WO2024138193A1

WO2024138193A1 - Battery module systems, assemblies, and methods of manufacture

Info

Publication number: WO2024138193A1
Application number: PCT/US2023/085819
Authority: WO
Inventors: Joseph James; Michael Armstrong
Original assignee: Electric Power Systems, Inc.
Priority date: 2022-12-22
Filing date: 2023-12-22
Publication date: 2024-06-27

Abstract

A battery module can comprise a housing and a plurality of cells disposed within the housing. The housing can be designed and configured to prevent thermal runaway propagation to an adjacent battery module of a battery system including a plurality of the battery module. Stated another way, the battery module can be hermetically sealed from an external environment with the exclusion of a vent port that routes any gas or debris from a thermal runaway event away from the battery module.

Description

TITLE: BATTERY MODULE SYSTEMS, ASSEMBLIES, AND

METHODS OF MANUFACTURE

INVENTOR: JOSEPH JAMES

MICHAEL ARMSTRONG

ASSIGNEE : ELECTRIC POWER SYSTEMS, INC.

FIELD

[0001] The present disclosure generally relates to apparatus, systems, and methods for providing interconnected battery modules.

BACKGROUND

[0002] The subject matter discussed in the background section should not be assumed to be prior art merely because of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously- recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may be inventions.

[0003] A battery module, for purposes of this disclosure, includes a plurality of electrically connected cell-brick assemblies. These cell-brick assemblies may, in turn, include a parallel, series, or combination of both, collection of electrochemical or electrostatic cells hereafter referred to collectively as "cells'’, that can be charged electrically to provide a static potential for power or released electrical charge when needed. When cells are assembled into a battery module, the cells are often linked together through metal strips, straps, wires, bus bars, etc., that are welded, soldered, or otherwise fastened to each cell to link them together in the desired configuration.

[0004] A cell may be comprised of at least one positive electrode and at least one negative electrode. One common form of such a cell is the well-known secondary⁷ cells packaged in a cylindrical metal can or in a prismatic case. Examples of chemistry used in such secondary cells are lithium cobalt oxide, lithium manganese, lithium iron phosphate, nickel cadmium, nickel zinc, and nickel metal hydride. Such cells are mass produced, driven by an ever-increasing consumer market that demands low-cost rechargeable energy for portable electronics. [0005] Custom batten- solutions may be expensive for a respective customer. Custom battery solutions may include longer lead times due to the customization desired by the customer. Custom battery solutions may be engineering intensive to meet desired characteristics by a customer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The subject mater of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the following detailed description and claims in connection with the following drawings. While the drawings illustrate various embodiments employing the principles described herein, the drawings do not limit the scope of the claims.

[0007] FIG. 1 illustrates a schematic view of an electrically powered aircraft, in accordance with various embodiments.

[0008] FIG. 2 illustrates an exploded view of a batery' module for use in a battery system of the electrically powered aircraft from FIG. 1, in accordance with various embodiments.

[0009] FIG. 3 illustrates various views of the batery module from FIG. 2 during an assembly of the batery' module, in accordance with various embodiments.

[0010] FIG. 4 illustrates cross-sectional view of a vent port connection of a battery system, in accordance with various embodiments.

[0011] FIG. 5 illustrates a cross-sectional view of an electrical connector, in accordance yvith various embodiments.

[0012] FIG. 6 illustrates a cross-sectional view of an electrical connector, in accordance yvith various embodiments.

[0013] FIG. 7 illustrates an exploded view of the electrical connector from FIG. 5, in accordance yvith various embodiments.

[0014] FIG. 8 illustrates an exploded view of the electrical connector from FIG. 6, in accordance yvith various embodiments.

[0015] FIG. 9 illustrates a cross-sectional view of a communications connector, in accordance yvith various embodiments.

[0016] FIG. 10 illustrates a cross-sectional view of a communications connector, in accordance with various embodiments.

[0017] FIG. 11 illustrates an exploded view of the communications connector from FIG. 9, in accordance with various embodiments.

[0018] FIG. 12 illustrates an exploded view of the communications connector from FIG. 10, in accordance with various embodiments.

[0019] FIG. 13 illustrates a side view of a connector shield of a batery module, in accordance with various embodiments. [0020] FIG. 14 illustrates a side view of a connector shield of a battery module, in accordance with various embodiments.

[0021] FIG. 15 illustrates a perspective view of a portion of a battery system, in accordance with various embodiments. [0022] FIG. 16 illustrates an electrical connection between electrical connectors of adjacent battery modules, in accordance with various embodiments.

[0023] FIG. 17 illustrates an electrical connection between adjacent communications connectors of adjacent battery modules, in accordance with various embodiments.

DETAILED DESCRIPTION

[0024] The following detailed description of various embodiments herein refers to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to “a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.

[0025] Disclosed herein is a battery system adaptable to power an electrically powered vehicle (e.g., an electrically powered aircraft, an electrically powered boat, an electrically powered submarine, or the like). The battery system comprises a plurality of battery modules coupled together to form an energy storage device. Each of the plurality of battery modules are configured to be electrically coupled to an adjacent of the plurality of battery modules via electrical connectors to form an electrical path between modules. Similarly, each of the plurality of battery modules are configured to form a communications path via communications connectors. In this regard, each of the plurality' of battery modules are designed and configured for an ease of assembly. Stated another way, by having a connector interface and a communications interface that can be created in response to sliding a first electrical connector (e.g., a male connector) and a communications connector (e.g.. a male connector) of a first battery module toward and into an electrical connector (e.g., a female connector) and a communications connector (e.g., a female connector) of a second battery module, an assembly of the battery system can be performed in a quick and efficient manner relative to typical battery systems for electrically-powered vehicles. [0026] In various embodiments, the battery module disclosed herein includes a housing with a plurality’ of cells disposed therein. In various embodiments, the housing is configured to prevent thermal runaway propagation from the battery module to an adj acent battery' module of the battery system. Stated another way, thermal runaway may propagate within a battery' module disclosed herein; however, the housing of the battery module is configured to contain the event within a single battery module of the battery system. In various embodiments, the housing comprises a vent port. In various embodiments, excluding the vent port, an internal cavity of the battery module that is defined by the housing is hermetically sealed from an external environment. Stated another way, the housing disclosed herein forms an air-tight enclosure around the plurality of cells disposed therein, in accordance with various embodiments. In various embodiments, the gases and/or ejecta from a thermal runaway event are ejected through the vent port into a vent system (e.g., an exhaust duct, an exhaust tube, or the like). Stated another way, since the housing is hermetically sealed excluding the vent port, there are no leakage paths where gases from a thermal runaway event may escape, and accordingly, the gases are directed only through the vent port.

[0027] Referring now to FIG. 1 , a schematic view of an aircraft 100 with an electric propulsion system 101 is illustrated, in accordance with various embodiments. In various embodiments, the electric propulsion system 101 comprises a propulsor 110 and a propulsor 120. In various embodiments, propulsor 110 and the propulsor 120 each comprise and electric motor and a propeller. For example, the propulsor 1 10 comprises an electric motor 111 and a propeller 112, and the propulsor 120 comprises an electric motor 121 and a propeller 122. The electric motor 111 is configured to drive a propeller 112, and the electric motor 121 is configured to drive the propeller 122. The propulsor 120 is disposed on a wing 103 of the aircraft 100, and the propulsor 110 is disposed on a w ing 104 of the aircraft 100. In various embodiments, the propellers 112, 122 can be variable pitch propellers or fixed pitch propellers, the present disclosure is not limited in this regard. Although described herein with an aircraft having one propulsor per wing, in various other embodiments, any number of propulsors per wing may be used, a propulsor may be disposed on a nose of the aircraft 100, or the like and still be within the scope of this disclosure.

[0028] In various embodiments, the electric propulsion system 101 further comprises an electrical system 140. The electrical system 140 comprises a battery system 150 and a battery system 160. The battery system 150 can be configured to power the electric motor 121 and the battery system 160 can be configured to power the electric motor 111. The battery system 150 and the battery’ system 160 can be independent battery systems, in accordance with various embodiments. In various embodiments, the battery system 150 is disposed aft of the propulsor 120, and the battery system 160 is disposed aft of the propulsor 130. The battery system 150 can be disposed in a nacelle of the wing 103 and the battery system 160 can be disposed in a nacelle of the wing 104.

[0029] Although described herein with respect to an aircraft 100, the present disclosure is not limited in this regard. For example, the battery’ module 200 and the battery systems 150, 160 can be utilized in other electric vehicle applications, such as land vehicles (e.g.. trucks, cars, etc.), sea vehicles (e.g.. boats, submersibles, submarines, etc.), or air vehicles (e.g., aircraft 100) and still be within the scope of this disclosure.

[0030] Referring now to FIG. 2, a perspective exploded view of the battery module 200 is illustrated, in accordance with various embodiments. The battery module 200 comprises a housing 210 and a cell-brick assembly 220 disposed therein. In various embodiments, the cell-brick assembly 220 comprises a plurality of cells 222 (e.g., prismatic cells, pouch cells, cylindrical cells, or the like) disposed within the housing 210.

[0031] In various embodiments, the housing 210 (e.g.. an enclosure assembly) comprises a plurality of sidewalls 290 that form, in an assembled state, a generally cuboid shape (e.g., as shown in FIG. 3 and described further herein). The plurality' of sidew alls 290 can include lateral sidew alls (e.g., sidewall 291 and sidewall 292), broad sidewalls (e.g.. sidewall 293 and sidewall 294), atop sidewall (e.g., lid 295) and a bottom sidewall (e.g., bottom panel 296). The sidewall 291 is disposed opposite the sidewall 292. Stated another way, the sidewall 291 is spaced apart longitudinally^ (i.e., in the Z-direction) from the sidewall 292, the sidewall 291 defines a first longitudinal side of the housing 210, and the side wall 292 defines a second longitudinal side of the housing 210. In a similar manner, the sidewall 293 is disposed opposite the sidewall 294. Stated another way, the sidewall 293 is spaced apart laterally (i.e., in the X-direction) from the sidew all 294, the sidew all 293 defining a first lateral side of the housing 210, and the sidewall 294 defining a second lateral side of the housing 210. Similarly, the bottom panel 296 is disposed opposite the lid 295. Stated another way, the lid 295 is spaced apart vertically (i.e., in the Y-direction) from the bottom panel 296, the lid 295 defines a first vertical side (e.g., atop side) of the housing 210, and the bottom panel 296 defines a second vertical side (e.g., a bottom side) ofthe housing 210.

[0032] In various embodiments, with brief reference to FIG. 3, with like numerals depicting like elements, the generally cuboid shape 310 of the housing 210 includes a plurality of seams 301 (e.g., seams 311, 312, 313, 321, 322, 323, 331, 341, 351, 352. 353, 354). Each of the plurality of seams can at least partially define an edge of the housing 210. In various embodiments all the edges of the housing 210 are defined by a respective seam. In this regard, each edge of the generally cuboid shape 310 can be hermetically sealed by fusing a first of the plurality of sidewalls to a second of the plurality of sidewalls, in accordance with various embodiments. In various embodiments, each of the plurality of seams is formed by a first of the plurality of sidewalls being fused to a second of the plurality of sidewalls. Stated another way, a joint is formed between each pair of adjacent sidewalls, such as a weld joint, a braze joint, or the like. For example, the sidewall 293 can be welded (e.g., laser welded) to the sidewall 291 to form the seam 311. In this regard, the seam 311 formed by fusing adjacent sidewalls (e.g., sidewall 291 and sidewall 293) together can form a hermetic seal (i.e., an air-tight seal) along the seam 311. In various embodiments, each of the plurality of seams 301 of FIG. 3 can be formed as described herein. For the sake of brevity, each seam will not be described, and it should be recognized that each seam can be formed as described with respect to the seam 311.

[0033] In various embodiments, each of the plurality' of sidewalls 290 comprises a flat plate (e.g., a sheet metal plate). For example, each of the plurality of sidewalls 290 can comprise a sheet metal plate that is commercially pure titanium (e.g., a composition greater than 99% titanium, or greater than 99.5% titanium, or greater than 99.9% titanium), or a sheet metal plate that is a titanium alloy, in accordance with various embodiments.

[0034] Typically, housing materials for battery modules utilized in aviation type applications are made from aluminum or a non-metal, such as carbon fiber composite, thermoplastics, etc. A main driver in aviation type applications is weight and cost. Accordingly, aluminum, carbon fiber, and thermoplastics are lighter than pure titanium, or a titanium alloy. However, by utilizing pure titanium, or a titanium alloy for the housing 210, a strength to weight ratio of the housing 210 can be greatly increased relative to aluminum, which can facilitate the housing of heavier battery modules. In various embodiments, thermal properties of the housing 210 can be significantly improved by utilizing titanium relative to aluminum. For example, by utilizing pure titanium for the housing 210, a thermal conductivity of the housing 210 can be approximately ten times less relative to an aluminum housing. In this regard, heat generated during a thermal runaway event can trickle into a frame that is made of aluminum via the housing 210 when the housing is made of titanium as opposed to heating up that frame significantly faster if the housing is made of aluminum.

[0035] In various embodiments, by using a flat plate in each of the plurality of sidewalls 290, joining of adjacent sidewalls in the plurality of sidewalls 290 can be simplified. For example, each sidewall can include a flat plate that has a same nominal thickness (i.e., a flat plate that is formed from the same sheet metal stock). In this regard, welding between flat plates of similar thickness can facilitate a strong joint, which can help facilitate the hermetic seal along the respective seam.

[0036] In various embodiments, by using a flat plate in each of the plurality of sidewalls 290, a structure for each of the plurality of sidewalls 290 can be simplified, reducing costs and manufacturing time. Although described herein as forming the housing 210 by welding together each adjacent sidewall to form a plurality of seams 301, the present disclosure is not limited in this regard. For example, a majority of the housing 210 (e.g., sidewalls 291, 292, 293, 294 and bottom panel 296) can be formed via a deep drawn process, and the lid 295 can be welded to the edges of the sidewalls 291, 292, 293. 294 to form the housing 210 and still be within the scope of this disclosure.

[0037] Referring back to FIG. 2, the housing 210 comprises a cavity 212 disposed within the plurality of sidewalls 290. As described previously herein, the plurality of cells from the cell-brick assembly 220 are disposed within the cavity 212 of the housing 210.

[0038] In various embodiments, the housing 210 further comprises a vent port 230. In various embodiments, the vent port 230 disposed through one of the plurality of sidewalls (e.g.. lid 295). The vent port 230 is in fluid communication with the cavity 212 to facilitate an evacuation of hot gases and debris in response to athermal runaway event. In this regard, the vent port 230 can be configured to be coupled to a vent (e.g., a vent tube, a vent duct, or the like), which can route the hot gases and debris away from the battery module 200 in response to a thermal runaway event.

[0039] In various embodiments, the vent port 230 comprises a generally cylindrical body extending from an edge 231 of the vent port into the cavity 212. The term “generally’' when followed by a shape, as referred to herein, includes variations of the shape within an inch profile of the nominal shape. Stated another way, body that may not be considered technically cylindrical would be considered generally cylindrical if the body would fit in an envelope of a nominal cylindrical profile that is plus or minus 1 inch (2.54 cm).

[0040] In various embodiments, the vent port 230 is configured to be coupled to a tube or a coupling for a vent system. In this regard, with brief reference to FIG. 4, an inner diameter surface 232 of the vent port 230 can comprise a threaded surface. Although described herein as comprising a threaded surface, the present disclosure is not limited in this regard. For example, the vent port 230 could comprise a flat wall and be configured to interface with a piloted O-ring connection and still be within the scope of this disclosure. In various embodiments, by having a threaded surface and being configured to interface with a male threaded surface of a vent coupling 410 that is of a different material (e.g., aluminum), a vent port interface 401 between the components (e.g., between the vent port 230 and the vent coupling 410) can be self-sealing during a thermal runaway event. Stated another way, the interfacing material of the vent coupling 410 can be configured to expand more than the vent port 230 in response to being heated, causing the interfacing material of the vent coupling 410 to expand radially outward and into the inner diameter surface 232 of the vent port

230 to seal the respective venting system from an external environment during the thermal runway event, protecting various components within a structure of the aircraft 100 from FIG. 1, in accordance with various embodiments. Stated another way, the vent coupling 410 can have a higher coefficient of thermal expansion than the vent port 230.

[0041] Referring back to FIG. 2, and in accordance with various embodiments, the edge 231 of the vent port 230 is fused (e.g., via welding, brazing, or the like) to the flat plate 299 of the lid 295. In various embodiments, by fusing the edge

231 of the vent port 230 to the lid 295, the connection between the vent port 230 and the lid 295 can be hermetically sealed.

[0042] With continued reference to FIG. 2, in various embodiments, the housing 210 further comprises at least one of a cold plate 241. In various embodiments, each of the broad sidewalls (e.g., sidewall 293 and sidewall 294) comprises a cold plate 241 coupled thereto. For example, the battery module 200 can comprise a first cold plate (e.g., cold plate 241 on a first lateral side of the housing 210) and a second cold plate (e.g., cold plate 241 on a second lateral side of the housing 210), the first cold plate comprising a first broad sidewall (e.g.. sidewall 293) of the plurality of sidewalls 290 and a first vane plate (e.g., vane plate 242) coupled thereto, the second cold plate comprising a second broad sidewall (e.g., sidewall 294) of the plurality of sidewalls 290 and a second vane plate (e.g., vane plate 242) coupled thereto. Although described further herein with respect to sidewall 294, the sidewall 293 can includes the same features of the sidewall 294. in accordance with various embodiments. Stated another way, in various embodiments, both the sidewall 293 and the sidewall 294 comprise the cold plate 241 described further herein. In this regard, a heating and/or cooling of the battery module 200 during charging of the battery module 200 can be more uniform relative to only having the cold plate 241 on a single side of the battery module 200.

[0043] In various embodiments, the sidewall 294 can comprise a flat plate 299 and a vane plate 242 coupled thereto to form the cold plate 241. Stated another way, the flat plate 299 and the vane plate 242 can define a flow path therethrough (e.g., a serpentine flow path or the like). Although illustrated as a serpentine flow path, the present disclosure is not limited in this regard. For example, the flow path could include parallel channels extending longitudinally (i.e., in the Z-direction), or the like and still be within the scope of this disclosure. In various embodiments, by having a serpentine flow path that travels from a top side of the housing 210, to a bottom side of the housing 210, back up to the top side of the housing 210, and so on. the cold plate 241 may be more efficiently purged after charging of the battery systems disclosed herein (e.g., battery system 150 and/or battery system 160 from FIG. 1).

[0044] In various embodiments, the vane plate 242 is coupled to the flat plate 299 in a similar manner to the joining of adjacent sidewalls as described previously herein. For example, the vane plate 242 can be fused (e.g., via welding, brazing, or the like) to the flat plate 299 (e.g., along a perimeter of the vane plate 242 and between adjacent channels, such as between channel 243 and channel 244, between channel 244 and channel 245, and so on). Stated another way, in various embodiments, the vane plate 242 is fused to the flat plate 299 of a respective broad sidewall (e.g.. sidewall 293 or sidewall 294) of the plurality of sidewalls 290 to form the respective broad sidewall (e.g., sidewall 293 or sidewall 294). Moreover, any suitable way of connecting the vane plate 242 to the flat plate 299 may be used.

[0045] For example, in various embodiments, for a battery system 150, 160 from FIG. 1, a fluid may be flowed through the cold plate 241 during charging of the respective battery system 150 (e.g., to cool or heat the cell-brick assembly 220). However, when the battery system 150, 160 is in operation (i.e., when aircraft 100 from FIG. 1 is flying), the cold plate 241 may not be utilized, and this is configured to reduce a weight on-board the aircraft 100. Stated another way, the battery system 150, 160 from FIG. 1 may not utilize active cooling during operation of the aircraft 100, which can facilitate eliminating a cooling source (e.g., fluid) that would otherwise have to be carried on-board the aircraft 100. Accordingly, after a charging of the battery system 150, 160 from FIG. 1, it may be desirable to purge any remaining fluid disposed therein. In various embodiments, the serpentine shape of the flow path for the cold plate 241 can facilitate a purging of fluid of between 70% and 100%, or between 80% and 100%, or approximately between 85% and 99%, in accordance with various embodiments.

[0046] In various embodiments, the battery module 200 further comprises a mounting arrangement 250. In various embodiments, the mounting arrangement 250 comprises a plurality of brackets 251. Each of the plurality of brackets 251 is coupled to the housing 210. In this regard, each of the plurality of brackets 251 are configured to facilitate mounting the batten' module 200 to a respective support structure (e.g., a support structure within the aircraft 100 from FIG. 1, or the like). In various embodiments, by having the plurality of brackets 251 for interfacing with a respective support structure, the battery module 200 can remain the same across various use cases and only the plurality of brackets 251 and their respective mounting locations may have to be changed, in accordance with various embodiments.

[0047] In various embodiments, each of the plurality of brackets 251 can comprise an aperture (e.g., aperture 259 for a first 252 of the plurality of brackets 251) that corresponds to an aperture disposed through one of the plurality of sidewalls 290 (e.g., aperture 298 disposed through the lid 295). In this regard, each of the plurality of brackets 251 can be fused to the housing 210 (e.g., via welding, brazing, or the like), and the fused region can hermetically seal the joining location of the respective bracket in the plurality of brackets 251, in accordance with various embodiments.

[0048] In various embodiments, a first 252 the plurality of brackets 251 is spaced apart longitudinally (i.e., in the Z-direction) from a second 253 of the plurality of brackets 251. The first 252 and the second 253 of the plurality of brackets 251 can be coupled to the housing 210. Although the first 252 and the second 253 of the plurality of brackets are illustrated as being coupled to the lid 295. the present disclosure is not limited in this regard. For example, the first 252 of the plurality of brackets 251 can be coupled to sidewall 291, sidewall 293, or sidewall 294 and still be within the scope of this disclosure. Similarly, the second 253 of the plurality of brackets 251 can be coupled to the sidewall 292, sidewall 293, and/or sidewall 294 and still be within the scope of this disclosure.

[0049] In various embodiments, a third 254 of the plurality⁷ of brackets 251 is spaced apart longitudinally (i.e., in the Z-direction) from a fourth 255 of the plurality of brackets 251. The third 254 and the fourth 255 of the plurality⁷ of brackets 251 can be coupled to the housing 210. Although the third 254 and the fourth 255 of the plurality of brackets are illustrated as being coupled to the sidewall 291 and the sidewall 292 respectively, the present disclosure is not limited in this regard. For example, the third

254 of the plurality of brackets 251 can be coupled to sidewall 293, sidewall 294, and/or bottom panel 296 and still be within the scope of this disclosure. Similarly, the fourth

255 of the plurality⁷ of brackets 251 can be coupled to the sidewall 293, sidewall 294, and/or bottom panel 296 and still be within the scope of this disclosure.

[0050] In various embodiments, the third 254 of the plurality of brackets 251 is spaced apart vertically from the first 252 of the plurality of brackets 251. Similarly, the fourth 255 of the plurality of brackets 251 is spaced apart vertically⁷ from the second 253 of the plurality⁷ of brackets 251. In this regard, the mounting arrangement 250 can include a first mounting side (e.g., on a first lateral side of the housing 210) and a second mounting side (e.g., on a second lateral side of the housing 210). Additionally, in accordance with various embodiments, the mounting arrangement 250 can include a third mounting side (e.g., a top side of the housing 210) and/or a fourth mounting side (e.g., a bottom side of the housing 210). In this regard, the mounting arrangement 250 can facilitate multiple potential interfaces based on a respective use case, in accordance with various embodiments.

[0051] In various embodiments, each of the plurality of brackets 251 comprises at least two of a nut 258 coupled thereto. In various embodiments, the nut 258 can be coupled to a respective flange of the respective bracket by any method known in the art (e.g., welding, riveting, brazing, or the like). In various embodiments, the nut can be configured to receive a fastener (e.g., a bolt) to couple a respective support structure to the respective bracket.

[0052] In various embodiments, each of the plurality⁷ of brackets 251 comprises a main body (e.g., main body 261 for the second 253 of the plurality⁷ of brackets 251); a first flange extending outward from a first edge of the main body (e.g., first flange 262 for the second 253 of the plurality of brackets 251); and a second flange extending outward from a second edge of the main body (e.g.. second flange 263 for the second 253 of the plurality of brackets 251).

[0053] In various embodiments, to facilitate an electrical connection between a first of the batten- module 200 and a second of the battery module 200, a first electrical connector 281 (e.g., having a positive electrode as described further herein) is coupled to the sidewall 291 that is on a first longitudinal side of the housing 210, and a second electrical connector 282 (e g., having anegative electrode as further described herein) is coupled to the sidewall 292 that is opposite the sidewall 291 on the second longitudinal side of the housing 210. Similarly, a first communications connector 271 (e.g., having a plurality of pins to facilitate connection of a communications line of the battery system) is coupled to the sidewall 291 that is on a first longitudinal side of the housing 210, and a second communications connector 272 (e.g., having a plurality of receptacles, each of the plurality of receptacles configured to receive a respective pin from the plurality of pins) is coupled to the sidewall 292 that is opposite the sidewall 291 on the second longitudinal side of the housing 210. Accordingly, as described further herein, a battery connections step during assembly of a battery' system (e.g., battery' system 150 or battery' system 160 from FIG. 1) can include sliding the sidewall 292 of a first of the battery module 200 toward (i.e., in a longitudinal direction / in the z-direction) the sidewall 291 of a second of the battery module 200. In response to the battery connection step being performed, the second electrical connector 282 of the first of the battery module 200 is coupled to the first electrical connector 281 of the second of the battery module 200 and the second communications connector 272 of the first of the battery module 200 is coupled to the first communications connector 271 of the second of the battery module 200.

[0054] In various embodiments, although described herein as including the first electrical connector 281 and the first communications connector 271 as both being male connectors, and the second electrical connector 282 and the second communications connector 272 as both being female connectors, the present disclosure is not limited in this regard. For example, the first electrical connector 281 can be a male connector and the first communications connector 271 can be a female connector, as long as the second electrical connector 282 is a female connector and the second communications connector 272 is a male connector. Stated another way, as long as one of the first electrical connector 281 and the second electrical connector 282 is a male connector and the other of the first electrical connector 281 and the second electrical connector 282 is a female connector, an electrical interface between adjacent of the battery module 200 in a battery system 150 or a battery system 160 from FIG. 1 can be facilitated. Similarly, as long as one of the first communications connector 271 and the second communications connector 272 is a male connector and the other of the first communications connector 271 and the second communications connector 272 is a female connector, a communications interface between adjacent of the battery module 200 in a battery system 150 or a battery system 160 from FIG. 1 can be facilitated.

[0055] Referring now to FIGs. 5, 6, 7, and 8, a cross-sectional view of an electrical connector 500 that is a female electrical connector (FIG. 5), a cross-sectional view of an electrical connector 600 that is a male electrical connector (FIG. 6), an exploded view of the electrical connector 500 (FIG. 7), and an exploded view of the electrical connector 600 (FIG. 8) are illustrated, in accordance with various embodiments. With combined reference to FIGs. 2, 5, 6, 7, and 8, if the first electrical connector 281 is the electrical connector 500, then the second electrical connector 282 is the electrical connector 600. Similarly, if the first electrical connector 281 is the electrical connector 600, then the second electrical connector 282 is the electrical connector 500. Stated another way, the battery' module 200 comprises a male electrical connector (e g., electrical connector 600) and a female electrical connector (e.g., electrical connector 500) to facilitate electrical couplings between adjacent battery modules in a battery system having a plurality of the battery module 200 (e g., battery system 150 or battery' system 160 from FIG. 1).

[0056] In various embodiments, the electrical connector 500 can be configured as a positive terminal of the battery module 200 or a negative terminal of the battery module 200. Similarly, the electrical connector 600 can be configured as a positive terminal of the battery' module 200 or a negative terminal of the battery module 200. The present disclosure is not limited in this regard. In various embodiments, if the electrical connector 500 is configured as a positive terminal of the battery module 200, then the electrical connector 600 is configured as a negative terminal of the battery module 200. Similarly, if the electrical connector 500 is configured as the negative terminal of the battery' module 200, then the electrical connector 600 is configured as the positive terminal of the battery module 200. Stated another way, the battery module 200 disclosed herein can be configured to facilitate direct series connections with an adjacent of the battery module 200, in accordance with various embodiments. Although described herein as facilitating series connections, the present disclosure is not limited in this regard. For example, the battery module 200 could be configured to facilitate parallel electrical connections with an adjacent of the battery module 200, and still be within the scope of this disclosure.

[0057] In various embodiments, the electrical connector 500 and the electrical connector 600 disclosed herein are high voltage connectors. “High voltage,” as referred to herein includes any voltage over 600 volts, or voltages between 601 and 5,000 volts. Although described herein as being high voltage, the electrical connector 500, 600 is not limited in this regard.

[0058] In various embodiments, the electrical connector 500 and the electrical connector 600 disclosed herein are significantly lower profile (i.e., take up a smaller envelope) relative to typical high voltage connectors. In various embodiments, the electrical connector 500 and the electrical connector assembly each comprise a simplified construction relative to typical high voltage connectors. In various embodiments, a cost of manufacture for each of the electrical connector 500 and the electrical connector 600 can be approximately 75% less relative to a typical high voltage connector.

[0059] In various embodiments, each of the electrical connector 500 and the electrical connector 600 comprise a connector housing 510, 610, a seal 520, 620, and an electrode 530, 630. In various embodiments, the connector housing 510. 610 is configured to be coupled to the housing 210 of the battery module 200 from FIG. 2. For example, the connector housing 510 can be configured to be coupled to a flat plate 299 of one of the plurality of sidewalls 290 (e.g., sidewall 291 for the first electrical connector 281 or sidewall 292 for the second electrical connector 282). In various embodiments, the seal 520, 620 is directly coupled to the connector housing 510, 610 and the electrode 530, 630. In this regard, the seal 520, 620 can comprise a non- conductive material (e.g., a thermoplastic material, such as polyether ether ketone (PEEK) or any other thermoplastic or electrical insulator known in the art).

[0060] In various embodiments, a first longitudinal end 531, 631 of the electrical connector 500, 600 is configured to be coupled to a bus bar. In this regard, the first longitudinal end 531, 631 of each of the electrical connector 500, 600 can comprise an axial surface that is configured to be welded to a bus bar, fastened to a bus bar, or the like. The present disclosure is not limited in this regard. Accordingly, the first longitudinal end 531, 631 is disposed in the cavity 212 of the housing 210 of the batery module 200 from FIG. 2 and electrically coupled to the cell-brick assembly 220 (e.g., via a bus bar), in accordance with various embodiments.

[0061] In various embodiments, the seal 520, 620 can provide dual functionality for the electrical connector 500, 600. For example, the seal 520, 620 can be configured to seal the cavity⁷ 212 of the housing 210 from an external environment through the electrical connector 500, 600. In this regard, a leakage path can be prevented through the electrical connector 500, 600 by the seal 520. 620. For example, in response to a thermal runaway event within a batery module 200 from FIG. 2, the cavity' 212 of the housing 210 can be heated up significantly. This increase in temperature can cause the electrical connector 500, 600 to be heated in a similar manner. In various embodiments, the seal 520, 620 can be configured to expand a greater amount radially relative to mating components with the seal 520, 620 (i.e. , the connector housing 510, 610 and the electrode 530, 630). Accordingly, the seal 520, 620 can grow radially outward and radially inward and press into the electrode 530, 630 and the connector housing 510. 610, forming a seal therebetween and preventing any of the hot gases or ej ecta from the thermal runaway event from escaping to an adj acent module in a batery' system 150, 160 from FIG. 1 as described previously herein. Stated another way, the seal 520, 620 may have a higher coefficient of thermal expansion than the connector housing 510, 610 and the electrode 530, 630.

[0062] In various embodiments, the seal 520, 620 can further be configured to electrically insulate the electrode 530, 630 from the connector housing 510, 610, and the housing 210. In this regard, since the housing 210 and the connector housing 510, 610 are both made of a metal (e.g.. pure titanium, a titanium alloy, or the like), the electrode 530, 630 is configured to be insulated from the connector housing 510, 610 and the housing 210 to prevent a short during operation of the batery module 200 from FIG. 2.

[0063] In various embodiments, the seal 520, 620 comprises a body 525, 625 that extends from a first longitudinal end 521 , 621 along a longitudinal axis defined by the body 525. 625 to a second longitudinal end 529. 629. In various embodiments, the body 525 comprises an inner diameter surface 522, 622 and an outer diameter surface 528, 628. At least a portion of the inner diameter surface 522, 622 and at least a portion of the outer diameter surface 528, 628 is threaded. In this regard, at least a portion of an outer diameter surface 532, 632, of a respective mating electrode (e.g., electrode 530, 630) is threaded in a complimentary manner to the threaded surface on the inner diameter surface 522, 622 of the seal 520, 620. Similarly, at least a portion of an outer diameter surface 518, 618 of a respective mating connector housing (e.g., connector housing 510, 610) is threaded in a complimentary manner to the threaded surface on the outer diameter surface 528, 628 of the seal 520, 620. In this regard, the connector housing 510, 610 can be secured to the seal 520, 620 via a threaded connection, and electrode 530, 630 can be secured to the secured to the seal 520, 620 via a threaded connection. Although described herein as being coupled together via threaded connections, the present disclosure is not limited in this regard. For example, couplings between components of the electrical connector 500, 600 can be facilitated by alternative coupling means, such as press fit, an adhesive, bonding, or the like. The present disclosure is not limited in this regard. However, as described previously herein, the threaded connection, combined with the utilization of a seal 520, 620 that has a different material with a different coefficient of thermal expansion relative to the mating components (e.g., the connector housing 510, 610 and the electrode 530, 630) can facilitate a sealing effect during a thermal runaway event within a cavity 212 of a housing 210 of the battery module 200 from FIG. 2.

[0064] In various embodiments, the electrode 530 further comprises a main body 533 and a generally cylindrical body 534 extending along a longitudinal axis defined by the electrical connector 530. The generally cylindrical body 534 can at least partially define a receptacle 536 configured to receive a mating electrode (e.g.. electrode 630). An inner diameter surface 535 of the electrode 530 is configured to mate with a mating electrode (e.g., electrode 630 of the electrical connector 600) via a radial connection as described further herein. In various embodiments, the seal 520 further comprises a generally cylindrical body 526 disposed radially outward from the generally cylindrical body 534 of the electrode 530. In this regard, the electrode 530 can be further protected by the seal 520 (e.g., during transport or the like), in accordance with various embodiments.

[0065] For example, the electrode 630 can comprise a main body 635 extending along a longitudinal axis defined by the main body 635 from a first longitudinal end 631 to a second longitudinal end 639, and one or more conductive elements 641 coupled to the main body 635. In this regard, disposed in the outer diameter surface 632 of the main body 635, and spaced apart longitudinally from the threaded surface that is configured to mate with the seal 620, is at least one radial groove 633. The radial groove 633 is configured to receive one of the one or more conductive elements 641 therein. In various embodiments, the conductive element 641 is configured to compress in a radial direction (e.g., in response to being inserted into the generally cylindrical body 534 of the electrode 530). In this regard, the conductive element 641 can comprise a conductive coil, a hollow conductive ring, or any other annular structure configured to compress in a radial direction in response to partially contacting a radially inner mating surface (e.g.. inner diameter surface 535 of the electrode 530). Although illustrated as comprising two of the one or more conductive elements 641, each disposed in a respective radial groove 633, the present disclosure is not limited in this regard. For example, the electrode 630 can comprise one of the one or more conductive elements 641 disposed in a radial groove 633, two or more of the conductive element 641 disposed in respective grooves, or the like and still be within the scope of this disclosure. In various embodiments, by having more than one (e.g., two or more) of the conductive element 641, a redundant electrical connection can be formed, improving robustness of the electrical connection, in accordance with various embodiments.

[0066] In various embodiments, the electrode 530, 630 of the electrical connector 500, 600 protrudes past an outer surface of the housing 210. In this regard, during a battery⁷ connection step between electrodes, the connection can be visualized and ensured, as described further herein.

[0067] In various embodiments, the connector housing 510, 610 of the electrical connector 500, 600 is fused (e.g., via welding, brazing, or the like) to the housing 210. In this regard, the connector housing 510, 610 can comprise a same material as the housing 210 as described previously herein to facilitate metal -to-metal joining (e.g., via welding, brazing, or the like). In this regard, the cavity 212 of the housing 210 is further sealed from an external environment through a joint between the connector housing 510, 610 and the housing 210.

[0068] In various embodiments, the electrical connector 500 and the electrical connector 600 each comprise a protective component (e.g., a plug 540 configured to prevent a finger of a user from entering the receptacle 536 of the electrode 530 and an electrode cap 640 coupled to the second longitudinal end 639 of the electrode 630). In this regard, the protective components (e.g., the plug 540 and the electrode cap 640) can comprise non-conductive material (e.g., a thermoplastic material, or any other non-conductive material known in the art).

[0069] Referring now to FIGs. 9, 10, 11, and 12, a cross-sectional view of a communications connector 900 that is a female communications connector (FIG. 9), a cross-sectional view of a communications connector 1000 that is a male electrical connector (FIG. 10), an exploded view of the communications connector 900 (FIG. 11), and an exploded view of the communications connector 1000 (FIG. 8) are illustrated, in accordance with various embodiments. With combined reference to FIGs. 2, 9, 10, 11, and 12, if the first communications connector 271 is the communications connector 900, then the second communications connector 272 is the communications connector 1000. Similarly, if the first communications connector 271 is the communications connector 1000, then the second communications connector 272 is the communications connector 900. Stated another way, the battery module 200 comprises a male communications connector (e.g.. communications connector 1000) and a female communications connector (e.g., communications connector 900) to facilitate communications couplings between adjacent battery modules in a battery system having a plurality of the batten' module 200 (e.g., battery' system 150 or battery system 160 from FIG. 1). In various embodiments, a male communications connector (e.g., communications connector 1000) can be on a same side of the housing 210 as a male electrical connector (e.g., electrical connector 600 from FIG. 6) or on a different side of the housing 210 as the male electrical connector. The present disclosure is not limited in this regard.

[0070] In various embodiments, the communications connector 900 and the communications connector 1000 each comprise a shield 910, 1010, a communications board 920, 1020 (e.g., a target board 922 for the communications connector 900 and a pin board 1022 for the communications connector 1000), a seal 930, 1030, and a gasket 940, 1040. In various embodiments, the shield 910. 1010, and the seal 930, 1030, are configured to prevent gases and/or ejecta from a thermal runaway event within the battery module 200 from FIG. 2 from escaping through the housing at the communications connector 900, 1000 location. Stated another way, the shield 910, 1010. and the seal 930, 1030 are provided in an assembly for the communications connector 900. 1000 to strengthen the location of the communications connector 900. 1000, in accordance with various embodiments.

[0071] In various embodiments, the communications connector 900 and the communications connector 1000 disclosed herein are significantly lower profile (i.e., take up a smaller envelope) relative to typical communications connector for a high voltage battery module application. In various embodiments, a cost of manufacture for each of the communications connector 900 and the communications connector 1000 can be greatly reduced relative to typical communications connectors for high voltage applications. In various embodiments, the communications connector 900 and the communications connector 1000 can prevent thermal runaway propagation from one of the battery' module 200 to an adjacent of the battery module 200 from FIG. 2.

[0072] In various embodiments, with reference now to FIGs. 11 and 12, the housing 210 (e.g., one of the plurality of sidewalls 290 from FIG. 2) can comprise a plurality of studs 991, 1091 coupled thereto and extending into the cavity 212 of the housing 210 from FIG. 2. In various embodiments, to prevent a potential leakage path, each of the plurality of studs 991, 1091 can be fused to the housing 210 (e.g., via welding, brazing, or the like).

[0073] In various embodiments, a stack up that forms the communications connector 900, 1000 is configured to be coupled to the housing 210 by coupling each of the plurality of studs 991, 1091 to a respective fastener 993, 1093 (e.g., a nut or any other clamping or fastening hardware known in the art).

[0074] In various embodiments, the housing 210 for each of the communications connector 900 and the communications connector 1000 comprises an aperture 992, 1092 disposed therethrough. The aperture 992, 1092 is configured to receive an axial protrusion 932, 1032 of the seal 930, 1030 therethrough.

[0075] In various embodiments, a plurality of pins 1025 disposed on the pin board 1022 of the communications board 1020 are configured to mate with, and electrically couple to, a plurality of pin receptacles 925 on the target board 922 of the communications board 920. In this regard, in response to a battery connection step as described further herein, the communications connector 900 of a first of the battery module 200 is configured to be electrically coupled to a communications connector 1000 of a second of the battery module 200 to facilitate a daisy chain of communications between battery' modules in a respective battery system (e.g., battery system 150 or battery’ system 160 from FIG. 1).

[0076] In various embodiments, similar to the electrical connector 500, 600. the seal 930 and the shield 910 of the communications connector 900, 1000 can comprise an electrically isolating material (e.g., a thermoplastic or the like). In various embodiments, the seal 930 and the shield 910 can each comprise a high-strength thermoplastic material, such as PEEK, or any other high-strength electrically isolating material known in the art. The present disclosure is not limited in this regard. [0077] In various embodiments, the gasket 940 can comprise a flexible material, such as silicone, natural rubber, or the like. In this regard, the gasket 940 can be configured to create a seal between the cavity 212 in the housing 210 from FIG. 2 and an external environment, in accordance with various embodiments.

[0078] Referring now to FIGs. 13 and 14, a side view of the battery module 200 (e.g.. looking towards sidewall 291 for FIG. 13 and looking towards sidewall 292 for FIG. 14) are illustrated in accordance with various embodiments, with like numerals depicting like elements. In various embodiments, the battery module 200 further comprises a connector shield 1310 and a connector shield 1410. In various embodiments, as described further herein, the connector shield 1310 of a first of the battery module 200 is configured to be coupled to the connector shield 1410 of a second of the battery module 200 in response to coupling the first of the battery module 200 to the second of the battery module 200 as described further herein. In this regard, a connection between the connector shield 1310 of the first of the battery module 200 and the connector shield 1410 of the second of the battery’ module 200 can be configured to protect the electrical connection between the first and the second of the battery module 200 from an external environment.

[0079] In various embodiments, each electrical connection (e.g., an electrical connection between the first electrical connector 281 and the second electrical connector 282, a communications connection between the first communications connector 271 and the second communications connector 272, or the like) can be a respective adapter connection. For example, the connector shield 1310 can comprise an adapter 1312 and an adapter 1314, and the connector shield 1410 can comprise an adapter 1412 and an adapter 1414. The adapter 1312 can be configured to be coupled to and interface with the adapter 1412 and the adapter 1314 can be configured to be coupled to and interface with the adapter 1414. In this regard, the adapter 1312, 1412 and the adapter 1314, 1414 can be separate and distinct components, or they can be combined as a single adapter / fitting as illustrated. The present disclosure is not limited in this regard. However, in various embodiments, by having the adapter 1312 and the adapter 1314 formed as a monolithic component, a part count of the assembly’ can be reduced and fewer mounting locations to the housing 210 can be utilized, in accordance with various embodiments.

[0080] In various embodiments, the connector shield 1310, 1410 is coupled to the sidewall 291 of the housing 210. The connector shield 1310 can be coupled to the housing 210 via fasteners or the like. In various embodiments, a plurality' of blind nuts 1322, 1422 are fused (e.g., via welding, brazing, or the like) to the housing 210 and configured to receive a respective fastener (e.g., a stud, a bolt, or the like) to mount the connector shield 1310, 1410 to the housing 210. In this regard, by fusing each of the plurality' of blind nuts 1322, 1422 to the housing 210, the cavity 212 of the housing 210 can be hermetically sealed from an external environment through the respective joint.

[0081] Referring now to FIG. 15, a perspective view of a portion of abattery system 1500 (e.g., battery system 150 and/or battery system 160 from FIG. 1) is illustrated with like numerals depicting like elements, in accordance with various embodiments. The battery system 1500 comprises a first 1510 of the battery module 200 coupled to a second 1520 of the battery module 200. In various embodiments, the first 1510 of the battery module 200 is coupled to the second 1520 of the battery module 200 in series through an electrical connection 1600. Similarly, a communications system of the battery system 1500 includes various communications lines, which extend from the first 1510 of the battery module 200 to the second 1520 of the battery module 200 through the electrical connection 1600 described further herein. Although described herein as being connected in series, the present disclosure is not limited in this regard and similar principles to those described herein can be utilized to form a parallel connection between two or more of the battery module 200 and still be within the scope of this disclosure. In various embodiments, the battery module 200 can comprise various electronic components therein (e.g., sensors, one or more processors, or any other electronic component known in the art). In this regard, the communications system and the communications connection formed between battery modules as described herein can allow the respective components disposed within a respective battery module to communicate with a battery management system of the battery system (e.g., battery' system 150 and/or battery' system 160 from Fig. 1), in accordance with various embodiments.

[0082] In various embodiments, a fluid path between a cold plate 241 of the first 1510 of the battery module 200 and a cold plate 241 of the second 1520 of the battery module 200 can be fluidly coupled together through a fluid conduit 1530 (e.g., a tube assembly, a fitting assembly, or the like). In this regard, a thermal management system for the battery system 1500 can include a fluid path defined in series through a plurality of the battery module 200, in accordance with various embodiments. [0083] In various embodiments, to facilitate the electrical connection 1600 between the first 1510 of the battery module 200 and the second 1520 of the battery module 200, the first 1510 of the battery module 200 and the second 1520 of the battery module 200 are pushed together in a longitudinal direction (i.e., the Z-direction). In this regard, with combined reference to FIG. 2 and 13, the sidewall 292 of the first 1510 of the battery module 200 is pushed towards the sidewall 291 of the second 1520 of the battery module 200. In response to pushing the first 1510 of the battery module 200 together with the second 1520 of the battery module 200, the electrical connection 1600 between the first 1510 of the battery module 200 and the second 1520 of the battery module 200 is formed without any tooling hardware, or any additional external connections. Stated another way, an electrical connection (i.e., an electrical connection between cells and an electrical connection between communications) can be formed simply in response to pushing the first 1510 of the battery module 200 and the second 1520 of the battery module 200 together.

[0084] Referring now to FIGs. 16 and 17, a cross-sectional view of the electrical connection 1600 formed between the first 1510 of the battery module 200 and the second 1520 of the battery module 200 is illustrated, in accordance with various embodiments. The electrical connection 1600 includes a first connection 1601 between the electrical connector 500 and the electrical connector 600 and a second connection 1602 between the communications connector 900 and the communications connector 1000 described previously herein.

[0085] In various embodiments, in response to forming the electrical connection 1600, an additional seal can be provided between the first connection 1601 and the second connection 1602 to protect the electrical connection from an external environment. For example, the connector shield 1310 can comprise a generally cylindrical body 1714 protruding from a flange 1712 of the connector shield 1310, the generally cylindrical body 1714 including a radially outer surface with a groove 1716 disposed therein. Disposed within the groove 1716 is an O-ring 1718 (e.g., made of a flexible material, such as silicone, natural rubber, or the like). The O-ring 1718 is configured to interface with, and form a seal with, a radially inner surface of a generally cylindrical body 1626 extending outward from a flange 1622 of the connector shield 1410. In this regard, a portion of connector shield 1310 and a portion of the connector shield 1410 are configured to be coupled together and create a seal around the electrical connection formed between the electrical connector 500 and the electrical connector 600, in accordance with various embodiments. In this regard, a piloted O-ring connection 1730 between the connector shield 1310 coupled to the first 1510 of the battery module 200 and the second 1520 of the battery module 200 can protect the electrical connection from an external environment.

[0086] In this regard, in a similar manner, the connector shield 1310 and the connector shield 1410 can form a piloted O-ring connection 1730 around the electrical connection between the communications connector 900 of the first 1510 of the battery module 200 and the second 1520 of the battery module 200, in accordance with various embodiments.

[0087] Benefits, other advantages, and solutions to problems have been described herein regarding specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

[0088] Systems, methods, and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “various embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

[0089] Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase "means for."’ As used herein, the terms “comprises,’' “comprising.” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0090] Finally, any of the above-described concepts can be used alone or in combination with any or all the other above-described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible considering the above teaching.

Claims

CLAIMS What is claimed is:

1. A battery module, comprising: a housing comprising a first sidewall disposed opposite a second sidewall of the housing; a plurality of cells disposed within the housing; a first electrical connector coupled to the first sidewall of the housing; a second electrical connector coupled to the second sidewall of the housing; a first communications connector coupled to the first sidewall of the housing; and a second communications connector coupled to the second sidewall of the housing, wherein in response to a battery connections step including sliding the second sidewall of a first of the battery module to the first sidewall of a second of the battery module, the second electrical connector of the first of the battery module is coupled to the first electrical connector of the second of the battery module and the second communications connector of the first of the battery module is coupled to the first communications connector of the second of the battery module.

2. The battery module of claim 1. wherein the second electrical connector of the first of the battery module is configured to apply a clamping force to secure the first electrical connector of the second of the battery module in response to the sliding the second sidewall of the first of the battery module to the second sidewall of the second of the battery module.

3. The battery module of claim 1, wherein the first electrical connector comprises: a connector housing coupled to the housing, a seal coupled to the connector housing, the seal comprising an insulating material, and a first electrode coupled to the seal.

4. The battery module of claim 3, wherein the seal is configured to electrically isolate the first electrode from the connector housing.

5. The batery module of claim 3, wherein the first electrode is protruding laterally outward relative to an external surface of the housing.

6. The batery module of claim 5, wherein: the first electrode comprises a radially outer surface and a radial groove disposed in the radially outer surface, and a conductive coil disposed at least partially within the radial groove and extending radially outward past the radially outer surface.

7. The batery module of claim 6, wherein: the second electrical connector comprises a second electrode, the second electrode comprises a radial inner surface, and the radial inner surface of the first of the battery module is configured to interface with and compress the conductive coil of the second of the batery module in response to the batery connections step.

8. The batery module of claim 1, further comprising: a first adapter coupled to the first sidewall of the housing and disposed radially outward from the first electrical connector; a second adapter coupled to the first sidewall of the housing and disposed radially outward from the first communications connector; a third adapter coupled to the second sidewall of the housing and disposed radially outward from the second electrical connector; and a fourth adapter coupled to the second sidewall of the housing and disposed radially outward from the second communications connector.

9. The batery module of claim 8, further comprising: a first O-ring coupled to one of the first adapter or the third adapter; and a second O-ring coupled to one of the second adapter or the fourth adapter.

10. The batery⁷ module of claim 8, wherein in response to the batery connections step, the third adapter of the first of the batery module is secured to the first adapter of the second of the battery' module, and the fourth adapter of the first of the battery module is secured to the second adapter of the second of the battery module.

11. The battery module of claim 10, wherein in response to the battery connections step: a first seal is formed by the coupling of the third adapter of the first of the battery module to the third adapter of the second of the battery module, the first seal being between an external environment and an electrical connection formed between the second electrical connector of the first of the battery' module and the first electrical connector of the second of the battery module, and a second seal is formed by the coupling of the fourth adapter of the first of the battery module to the second adapter of the second of the battery module, the second seal being between the external environment and a communications connection formed between the second communications connector of the first of the battery' module and the first communications connector of the second of the battery module.

12. The battery^ module of claim 8, further comprising: a first connector shield comprising the first adapter and the second adapter; and a second connector shield comprising the third adapter and the fourth adapter.

13. The battery' module of claim 12, wherein: the first connector shield is a first monolithic component, and the second connector shield is a second monolithic component.

14. The battery^ module of claim 1, wherein: each of the first sidewall and the second sidewall extend from a first lateral side of the housing to a second lateral side of the housing. the housing further comprises: a third sidewall extending longitudinally from the first sidewall to the second sidewall on the first lateral side of the housing, and a fourth sidewall extending longitudinally from the first sidewall to the second sidewall on the second lateral side of the housing.

15. The batery module of claim 14, wherein the third sidewall and the fourth sidewall each comprise a fluid path disposed therethrough.

16. The batery module of claim 15, wherein the fluid path includes a serpentine shape.

17. The battery module of claim 14, wherein each of the third sidewall and the fourth sidewall comprise a fluid inlet port disposed proximate the first sidewall, a fluid outlet port disposed proximate the second sidewall, and a fluid path extending from the fluid inlet port to the fluid outlet port.

18. A battery module, comprising: a housing comprising a plurality of sidewalls forming a generally cuboid shape, the generally cuboid shape at least partially including a plurality-' of seams formed between adjacent sidewalls in the plurality of sidewalls, each of the plurality of seams compnsing a first of the plurality of sidewalls fused to a second of the plurality of sidewalls, the housing comprising a cavity disposed within the plurality of sidewalls; a vent port coupled to one of the plurality of sidewalls; and a plurality of cells disposed within the cavity of the housing.

19. The batery module of claim 18, wherein each of the plurality of sidewalls comprises a flat plate.

20. The batery module of claim 19, further comprising a first cold plate and a second cold plate, the first cold plate comprising a first broad sidewall of the plurality of sidewalls and a first vane plate coupled thereto, the second cold plate comprising a second broad sidewall of the plurality of sidewalls and a second vane plate coupled thereto.

21. The batery module of claim 20, wherein: the first vane plate is fused to the flat plate of the first broad sidewall of the plurality of sidewalls to form the first broad sidewall, and the second vane plate is fused to the flat plate of the second broad sidewall of the plurality of sidewalls.

22. The batter}⁷ module of claim 20, wherein: the first cold plate at least partially defines a first flow path therethrough, and the second cold plate at least partially defines a second flow path therebetween.

23. The battery' module of claim 18, wherein each of the plurality⁷ of seams is formed by one of welding or brazing.

24. The battery module of claim 18, wherein the each of the plurality of sidewalls is made of titanium or a titanium alloy.

25. The battery module of claim 24, wherein each of the plurality of sidewalls comprises sheet metal.

26. The battery⁷ module of claim 18, wherein the plurality of sidewalls comprises a lid disposed on a top side of the housing, the lid comprising the vent port coupled thereto.

27. The battery⁷ module of claim 26, wherein an edge of the vent port is fused to an edge of an aperture disposed through the lid.

28. The battery module of claim 27, wherein the vent port comprises a generally cylindrical body extending from the edge of the vent port into the cavity.

29. The battery module of claim 28, wherein an inner diameter surface of the vent port comprises a threaded surface.

30. The battery⁷ module of claim 18, further comprising: a first mounting bracket coupled to the housing; and a second mounting bracket coupled to the housing and spaced apart longitudinally from the first mounting bracket.

31. The batery module of claim 30, further comprising: a third mounting bracket coupled to the housing and spaced apart vertically from the first mounting bracket; and a fourth mounting bracket coupled to the housing and spaced apart longitudinally from the third mounting bracket and spaced apart vertically from the second mounting bracket.

32. The batery' module of claim 31, wherein each of the first mounting bracket, the second mounting bracket, the third mounting bracket, and the fourth mounting bracket is at least partially fused to the housing.

33. The batery' module of claim 31, wherein each of the first mounting bracket, the second mounting bracket, the third mounting bracket, and the fourth mounting bracket comprises one or more nuts coupled thereto.

34. The batery module of claim 30, wherein each of the first mounting bracket and the second mounting bracket comprises: a main body; a first flange extending outward from a first edge of the main body; and a second flange extending outward from a second edge of the main body.

35. The batery module of claim 34, wherein the first flange of each of the first mounting bracket and the second mounting bracket is spaced apart from a first broad sidewall of the plurality of sidewalls and the second flange of each of the first mounting bracket and the second mounting bracket is spaced apart from a second broad sidewall of the plurality of sidewalls.

36. A batery system comprising a plurality of the batery module of claim 1, wherein the plurality' of the batery' module include: a first of the batery module; a second of the batery module coupled to the first of the batery module; and a third of the batery module coupled to the second of the batery module, wherein the first of the battery module, the second of the battery module, and the third of the battery module define an electrical path therethrough.