Bus bars for battery packs
A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in one of a series connection, a parallel connection or a series and parallel connection.
1. A battery pack comprising:
a cell holder;
a plurality of bus bars positioned at a first end of the cell holder; and
a plurality of battery cells arranged in the cell holder with each of the plurality of battery cells having a first terminal proximate to the plurality of bus bars and a portion of a second terminal proximate to the plurality of bus bars, the first terminal and the portion of the second terminal electrically coupled to the plurality of bus bars at a first end of the battery cell such that the plurality of battery cells is in one of a parallel connection, a series connection or a parallel and series connection;
the plurality of bus bars comprising:
a first planar bus bar directly electrically coupled to a first one of the first terminals by a first wire;
a second planar bus bar separated from and coplanar with the first planar bus bar, the second planar bus bar directly electrically coupled to a first one of the second terminals by a second wire and to a second one of the first terminals by a third wire; and
a third bus bar directly electrically coupled to a second one of the second terminals by a fourth wire, the third bus bar disposed over an insulator layer, the insulator layer disposed over the first planar bus bar and the second planar bus bar, wherein the third bus bar is coupled to the second one of the second terminals by the fourth wire extending through aligned apertures of the first planar bus bar, the insulator layer and the third bus bar.
2. The battery pack of claim 1 wherein the plurality of bus bars includes the first planar bus bar, the insulator layer and the third bus bar, in a stacked parallel arrangement.
3. The battery pack of claim 2 , wherein the aperture of the first planar bus bar and the aperture of the third bus bar are larger than the aperture of the insulator layer.
4. The battery pack of claim 1 , wherein each wire electrically coupling the plurality of bus bars to the first terminals or the portion of the second terminals of the battery cells has a length less than a length of each battery cell.
5. The battery pack of claim 1 , wherein the battery pack is integrated into a rechargeable vehicle.
6. The battery pack of claim 1 , further comprising a heat sink attached to an opposed second end of the cell holder.
7. The battery pack of claim 1 , wherein the plurality of battery cells includes a first group of battery cells that are coupled in parallel, and includes a second group of battery cells that are coupled in parallel, which is in series with the first group.