ELECTRICAL CELL CONNECTION ARRANGEMENTS AND METHOD THEREOF
In an embodiment, a multi-cell hold-down mechanism is clamped over multiple contact tabs aligned with respective cell terminals (e.g., positive and/or negative cell terminal(s). While clamped, the contact tabs are securely welded to respective cell terminals through respective gaps in the multi-cell hold-down mechanism. In another embodiment, a multi-cell hold-down mechanism is clamped over an electrically conductive part that is coupled to multiple cell rims which are configured as negative cell terminals. A respective negative contact tab is welded to the electrically conductive part through a gap in the multi-cell hold-down mechanism. In another embodiment, three (or more) battery cell terminals (e.g., positive or negative terminals) are coupled to an electrically conductive bar that is welded to a contact tab of a busbar.
1 . An electrical cell connection arrangement for a battery module, comprising:
a first battery cell comprising a first terminal;
a second battery cell comprising a second terminal;
at least one busbar comprising a first contact tab aligned with the first terminal and a second contact tab aligned with the second terminal;
a multi-cell hold-down mechanism that comprises a first part clamped over the first contact tab and a second part clamped over the second contact tab,
wherein the first contact tab is welded to the first terminal through a first gap in the first part of the multi-cell hold-down mechanism, and
wherein the second contact tab is welded to the second terminal through a second gap in the second part of the multi-cell hold-down mechanism.
2 . The electrical cell connection arrangement of claim 1 ,
wherein the first and second terminals are positive terminals, or
wherein the first terminal is a positive terminal and the second terminal is a negative terminal.
3 . The electrical cell connection arrangement of claim 1 , wherein the first contact tab is a multi-terminal contact tab that is coupled to negative terminals of the first and second battery cells.
4 . The electrical cell connection arrangement of claim 1 , wherein the multi-cell hold-down mechanism is formed from an electrically insulative material.
5 . The electrical cell connection arrangement of claim 1 ,
wherein the multi-cell hold-down mechanism comprises a plurality of parts aligned with a respective plurality of positive terminals of a respective plurality of battery cells, and
wherein the multi-cell hold-down mechanism comprises a single part aligned with a respective plurality of negative terminals of the respective plurality of battery cells.
6 . A method of assembling a battery module, comprising:
aligning a first contact tab of at least one busbar with a first terminal of a first battery cell;
aligning a second contact tab of the at least one busbar with a second terminal of a second battery cell;
clamping a multi-cell hold-down mechanism onto the first and second contact tabs such that the first and second contact tabs are secured to the first and second terminals;
welding, during the clamping, the first contact tab to the first terminal through a first gap in a first part of the multi-cell hold-down mechanism; and
welding, during the clamping, the second contact tab to the second terminal through a second gap in a second part of the multi-cell hold-down mechanism.
7 . The method of claim 6 ,
wherein the first and second terminals are positive terminals, or
wherein the first terminal is a positive terminal and the second terminal is a negative terminal.
8 . The method of claim 6 ,
wherein the first contact tab is a multi-terminal contact tab,
wherein the welding of the first contact tab welds the first contact tab to negative terminals of the first and second battery cells.
9 . The method of claim 6 , wherein the multi-cell hold-down mechanism is formed from an electrically insulative material.
10 . The method of claim 6 ,
wherein the clamping aligns a plurality of parts of the multi-cell hold-down mechanism with a respective plurality of positive terminals of a respective plurality of battery cells, and
wherein the clamping aligns a single part of the multi-cell hold-down mechanism with a respective plurality of negative terminals of the respective plurality of battery cells.
11 . An electrical cell connection arrangement for a battery module, comprising:
a first battery cell comprising a first positive terminal and a first cell rim arranged as a first negative terminal;
a second battery cell comprising a second positive terminal and a second cell rim arranged as a second negative terminal;
an electrically conductive part coupled to the first and second cell rims;
a busbar comprising a negative contact tab; and
a multi-cell hold-down mechanism that is clamped over the electrically conductive part,
wherein the negative contact tab is welded to a welding interface of the electrically conductive part that is exposed through a gap in the multi-cell hold-down mechanism.
12 . The electrical cell connection arrangement of claim 11 , further comprising:
a third battery cell comprising a third positive terminal and a third cell rim arranged as a third negative terminal,
wherein the electrically conductive part is further coupled to the third cell rim.
13 . The electrical cell connection arrangement of claim 11 ,
wherein the electrically conductive part includes a flat section in direct contact with the first and second cell rims, and
wherein the welding interface is arranged as an electrically conductive pin.
14 . The electrical cell connection arrangement of claim 13 , wherein part of the multi-cell hold-down mechanism is wrapped around the electrically conductive pin.
15 . The electrical cell connection arrangement of claim 13 ,
wherein the flat section comprises a first welding area exposed by the multi-cell hold-down mechanism that is welded to the first negative terminal, and
wherein the flat section comprises a second welding area exposed by the multi-cell hold-down mechanism that is welded to the second negative terminal.
16 . The electrical cell connection arrangement of claim 13 , wherein the flat section comprises sheet metal and the electrically conductive pin comprises aluminum or copper.
17 . The electrical cell connection arrangement of claim 11 , wherein the multi-cell hold-down mechanism is formed from an electrically insulative material.
18 . The electrical cell connection arrangement of claim 11 ,
wherein the first positive terminal is encircled by the first cell rim, and
wherein the multi-cell hold-down mechanism comprises a first section arranged as a wall between the first positive terminal and the first cell rim.
19 . The electrical cell connection arrangement of claim 18 ,
wherein the second positive terminal is encircled by the second cell rim, and
wherein the multi-cell hold-down mechanism comprises a second section arranged as a wall between the second positive terminal and the second cell rim.
20 . The electrical cell connection arrangement of claim 11 , wherein the multi-cell hold-down mechanism and the electrically conductive part are pre-assembled with the first and second battery cells before the battery module is assembled.
21 . An electrical cell connection arrangement for a battery module, comprising:
a first battery cell comprising a first terminal;
a second battery cell comprising a second terminal;
a third battery cell comprising a third terminal;
an electrically conductive part coupled to the first, second and third terminals; and
a busbar comprising a contact tab that is welded to a welding interface of the electrically conductive part.
22 . The electrical cell connection arrangement of claim 21 , wherein the welding interface is an electrically conductive pin.
23 . The electrical cell connection arrangement of claim 21 ,
wherein the first, second and third terminals are negative terminals, or
wherein the first, second and third terminals are positive terminals.
24 . The electrical cell connection arrangement of claim 21 , wherein the electrically conductive part comprises sheet metal.
25 . The electrical cell connection arrangement of claim 21 , wherein the electrically conductive part is pre-assembled with the first, second and third battery cells before the battery module is assembled.
26 . The electrical cell connection arrangement of claim 21 , wherein the electrically conductive part is pre-assembled with an insulative foil that is separate from the first, second and third battery cells before the battery module is assembled.