple the plurality of electrochemical cells;

at least two sensors in electrical communication with the plurality of bus bars and at least two sensor leads corresponding with, and extending from, the at least two sensors;

a harness configured to bundle the at least two sensor leads into a bundle;

a pass through opening in the plastic housing sized to accommodate the harness and configured to enable the bundle of two or more lead sensors to extend to a second side of the plastic housing adjacent to the first side of the plastic housing.

19 . The battery module of claim 18 , comprising:

a cover disposed over the second side of the plastic housing to enclose a cove between the second side of the housing and the cover; and

a printed circuit board (PCB) disposed in the cove and configured to receive the bundle of lead wires.

20 . The battery module of claim 18 , wherein the pass through opening is disposed through the first side of the housing, the second side of the housing, or both.

21 . The battery module of claim 18 , wherein a first sensor of the at least two sensors is in electrical communication with a minor bus bar of the plurality of bus bars, a second sensor of the at least two sensors is in electrical communication with a major bus bar of the plurality of bus bars, and the first and second sensors are configured to sense first and second operating conditions through the minor and major bus bars, respectively.

22 . The battery module of claim 21 , wherein the first operating condition comprises voltage or temperature, wherein the second operating condition comprises voltage or temperature, or a combination thereof.

23 . The battery module of claim 18 , wherein the plurality of electrochemical cells is a plurality of prismatic lithium-ion (Li-ion) electrochemical cells.

24 . The battery module of claim 18 , wherein the second side of the plastic housing is substantially orthogonal to the first side of the plastic housing.