Battery pack structures and systems

Abstract

Battery packs according to some embodiments of the present technology may include a longitudinal beam. The packs may include a plurality of battery cells disposed adjacent the longitudinal beam. Each battery cell may be characterized by a first surface, and a second surface opposite the first surface. Each battery cell may be characterized by a third surface extending vertically between the first surface and the second surface. The first surface may face the longitudinal beam, and battery terminals may extend from the third surface. Each battery cell may be characterized by a fourth surface opposite the third surface. The packs may include a lid coupled with the first surface of each battery cell of the plurality of battery cells. The packs may include a base coupled with the second surface of each battery cell of the plurality of battery cells.

What is claimed is: 
     
         1 . A battery pack comprising:
 an enclosure having at least four sidewalls connected to a base, wherein one or more components of the enclosure are extruded; and   a plurality of cells arranged in one or more rows and disposed on the base, wherein each cell of the plurality of cells has a large wall surface and a small wall surface, and wherein a surface area of the small wall surface is less than a surface area of the large wall surface;   wherein, for each row of the one or more rows, the plurality of cells are arranged such that their large wall surfaces are parallel to each other.   
     
     
         2 . The battery pack of  claim 1 , wherein two sidewalls of the at least four sidewalls are end plates that are arranged parallel to the large wall surfaces with one of the two sidewalls being adaptable to apply a compressive force to the plurality of cells. 
     
     
         3 . The battery pack of  claim 1 , wherein the at least four sidewalls are mechanically attached to the base. 
     
     
         4 . The battery pack of  claim 1 , wherein the enclosure comprises an electronics compartment that houses one or more battery pack electronics control modules. 
     
     
         5 . The battery pack of  claim 4 , wherein the battery pack electronic control modules include one or more of a Battery Energy Control Module (BECM), a sensor module or a high voltage connector. 
     
     
         6 . The battery pack of  claim 1 , wherein the base is an extrusion that comprises a plurality of fluid channels configured to cool the battery pack, wherein the plurality of fluid channels extend along a length of the base. 
     
     
         7 . The battery pack of  claim 6 , wherein the plurality of fluid channels have a substantially rectangular profile. 
     
     
         8 . The battery pack of  claim 6 , wherein the base defines a recess extending from a top surface of the base to a depth of the plurality of fluid channels. 
     
     
         9 . The battery pack of  claim 1 , wherein at least 70 percent of a volume of the battery pack is occupied by cells. 
     
     
         10 . The battery pack of  claim 1 , wherein each row of the one or more rows has a same number of cells. 
     
     
         11 . The battery pack of  claim 1 , wherein the battery pack has at least two rows and each row is separated from an adjacent row by a divider. 
     
     
         12 . The battery pack of  claim 1 , wherein two other sidewalls of the at least four sidewalls are arranged opposite each other along a plane of the small wall surface to confine to the plurality of cells. 
     
     
         13 . The battery pack of  claim 1 , further comprising one or more busbars connected to the plurality of cells through electrical connectors. 
     
     
         14 . A battery pack comprising:
 an enclosure having at least four sidewalls connected by a base, the base being an extrusion; and   a first endplate that forms one of said at least four sidewalls, the first endplate configured to be welded or attached to the base to apply compressive load to a plurality of cells;   wherein a body of the enclosure is made from extruded parts and the at least four sidewalls are mechanically attached or welded to the base.   
     
     
         15 . The battery pack of  claim 14 , wherein the enclosure comprises an electronics compartment that houses one or more battery pack electronics control modules. 
     
     
         16 . The battery pack of  claim 14 , wherein at least 70 percent of a volume of the battery pack is occupied by cells. 
     
     
         17 . A method for producing a battery pack, the method comprising:
 forming an enclosure that includes a base and at least four sidewalls, wherein the base is formed by extrusion to include a plurality of fluid channels;   providing a plurality of cells with each of the plurality of cells having a large wall surface and a small wall surface, a surface area of the small wall surface being less than a surface area of the large wall surface;   arranging the plurality of cells on the base such that their large wall surfaces are parallel to each other; and   retaining the plurality of cells under compression between two sidewalls of the at least four sidewalls, wherein the compression is in a direction perpendicular to the large wall surfaces;   wherein at least one sidewall of the at least four sidewalls is mechanically attached to the base.   
     
     
         18 . The method of  claim 17 , further comprising:
 creating a pressure differential, by a pump, to move a cooling liquid through the plurality of fluid channels to cool the plurality of cells.   
     
     
         19 . The method of  claim 17 , further comprising:
 forming, as part of the enclosure, an electronics compartment disposed on a second end of the battery pack to house one or more battery pack electronics control modules.   
     
     
         20 . The method of  claim 17 , further comprising forming the enclosure and arranging the plurality of cells on the base of the enclosure such that at least 70% of a volume of the battery pack is occupied by the plurality of cells.