WO2025240559A1 - Fungible multi-voltage energy storage device platforms, and methods thereof - Google Patents

Abstract

Fungible cell packs including common cells for energy storage devices are described, wherein the platform and/or architecture of the cells, cell packs and/or energy storage devices are structured so that they can be utilized in multiple energy storage devices with differing operating voltages depending on how the cells of cell pack are oriented and electrically connected together.

Description

FUNGIBLE MULTI- VOLTAGE ENERGY STORAGE DEVICE PLATFORMS, AND

METHODS THEREOF

INCORPORATION BY REFERENCE TO PRIORITY APPLICATION

[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet or PCT Request as filed with the present application are hereby incorporated by reference under 37 CFR 1.57, and Rules 4.18 and 20.6. This application claims priority to U.S. Provisional Patent Application No. 63/649264, titled “FUNGIBLE MULTI- VOLTAGE ENERGY STORAGE DEVICE PLATFORMS, AND METHODS THEREOF” and filed on May 17, 2024, the disclosure of which is hereby incorporated herein by reference in its entirety for all purposes.

BACKGROUND

Field

[0002] The present disclosure related generally to energy storage devices, particularly energy storage device cell packs.

Description of the Related Art

[0003] Energy storage devices are typically designed to operate at a single voltage. As such, if energy storage devices with different operating voltage as desired, different energy storage devices with different architectures are required. The energy storage devices with different operating voltages may differ in the architecture of the cell packs, housing, carriers and other components, which may increase manufacturing complexity and costs. For example, lead-acid batteries are configured to operate at a single voltage, and do not include electronics for management of the battery.

SUMMARY

[0004] For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention are described herein. Not all such objects or advantages may be achieved in any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0005] In one aspect, a method of assembling various energy storage devices is described. The method includes: selecting a first cell pack array comprising a first cell pack arrangement having a first voltage; selecting a second cell pack array comprising a second cell pack arrangement having a second voltage different from the first voltage; and on an assembly line: installing the first cell pack array in a first cell carrier to form a first cell pack; adhering the first cell pack into a first bottom housing; installing a first carrier, a first busbar arrangement disposed thereon, over the first cell pack; attaching a plurality of cell tabs of the first cell pack to the first carrier; installing a first printed circuit board assembly (“PCBA”) onto the first carrier; installing a first top cover on the first bottom housing to form a first energy storage device; installing the second cell pack array in a second cell carrier to form a second cell pack; adhering the second cell pack into a second bottom housing; installing a second carrier, a second busbar arrangement disposed thereon, over the second cell pack; attaching a plurality of cell tabs of the second cell pack to the second carrier; installing a second PCBA, wherein the second PCBA is substantially similar to the first PCBA onto the second carrier; and installing a second top cover on the second bottom housing to form a second energy storage device, wherein the assembly line is configured to form both the first energy storage device having the first voltage and the second energy storage device having the second voltage.

[0006] In another aspect, an energy storage device is described. The energy storage device includes: a housing; a carrier comprising a plurality of slot features forming a slot pattern; a printed circuit board assembly (“PCBA”); a cover; and a cell pack disposed within the housing, the cell pack including: a plurality of cells comprising a cell count, wherein each cell comprises an anode tab and a cathode tab, and wherein the plurality of cathode tab and the anode tabs form a tab pattern on a first side of the cell pack, wherein the cell count and the tab pattern are configured to operate the cell pack at an operating voltage, wherein a cathode tab and an anode tab of the cell pack are in electrical communication with the plurality of slot features and a tab pattern of the cell pack matches the slot pattern, and wherein the carrier is positioned over the first side of a cell pack, and the PCBA is positioned over the carrier. [0007] In some embodiments, each of the plurality of cells include at least a portion of a surface that forms the first side of the cell pack. In some embodiments, the tab pattern and the slot pattern are configured to operate the energy storage device at an operating voltage. In some embodiments, each of the plurality of cells comprise at least a portion of a surface that forms the first side of the cell pack. In some embodiments, the PCBA comprises a plurality of heating resistors. In some embodiments, the energy storage device includes a thermally conductive material disposed between the cathode and anode tabs and the PCBA. In some embodiments, the energy storage device includes a temperature sensor dispose on a surface of the cell pack. In some embodiments, the carrier includes a busbar arrangement.

[0008] In another aspect, a method of forming the energy storage device is described. The method includes: selecting and orienting the plurality of cells to form the cell pack; disposing the cell pack within the housing; selecting the carrier configured to operate the energy storage device at the operating voltage; and electrically connecting the carrier to the cell pack.

[0009] In another aspect, a method of assembling an energy storage device is described. The method includes: selecting a first cell pack array comprising a first cell pack arrangement; and on an assembly line: installing the first cell pack array in a first cell carrier to form a first cell pack; adhering the first cell pack into a first bottom housing; installing a first carrier, a first busbar arrangement disposed thereon, over the first cell pack; attaching a plurality of cell tabs of the first cell pack to the first carrier; installing a first PCBA onto the first carrier; and installing a first top cover on the first bottom housing.

[0010] In some embodiments, the method includes selecting the first carrier based on the first busbar arrangement disposed thereon. In some embodiments, attaching the plurality of cell tabs of the first cell pack to the first carrier includes bending and flattening one or more cell tabs on the first carrier, and creasing the one or more cell tabs onto the first carrier. In some embodiments, the first PCBA comprises one or more heat resistors. In some embodiment, the method includes: selecting a second cell pack array comprising a second cell pack arrangement, wherein the second cell pack arrangement is different than the first cell pack arrangement; and on the assembly line: installing the second cell pack array in a second cell carrier to form a second cell pack; adhering the second cell pack into a second bottom housing; installing a second carrier, a second busbar arrangement disposed thereon, over the second cell pack; attaching a plurality of cell tabs of the second cell pack to the second carrier; installing a second PCBA onto the second carrier; and installing a second top cover on the second bottom housing. In some embodiments, attaching the plurality of cell tabs of the first cell pack to the first carrier includes bending and flattening one or more cell tabs on the first carrier via a bending and flattening apparatus, and creasing the one or more cell tabs onto the first carrier via a rolling apparatus. In some embodiments, attaching the plurality of cell tabs of the second cell pack to the second carrier includes bending and flattening one or more cell tabs on the second carrier via the bending and flattening apparatus, and creasing the one or more cell tabs onto the second carrier via the rolling apparatus. In some embodiments, the first PCBA and the second PCBA are substantially the same. In some embodiments, the first cell pack has a first voltage and the second cell pack has a second, different voltage. In some embodiments, the first cell pack has a voltage selected from a group consisting of 12V or 16V and the second cell pack has a voltage of 48V.

[0011] In one aspect, a cell pack is described. The cell pack includes: a plurality of cells including a cell count, wherein each cell includes an anode tab and a cathode tab, and wherein the plurality of cathode and anode tabs form a tab pattern on a first side of the cell pack; wherein the cell count and the tab pattern are configured to operate the cell pack at an operating voltage.

[0012] In some embodiments, each of the plurality of cells include at least a portion of a surface that forms the first side of the cell pack.

[0013] In another aspect, an energy storage device is described. The energy storage device includes: a housing; a carrier comprising a plurality of slot features forming a slot pattern; a monitoring board; a cover; and a cell pack disposed within the housing, wherein the plurality of cathode and anode tabs in electrical communication with the slot features and the tab pattern matches the slot pattern.

[0014] In some embodiments, the tab pattern and the slot pattern are configured to operate the energy storage device at an operating voltage. In some embodiments, the carrier is positioned over the first side of the cell pack, and the monitoring board is positioned over the carrier.

[0015] In another aspect, a method of forming an energy storage device is described. The method includes: selecting and orienting a plurality of cells to form a cell pack; disposing the cell pack within a housing; selecting a carrier with a slot pattern that matches the tab pattern, and configured to operate the energy storage device at the operating voltage; and electrically connecting the carrier to the cell pack.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features, aspects, and advantages of the present disclosure are described with reference to the drawings of certain embodiments, which are intended to illustrate certain embodiments and not to limit the invention.

[0017] FIG. 1A is a perspective exploded schematic illustration of an energy storage device, according to some embodiments.

[0018] FIG. IB is a perspective schematic illustration of an energy storage device, according to some embodiments.

[0019] FIG. 1C is a perspective schematic illustration of an energy storage device, according to some embodiments.

[0020] FIG. 2A is a top view schematic illustration of a printed circuit board assembly (“PCBA”) installed on a carrier with a first arrangement for a first energy storage device having the first voltage, according to some embodiments.

[0021] FIG. 2B is a top view schematic illustration of a PCBA installed on a carrier with a second arrangement for a first energy storage device having the second voltage, according to some embodiments.

[0022] FIG. 3A is a top view schematic illustration of a carrier configured to operate an energy storage device at 12V, according to some embodiments.

[0023] FIG. 3B is a top view schematic illustration of a carrier configured to operate an energy storage device at 48V, according to some embodiments.

[0024] FIG. 4 is a flow chart illustrating a method of assembling an energy storage device, according to some embodiments.

[0025] FIG. 5 is a perspective schematic illustration of a carrier in electrical communication with the cell tabs on the cell pack, according to some embodiments.

[0026] FIG. 6A is a perspective schematic illustration of a monitoring board and cover of the energy storage device, according to some embodiments.

[0027] FIG. 6B is a top view schematic illustration of a monitoring board and cover of the energy storage device, according to some embodiments. [0028] FIG. 7 is a cross-sectional side view schematic illustration of an energy storage device including heating elements, according to some embodiments.

[0029] FIG. 8 is a cross-sectional side view schematic illustration of a monitoring board including heating elements, according to some embodiments.

[0030] FIG. 9 is a flow chart illustrating a method of heating an energy storage device, according to some embodiments.

DETAILED DESCRIPTION

[0031] Although certain preferred embodiments and examples are disclosed below, the inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and to modifications and equivalents thereof. Thus, the scope of the claims appended hereto is not limited by any of the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described as multiple discrete operations, in turn, in a manner that may be helpful in understanding certain embodiments; however, the order of description should not be construed to imply that these operations are order-dependent. Additionally, the structures, systems, and/or devices described herein may be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein.

[0032] Energy storage devices (e.g., batteries) including fungible elements, common cells and/or fungible cell packs are described, wherein the platform and/or architecture of the cells, cell packs and/or energy storage devices are structured so that they can be utilized in multiple energy storage devices with differing operating voltages (e.g., 6V, 12V, 16V, 24V, 36V, 48V) depending on howthe cells of cell pack are oriented and electrically connected together. The structure of the cells and common cell pack platform allow for a single cell pack design concept to be utilized for different operating voltages depending on desired operating voltage (e.g., 12V, 16V, 24V, 36V, 48V) with simple changes in orientation of the cells, number of cells within the cell pack, connections between the cells within the cell pack and/or dimensional changes to the remainer of the energy storage device. As such, the resulting manufacturing line for the cell packs and/or energy storage devices is shared such that one production line can produce both types of energy storage devices (e.g., batteries).

[0033] Advantageously, the energy storage devices described can include substantially the same, identical, fungible, and/or similar components. For example, components having dimensional commonalities, fastening commonalities, order of assembly commonalities, and other similarities. The commonalities can advantageously facilitate the production of various energy storage devices on the same assembly line. This can advantageously improve production efficiency, reduce upfront manufacturing costs, and improve product quality in energy cell production.

[0034] Advantageously, in some embodiments, many of the most complex and/or most difficult to manufacture components of the energy storage devices described can be fungible (e.g., interchangeable) between energy storage devices having different voltages. For example, PCBAs, PCBAs including heating resistors, cell packs, and/or temperature sensors. The interchangeability between these components can advantageously improve the reliability and quality control during manufacturing and operation of the energy storage devices.

[0035] Advantageously, in some embodiments, many of the most common elements of the energy storage devices described can be fungible (e.g., interchangeable) between energy storage devices having different voltages. For example, foam, fasteners, thermally conductive adhesive, thermally conductive material, and vents. The interchangeability between these components can advantageously improve the quality control, drastically reduce part count, simplify bills of materials, and reduce risks of supplier delays during manufacturing and operation of the energy storage devices.

[0036] Advantageously, in some embodiments, many of the steps for assembling the energy storage devices described can be fungible (e.g., interchangeable) between energy storage devices having different voltages. For example, bending and flattening cell tabs, creasing cell tabs, soldering, dispensing and/or applying adhesives, welding, and installing components. In some embodiments, the steps and/or apparatuses for manufacturing the energy storage devices may remain fungible for manufacturing different energy storage devices (e.g., energy storage devices of different sizes and/or operating voltage, and elements within the energy storage devices thereof). Advantageously, the steps may be completed on the same assembly line and using the same equipment regardless of the voltage of the energy storage device being assembled. In some embodiments, such fungibility is at least in part due to the fungibility and/or similarities of the energy storage device elements of different energy storage devices. The interchangeability between energy storage devices during the manufacturing process can advantageously improve the quality control, reduce the need for employee crosstraining, and reduce manufacturing time during manufacturing of the energy storage devices.

[0037] Advantageously, in some embodiments, energy storage devices having different voltages can include, include about, or include about at least 50%, 60%, 70%, or more of the same elements.

[0038] FIG. 1 A illustrates an exploded view of an embodiment of an energy storage device 100A. The energy storage device 100A includes a top cover 110, a vent 120, a connector 130, a printed circuit board assembly (PCBA) 140, a carrier 150, a flexible printed circuit 160, a cell pack array 170, a cell carrier 180, and a bottom housing 190. The cell pack array 170 includes a plurality of cells 174, a foam layer 176, and a plurality of tabs 172. The foam layer 176 is positioned around the plurality of cells 174. The tabs 172 extend upward from the plurality of cells 174. The flexible printed circuit 160 is attached to the cell carrier 180. The cell carrier 180 is positioned around the cell pack array 170 to form a cell pack. The flexible printed circuit 160 attaches to the cell pack array 170. The cell pack array 170 and cell carrier 180 are housed interior to the bottom housing 190. The PCBA 140 is positioned over the carrier 150. The carrier 150 attaches to a plurality of cell tabs 172 of the cell pack array 170. The flexible printed circuit 160 attaches to the PCBA 140. The connector 130 is attached to the PCBA 140 and disposed within an opening in the top cover 110. The vent 120 is disposed within an opening in the top cover 110. The top cover 110 attaches to the bottom housing 190 to seal the energy storage device 100A.

[0039] The cell pack includes a plurality of cells. In some embodiments, the cells of the cell pack are pouch cells. In some embodiments, each cell includes an anode tab and a cathode tab positioned on a first side of the cell (e.g., pouch cell). In some embodiments, the anode and cathode tabs of the each of the plurality of cells are positioned on a first side of the cell pack. In some embodiments, the anode tab is positioned on a first end of the first side of the cell and the cathode tab is positioned on a second end of the first side of the cell.

[0040] In some embodiments, the number and/or orientation of the cells within the cell pack are selected in order to achieve different operating voltages, and the cells, cell pack, and energy storage device architectures are configured to enable such changes in a single production line.

[0041] In some embodiments, different energy storage devices having different voltage requirements can utilize the same number of cells by having a different connection arrangement. Advantageously, substantially the same cells can be used in different energy storage devices. The connection arrangement of the cells can provide for an energy storage device having a 6V, 12V, 16V, 24V, 36V, or 48V capacity. In some embodiments, a 12V energy storage device and/or cell pack includes 12 total cells, with 4 cells connected in series and 3 cells connected in parallel. In some embodiments, a 16V energy storage device and/or cell pack includes 12 total cells. In some embodiments, a 48V energy storage device and/or cell pack includes 13 total cells within the cell pack, with 13 cells connected in series and 1 cell connected in parallel.

[0042] FIGS. IB and 1C illustrate example embodiments of assembled energy storage devices. FIG. IB is an illustration of an energy storage device 100B, and includes a bottom housing 190B, a cell pack with a plurality of cells, a carrier, a PCBA (for example, a battery monitoring board), and a top cover HOB. The energy storage device 100B includes a first arrangement of an energy storage device 100B. FIG. 1C is an illustration of an energy storage device 100C, and includes a bottom housing 190C, a cell pack with a plurality of cells, a carrier, a PCBA, and a top cover 110C. The energy storage device 100B includes a second arrangement of an energy storage device 100C. The energy storage device 100B includes a first cell pack arrangement. The energy storage device 100C includes a second cell pack arrangement. The bottom housing 190B of the energy storage device 100B has a different footprint shape than the bottom housing 190C of the energy storage device 100C to accommodate the first cell pack arrangement and the second cell pack arrangements, respectively. Likewise, the top cover HOB of the energy storage device 100B has a different footprint shape than the top cover 110C of the energy storage device 100C to attach to their respective bottom housings. [0043] The cells of the cell pack are configured to be able to be stacked together and orientated in an architecture that enables arrangement for different energy storage device voltage requirements (e.g., 6V, 12V, 16V, 24V, 36V, or 48V). The cell pack includes a plurality of cell tabs (e.g., a plurality of anode tabs and/or a plurality of cathode tabs) that are electrically connected (e.g., welded) to the carrier (e.g., busbar carrier).

[0044] In some embodiments, a cell pack having a 6V, 12V, 16V, 24V, 36V, or 48V capacity can be housed in the same, substantially the same, compatible, and/or fungible bottom housing and utilizing the same, substantially the same, compatible, and/or fungible top cover regardless of the arrangement of the cell pack. In some embodiments, a cell pack having a first arrangement (e.g., a cell pack with 12 total cells) and a cell pack having a second arrangement (e.g., a cell pack with 13 total cells) can be housed in different bottom housings. The different bottom housing can have different shapes to accommodate the cell packs having different numbers of cells in some embodiments. In some embodiments, the first arrangement bottom housing and second arrangement bottom housing can have commonalities which advantageously allow the first and second arrangement energy storage devices to be manufactured on the same, substantially the same, compatible, and/or fungible manufacturing line without substantial modifications to process. In some embodiments, the first and second bottom housings have the same, substantially the same, compatible, and/or fungible heights. In some embodiments, the first and second energy storage devices include the same, substantially the same, compatible, and/or fungible fastener patterns. In some embodiments, the first and second energy storage devices include the same, substantially the same, compatible, and/or fungible fastener torque specifications. In some embodiments, the first and energy storage devices include the same, substantially the same, compatible, and/or fungible machine locating features.

[0045] FIGS. 2A and 2B illustrate example embodiments of PCBAs. FIG. 2A is an illustration of a PCBA 240A, which includes a resistor arrangement 242A and a busbar arrangement 244A placed over the PCBA 240A. The PCBA 240A includes a first arrangement of a PCBA 240A for an energy storage device having a first voltage. FIG. 2B is an illustration of a PCBA 240B, which includes a resistor arrangement 242B and a busbar arrangement 244B placed over the PCBA 240B. The PCBA 240B includes a second arrangement of a PCBA 240B for an energy storage device having a second voltage. The resistor arrangement 242A is substantially the same as the resistor arrangement 242B. The busbar arrangement 244A differs from the busbar arrangement 244B so that the PCBA 240A can have the first arrangement for a first energy storage device having the first voltage (e.g., 48V) and the PCBA 240B can have the second arrangement for a second energy storage device having the second voltage (e.g., 12V or 16V).

[0046] Advantageously, the same, substantially the same, compatible, and/or fungible PCBAs can be used for various energy storage devices due to the resistor arrangement of the PCBAs in some embodiments. In some embodiments, the PCBAs can be identical. For example, the same, substantially the same, compatible, and/or fungible PCBA can be installed in a 6V, 12V, 16V, 24V, 36V, or 48V energy storage device. The busbar arrangement can be altered depending on the desired energy storage device voltage.

[0047] FIGS. 3A and 3B are illustrations of carriers (e.g., PCBA carriers and/or busbar carriers) 350A and 350B that include busbars 344A and 344B. The carrier 350A, 350B may be electrically connected by slots of the carrier 350A, 350B to the cell pack through the cell tabs to operate the energy storage device at 12V or 48V, respectively. In some embodiments, the energy storage devices can operate at 6V, 12V, 16V, 24V, 36V, or 48V.

[0048] FIG. 4 is a flow chart illustrating a method 400 of assembling an energy storage device. In some embodiments, the method can include selecting a cell pack array including a series of energy cells arranged in a cell pack arrangement. At step 402, the method includes installing a flex printed circuit on a cell carrier. In some embodiments, installing the flex print circuit on the cell carrier can include adhering (e.g., bonding, gluing, fusing, or uniting with or without a glue, adhesive, epoxy, cement, or paste) a temperature sensor connected to a flex print circuit to the cell carrier. At step 404, the method includes installing foam around a series of energy cells to form a cell pack array. At step 406, the method includes installing the cell pack array in the cell carrier to form a cell pack. In some embodiments, the temperature sensor connected to the flex print circuit is adhered (e.g., bonded, glued, fused, or united with or without a glue, adhesive, epoxy, cement, or paste) to a surface of the cell pack array. In some embodiment, the method includes adhering (e.g., bonding, gluing, fusing, or uniting with or without a glue, adhesive, epoxy, cement, or paste) the cell pack into the bottom housing. In step 408, the method includes dispensing thermally conductive adhesive in a bottom housing and adhering the cell pack into the bottom housing. At step 410, the method includes installing a carrier, a busbar arrangement disposed thereon, over the cell pack in the bottom housing. In some embodiments, the method includes attaching a plurality of cell tabs of a cell pack to a carrier. At step 412, the method includes bending and flattening one or more cell tabs on the carrier. In some embodiments, the bending and flattening can be performed via a bending and flattening apparatus. At step 414, the method includes creasing the one or more cell tabs on the carrier. In some embodiments, the creasing can be performed via a rolling apparatus. At step 416, the method includes soldering the busbar arrangement to the carrier and welding the one or more cell tabs. At step 418, the method includes applying thermally conductive material to the busbar arrangement. At step 420, the method includes installing a PCBA on the busbar arrangement. At step 422, the method includes soldering the PCBA to the busbar arrangement. At step 424, the method includes adhering (e.g., bonding, gluing, fusing, or uniting with or without a glue, adhesive, epoxy, or paste) a vent to a top cover. At step 426, the method includes applying cover adhesive to the bottom housing. In some embodiments, adhesive is applied to a connector header. At step 428, the method includes installing the top cover on the bottom housing.

[0049] In some embodiments, the same, substantially the same, compatible, and/or fungible steps can be repeated to form a second energy storage device having a different cell pack arrangement relative to a first energy storage device. In some embodiments, the same, substantially the same, compatible, and/or fungible PCBA is installed regardless of the cell pack array selected. In some embodiments, the carrier is selected based on the busbar arrangement disposed thereon. In some embodiments, the PCBA includes one or more heat resistors.

[0050] Advantageously, in some embodiments, the method can be applied on an assembly line and/or using the same, substantially the same, compatible, and/or fungible manufacturing equipment (e.g., assembly machinery) to produce an energy storage device having a first voltage and then on the same, substantially the same, compatible, and/or fungible assembly line to produce a second energy storage device having a second voltage. Advantageously, the method of assembling the energy storage device can be applied to energy storage devices having various voltages. For example, 6V, 12V, 16V, 24V, 36V, or 48V. Additionally, the method of assembling the energy storage device can be applied with the same, substantially the same, compatible, and/or fungible manufacturing equipment (e.g., assembly machinery) and/or on the same, substantially the same, compatible, and/or fungible assembly line regardless of the voltage of the energy storage device.

[0051] FIG. 5 is an illustration of a carrier (e.g., a PCBA carrier and/or busbar carrier) 550 in electrical communication with the cell tabs 572 of the cell pack 570. The carrier 550 includes slot features or patterns that interface with the cell tabs 572 during busbar-cell marriage to form an electrical connection. In some embodiments, the slot pattern of the carrier matches the pattern of the cell tabs.

[0052] In some embodiments, the carrier (e.g., PCBA carrier and/or busbar carrier) includes lead-in elements that are positioned to guide the cells tabs (into busbar slots during busbar-cell marriage. In some embodiments, the carrier (e.g., PCBA carrier and/or busbar carrier) and slot patterns may be configured such that the cell pack operates at a desired operating voltage. In some embodiments, the number and orientation of the cells of the cell pack are selected and configured to operate at different operating voltages (e.g., 12V or 48V) depending on the carrier (e.g., PCBA carrier and/or busbar carrier) and slot pattern selected.

[0053] FIGS. 6A and 6B are illustrations of a monitoring board 648 (e.g., battery monitoring board (BMB)) including a PCBA 640 and a carrier 650 within an energy storage device 600 and a top cover 610 of the energy storage device 600. The monitoring board 648 can include a wire harness or flexible print circuit (FPC) to connect the carrier 650 (e.g., PCBA carrier and/or busbar carrier) to the PCBA 640 (e.g., a circuit board) of the energy storage device 600, which creates small pins on the carrier 650 (e.g., PCBA carrier and/or busbar carrier) so that the PCBA 640 can be positioned on and be electrically connected (e.g., soldered) to the carrier 650 without an intermediate harness. In some embodiments, no wire harness and/or FPC is used to connect the PCBA 640 to the carrier 650. A busbar and PCBA 640 are shown stamped all together and over-molded with a plastic material that provides both structure support and electrical connection to form a monitoring board 648. The top cover 610 includes a connector header housing with terminal pins electrically connected (e.g., soldered) to the PCBA 640, and where the connector header housing is integrated into the top cover (e.g., plastic material).

[0054] In some embodiments, a monitoring board includes heating elements. FIG. 7 is a schematic illustration of an energy storage device 700 including heating elements, according to some embodiments. The energy storage device 700 includes a bottom housing 790, a cell pack 770 having a plurality of tabs 772, a thermally conductive material 752, a plurality of resistors 742, a PCBA 740, an application-specific integrated circuit (ASIC) 746, a flexible printed circuit 760, and a temperature sensor 762. The cell pack 770 is disposed in the bottom housing 790. The plurality of tabs 772 are positioned at the top of the cell pack 770 and contact the thermally conductive material 752. The thermally conductive material 752 is disposed between the plurality of tabs 772 and the PCBA 740. The plurality of resistors 742 are positioned above the thermally conductive material 752 and are surface mounted to the PCBA 740. The ASIC 746 is connected to the PCBA 740. The temperature sensor 762 is disposed on a surface of the cell pack 770. The temperature sensor 762 connects to the cell pack 770 and the flexible printed circuit 760. The flexible printed circuit 760 attaches to the PCBA 740.

[0055] As illustrated, the resistors 742 generate heat, which is transferred through the thermally conductive material 752, through the tabs 772 and into the cell pack 770. The resistors 742 (e.g., heater resistors) provide heat to the cell pack 770. The temperature sensor 762 senses the temperature of the cell pack 770. The flexible printed circuit 760 transmits the temperature sensor 762 information to the PCBA 740 and/or the ASIC 746. The PCBA 740 and/or ASIC 746 controls whether the resistors 742 provide heat to the cell pack 770.

[0056] In some embodiments, the resistors are surface mounted resistors. In some embodiments, the temperature sensor is a thermistor. In some embodiments, the temperature sensor is a negative temperature coefficient thermistor. In some embodiments, the temperature sensor can be open loop modeled.

[0057] FIG. 8 is an illustration of a monitoring board 848. The monitoring board 848 includes a carrier, PCBA, busbar, and heating elements 842 (e.g., heater resistors), where heating the cell is integrated. The heater resistors are shown disposed at bottom of the monitoring board 848, and conduct heat through a thermal adhesive between the monitoring board and the cell tabs (e.g., welded on top of the busbar).

[0058] In some embodiments, the energy storage device includes 1, 2, 3, 4, 5, 6, 7, 8, or more temperature sensors or any range of values therein. In some embodiments, the energy storage device includes 1, 2, 3, 4, 5, 6, 7, 8,9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 or more heater resistors or any range of values therein. In some embodiments, the PCBA and/or ASIC set the resistors to always on if the temperature is at, at about, below, or below about -40 °C, -30 °C, -20 °C, -10 °C, 0 °C, or any range of values therein. In some embodiments, the PCBA and/or ASIC turn on the resistors if the temperature is at, at about, below, or below about -40 °C, -30 °C, -20 °C, -10 °C, 0 °C, or any range of values therein. In some embodiments, the PCBA and/or ASIC set the resistors to run with bang-bang control if the temperature is at, at about, below, or below about -30 °C, -20 °C, -10 °C, 0 °C, 10 °C or any range of values therein. In some embodiments, the PCBA and/or ASIC turn on the resistors if the temperature is at, at about, below, or below about -40 °C, -30 °C, - 20 °C, -10 °C, 0 °C, or any range of values therein.

[0059] FIG. 9 a flow chart illustrating a method 900 of heating an energy storage device, according to some embodiments. At step 910, the method includes providing an energy storage device. At step 920, the method includes turning on one or more resistors. At step 930, the method includes heating a cell pack via the one or more resistors. At step 940, the method includes monitoring the cell pack array temperature via a temperature sensor in communication with an ASIC. At step 950, the method includes turning off the one or more resistors based on feedback from the ASIC.

[0060] Advantageously, the heating resistors can be integrated into the PCBA such that any energy storage device, regardless of voltage or cell arrangement, can include the embodiments of heating systems described in FIGS. 7-9.

[0061] While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims.

[0062] It is to be understood that the operating voltage describes the nominal voltage of the energy storage device, and that the actual voltages of the energy storage device may fluctuate depending on factors such as amount charged. In some embodiments, an energy storage device with an operating voltage of 12V may have voltages of, or of about, 12V, 13 V, 14V, 15V or 16V, or any range of values therebetween. In some embodiments, an energy storage device with an operating voltage of 48 V may have voltages of, or of about, 26V, 30V, 32V, 34V, 36V, 38V, 40V, 42V, 44V, 46V, 48V, 50V, 51V or 52V, or any range of values therebetween.

Electrode Materials. Electrode Films. Electrodes, and Energy Storage Devices

[0063] An active material (e.g., cathode active material, anode active material) may be used in the preparation of an electrode film and/or electrode for an energy storage device. In some embodiments, an electrode comprises a current collector (i.e., a foil layer) and an electrode film (i.e., coated lane).

[0064] In some embodiments, the active material is a cathode active material. In some embodiments, the cathode active material is selected from at least one of a metal oxide, metal sulfide, a sulfur-carbon composite, a lithium metal oxide, and a material including sulfur. In some embodiments, the cathode active material is selected from lithium iron phosphate (i.e., LiFePCh or “LFP”), lithium manganese iron phosphate (e.g., LiMno.6Feo.4PO4 or “LMFP”), lithium nickel manganese cobalt oxide (i.e., LiNi_xMn_yCoi-_x-yO2 or “NMC”), lithium nickel cobalt aluminum oxide (i.e., LiNi_xCo_yAl_zO2 or “NCA”), lithium manganese oxide (“LMO”), lithium nickel manganese oxide (“LNMO”), lithium cobalt oxide (“LCO”), lithium titanate (“LTO”), or combinations thereof. In some embodiments, the cathode active material includes at least two of LFP, LMFP, NMC, NCA, LMO, LNMO, LCO, LTO, and combinations thereof. In some embodiments, the cathode active material is an iron phosphate-based active material. In some embodiments, iron phosphate-based active materials include LiFePO4 (i.e., “lithium iron phosphate” and “LFP”) and LiMni-_xFe_xPO4 (i.e., “lithium manganese iron phosphate” and “LMFP”) (e.g., LiMno.6Feo.4PO4 or LiMno.sFeo.2PO4). In some embodiments, the iron phosphate-based active material includes LFP. In some embodiments, the iron phosphate- based active material includes an LMFP. In some embodiments, the iron phosphate-based active material includes an LFP and/or an LMFP.

[0065] In some embodiments, the active material is an anode active material. In some embodiments, anode active materials can include, for example, an insertion material (such as carbon, graphite, and/or graphene), an alloying/dealloying material (such as silicon, silicon oxide, tin, and/or tin oxide), a metal alloy or compound (such as Si-Al, and/or Si-Sn), and/or a conversion material (such as manganese oxide, molybdenum oxide, nickel oxide, and/or copper oxide). The anode active materials can be used alone or mixed together to form multi-phase materials (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si- SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx.). Anode active materials include common natural graphite, synthetic or artificial graphite, surface modified graphite, spherical-shaped graphite, flake-shaped graphite and blends or combinations of these types of graphite, metallic elements and its compound as well as metal-C composite for anode.

[0066] In some embodiments, the electrode film comprises the active material in an amount of, of about, of at least, or at least about, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 86 wt.%, 87 wt.%, 88 wt.%, 89 wt.%, 90 wt.%, 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, 95 wt.%, 96 wt.%, 97 wt.%, 98 wt.%, 98.5 wt.%, 99 wt.%, 99.5 wt.%, 99.8 wt.% or 99.9 wt.%, or any range of values therebetween.

[0067] In some embodiments, an electrode film comprises a carbon material configured to reversibly intercalate lithium ions. In some embodiments, the lithium intercalating carbon is selected from a graphitic carbon, graphite, hard carbon, soft carbon and combinations thereof. For example, the electrode film of the electrode can include a binder material, one or more of graphitic carbon, graphite, graphene-containing carbon, hard carbon and soft carbon, and an electrical conductivity promoting material. In some embodiments, an electrode is mixed with lithium metal and/or lithium ions. In some embodiments, the electrode comprises the carbon material in a total amount of, of about, of at most, or at most about, 20 wt.%, 15 wt.%, 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, or any range of values therebetween.

[0068] In some embodiments, an electrode film includes a conductive additive. In some embodiments, the conductive additive may comprise a conductive carbon additive, such as a carbon black. In some embodiments, the conductive additive may comprise a conductive carbon additive. In some embodiments, the conductive carbon additive comprises carbon black, carbon nanotubes, such as single- walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). In some embodiments, the electrode film comprises the conductive additive in a total amount of, of about, of at most, or at most about, 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, 0.5 wt.%, 0.25 wt.%, 0.1 wt.%, or any range of values therebetween. In some embodiments, each of the conductive additive is in an amount of, of about, of at most, or at most about, 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, 1 wt.%, 0.5 wt.%, 0.25 wt.%, 0.1 wt.%, of the electrode film, or any range of values therebetween. In some embodiments, the conductive additive is carbon black.

[0069] In some embodiments, the electrode film includes a binder. In some embodiments, binders can include polytetrafluoroethylene (PTFE), a polyolefin, polyalkylenes, polyethers, styrene-butadiene, co-polymers of polysiloxanes and polysiloxane, branched polyethers, polyvinylethers, a carboxymethylcellulose (CMC), co-polymers thereof, and/or combinations thereof. In some embodiments, the polyolefin can include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), co-polymers thereof, and/or combinations thereof. For example, the binder can include polyvinylene chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxane-coalkylmethylsiloxane, co-polymers thereof, and/or combinations thereof. In some embodiments, the binder may include a thermoplastic. In some embodiments, the binder comprises a fibrillizable and/or fibrillized polymer. In certain embodiments, the binder comprises, consists essentially, or consists of a single fibrillizable and/or fibrillized binder, such as PTFE. In some embodiments, the electrode film includes, includes about, includes at most, or includes at most about, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, or any range of values therebetween, of a binder.

[0070] In some embodiments, the electrode film can be a wet processed electrode film. In some embodiments, the electrode film is prepared by a wet or slurry-based electrode fabrication process. In some embodiments, the electrode film of the present disclosure can be a dry processed electrode film. In some embodiments, the electrode film is prepared by a dry electrode fabrication process. As used herein, a dry electrode fabrication process can refer to a process in which no or substantially no solvents are used to form a dry electrode film. For example, components of the active layer or electrode film, including carbon materials and binders, may comprise, consist of, or consist essentially of dry particles. The dry particles for forming the active layer or electrode film may be combined to provide a dry particle active layer mixture. In some embodiments, the active layer or electrode film may be formed from the dry particle active layer mixture such that weight percentages of the components of the active layer or electrode film and weight percentages of the components of the dry particles active layer mixture are substantially the same. In some embodiments, the active layer or electrode film formed from the dry particle active layer mixture using the dry fabrication process may be free from, or substantially free from, any processing additives such as solvents and solvent residues resulting therefrom. In some embodiments, the resulting active layer or electrode films are self-supporting films formed using the dry process from the dry particle mixture. In some embodiments, the resulting active layer or electrode films are free-standing films formed using the dry process from the dry particle mixture. A process for forming an active layer or electrode film can include fibrillizing the fibrillizable binder component(s) such that the film comprises fibrillized binder. In further embodiments, a free-standing active layer or electrode film may be formed in the absence of a current collector. In still further embodiments, an active layer or electrode film may comprise a fibrillized polymer matrix such that the film is self-supporting. It is thought that a matrix, lattice, or web of fibrils can be formed to provide mechanical structure to the electrode film.

[0071] In some embodiments, an electrode film is disposed on a current collector (e.g., a coated lane is disposed on a foil layer) to form an electrode. In some embodiments, a current collector can include a metallic material, such as a material comprising aluminum, nickel, copper, combinations of the foregoing. In some embodiments, a current collector comprises a pure metal. In some embodiments, a current collector comprises a metallized polymer film or metal coated polymer film. In some embodiments, the polymer comprises polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP) or a combination thereof. In some embodiments, the metal coating comprises aluminum. In some embodiments, coating the final electrode film mixture comprises forming a uniform electrode film mixture coating. In some embodiments, the current collector comprises a thickness of, of about, of at most, or at most about, 200 pm, 100 pm, 50 pm, 40 pm, 30 pm, 20 pm, 15 pm, 10 pm, 5 pm, or any range of values therebetween.

[0072] In some embodiments, an energy storage device comprises a separator, an anode electrode, the cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode and cathode electrode are disposed within the housing and the separator is positioned between the anode and cathode electrodes. In some embodiments, an energy storage device is formed by placing an electrolyte, a separator, an anode electrode and the cathode electrode described herein within a housing, wherein the separator is placed between the anode electrode and the cathode electrode.

[0073] In some embodiments, an electrode is a double-sided electrode. In some embodiments, the double-sided electrode includes two electrode films. In some embodiments, the double-sided electrode may include a current collector, a top electrode film, and a bottom electrode film. In some embodiments, each of the two electrode films can have any suitable shape, size and thickness.

[0074] An electrode assembly includes a cathode, an anode, and a separator positioned between the anode and cathode. In some embodiments, the electrode assembly is a wound electrode (i.e., rolled electrode) assembly (e.g., a jelly roll). In some embodiments, the energy storage device is selected from the group consisting of a cylindrical energy storage device, a stacked prismatic energy storage device, and a spiral-wound prismatic energy storage device.

[0075] The electrode disclosed herein may be used for an energy storage device. In some embodiments, the energy storage device comprises a separator, an anode electrode, the cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode and cathode electrode are disposed within the housing and the separator is positioned between the anode and cathode electrodes. In some embodiments, an energy storage device is formed by placing an electrolyte, a separator, an anode electrode and the cathode electrode described herein within a housing, wherein the separator is placed between the anode electrode and the cathode electrode. In some embodiments, the energy storage device comprises an anode electrode positioned between two cathode electrodes. In some embodiments, the anode electrode and/or the cathode electrode comprises a shaped electrode film.

[0076] In some embodiments, the energy storage device is a lithium-ion battery. In some embodiments, the energy storage devices may be a battery, capacitor, capacitor-battery hybrid, fuel cell, or combinations thereof. In some embodiments, the energy storage system or energy storage device may be used for electromobility. In some embodiments, the energy storage device may be used in motor vehicles, including hybrid electric vehicles (HEV), plugin hybrid electric vehicles (PHEV), and/or electric vehicles (EV). In some embodiments, the energy storage device used in motor vehicles, including hybrid electric vehicles (HEV), plug- in hybrid electric vehicles (PHEV), and/or electric vehicles (EV) reduces greenhouse gas emissions.

[0077] In some embodiments, the energy storage device is charged with a suitable lithium-containing electrolyte. For example, the energy storage device can include a lithium salt, and a solvent, such as a non-aqueous or organic solvent. Generally, the lithium salt includes an anion that is redox stable. In some embodiments, the anion can be monovalent. In some embodiments, a lithium salt can be selected from lithium hexafluorophosphate (LiPFe), lithium bis(trifluoromethanesulfonyl)imide (LiFSI), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiClO-i), lithium bis(trifluoromethansulfonyl)imide (LiN(SO2CF3)2), lithium trifluoromethansulfonate (LiSChCFs), lithium bis(oxalato)borate (LiB(C2O4)2), lithium bis(fluorosulfonyl)imide (LiN(SO2F)2, lithium difluoro(oxalato)borate (LiC2BF2O4) and combinations thereof. In some embodiments, the electrolyte can include a quaternary ammonium cation and an anion selected from the group consisting of hexafluorophosphate, tetrafluoroborate and iodide. In some embodiments, the salt concentration can be about 0.1 mol/L (M) to about 5 M, about 0.2 M to about 3 M, or about 0.3 M to about 2 M. In further embodiments, the salt concentration of the electrolyte can be about 0.7 M to about 2 M. In certain embodiments, the salt concentration of the electrolyte can be about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.6 M, about 0.7 M, about 0.8 M. about 0.9 M, about 1 M, about 1.1 M, about 1.2 M, 1.3M, 1.4M, 1.5M or values therebetween.

[0078] In some embodiments, an energy storage device can include a liquid solvent. The solvent need not dissolve every component, and need not completely dissolve any component, of the electrolyte. In further embodiments, the solvent can be an organic solvent. In some embodiments, a solvent can include one or more functional groups selected from dioxathiolane (e.g., l,3,2-dioxathiolane-2,2-dioxide (i.e., “DTD”)), carbonates, ethers and/or esters. In some embodiments, the solvent can comprise a carbonate. In further embodiments, the carbonate can be selected from cyclic carbonates such as, for example, ethylene carbonate (EC), propylene carbonate (PC), vinyl ethylene carbonate (VEC), vinylene carbonate (VC), fluoroethylene carbonate (FEC), and combinations thereof, or acyclic carbonates such as, for example, dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), 1,3-propene sultone (PRS), and combinations thereof. In some embodiments, the solvent can comprise an ester. In some embodiments, the ester is selected from methyl acetate (MA), methyl propionate (MP), ethyl acetate (EA), methyl butyrate (MB), and combinations thereof. In some embodiments, the solvent may include EC, PC, VEC, VC, FEC, DMC, DEC, EMC, MA, MP, EA, MB, and combinations thereof. In some embodiments, the solvent may include EC, DMC, DEC, EMC, MA, and combinations thereof. In some embodiments, the solvent may include EC, DMC, EMC, and combinations thereof. In some embodiments, the solvent may include a ratio of EC:DMC:EMC of 10-30:0-90:0-70.

[0079] In some embodiments, one or more solvents can be used at a concentration of, of about, of at least, or at least about, 30 wt. %, 35 wt. %, 40 wt. %, 45 wt. %, 50 wt. %, 55 wt. %, 60 wt. %, 65 wt. %, 70 wt. %, 75 wt. %, 80 wt. %, 85 wt. % or 90 wt. %, or any range of values therebetween. In some embodiments, solvents are utilized as additives in the electrolyte system, and can be used at a concentration of, of about, of at most, or at most about, 0.1 wt. %, 0.2 wt. %, 0.3 wt. %, 0.4 wt. %, 0.5 wt. %, 0.6 wt. %, 0.7 wt. %, 0.8 wt. %, 0.9 wt. %, 1 wt. %, 1.1 wt. %, 1.2 wt. %, 1.3 wt. %, 1.4 wt. %, 1.5 wt. %, 1.6 wt. %, 1.7 wt. %, 1.8 wt. %, 1.9 wt. %, 2 wt. %, 2.1 wt. %, 2.2 wt. %, 2.3 wt. %, 2.4 wt. %, 2.5 wt. %, 2.6 wt. %, 2.7 wt. %, 2.8 wt. %, 2.9 wt. %, 3 wt. %, 4 wt. %, 5 wt. %, 6 wt. %, 7 wt. %, 8 wt. %, 9 wt. % or 10 wt. %, or any range of values therebetween. For example, in some embodiments, the amount of an additive in the electrolyte is or is about in any one of the following ranges: 0.1-10 wt.%, 1-6 wt.%, 2-5 wt.%, 0.1-6 wt.%, 2-8 wt.%, 2-3 wt.%, or 1-4 wt.%.

[0080] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or embodiments disclosed herein. As such, it is contemplated that various alternative forms, embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure.

[0081] In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosed battery system. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, or materials may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all of which is apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as "including", "comprising", "incorporating", "consisting of, "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

[0082] Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., connected, associated, coupled, and the like) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the elements disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references may not necessarily infer that two elements are directly connected to each other.

[0083] Additionally, all numerical terms, such as, but not limited to, "first", "second", "one", "another", or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/ or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification.

[0084] It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed in certain cases, as is useful in accordance with a particular application.

[0085] The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. [0086] Although certain embodiments and examples have been described herein, it will be understood by those skilled in the art that many aspects of the systems shown and described in the present disclosure may be differently combined and/or modified to form still further embodiments or acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure. A wide variety of designs and approaches are possible. No feature, structure, or step disclosed herein is essential or indispensable.

[0087] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0088] Moreover, while illustrative embodiments have been described herein, the scope of any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. Further, the actions of the disclosed processes and methods may be modified in any manner, including by reordering actions and/or inserting additional actions and/or deleting actions. It is intended, therefore, that the specification and examples be considered as illustrative only, with a true scope and spirit being indicated by the claims and their full scope of equivalents.

[0089] Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that some embodiments include, while other embodiments do not include, certain features, elements, and/or states. Thus, such conditional language is not generally intended to imply that features, elements, blocks, and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.

[0090] The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited.

[0091] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0092] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

[0093] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. For example, any of the components for an energy storage system described herein can be provided separately, or integrated together (e.g., packaged together, or attached together) to form an energy storage system.

[0094] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0095] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.

[0096] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z. [0097] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount, depending on the desired function or desired result.

[0098] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.

Claims

WHAT IS CLAIMED IS:

1. A method of assembling various energy storage devices, comprising: selecting a first cell pack array comprising a first cell pack arrangement having a first voltage; selecting a second cell pack array comprising a second cell pack arrangement having a second voltage different from the first voltage; and on an assembly line: installing the first cell pack array in a first cell carrier to form a first cell pack; adhering the first cell pack into a first bottom housing; installing a first carrier, a first busbar arrangement disposed thereon, over the first cell pack array; attaching a plurality of cell tabs of the first cell pack array to the first cell carrier; installing a first printed circuit board assembly (“PCBA”) onto the first cell carrier; installing a first top cover on the first bottom housing to form a first energy storage device; installing the second cell pack array in a second cell carrier to form a second cell pack; adhering the second cell pack into a second bottom housing; installing a second carrier, a second busbar arrangement disposed thereon, over the second cell pack array; attaching a plurality of cell tabs of the second cell pack array to the second carrier; installing a second PCBA, wherein the second PCBA is substantially similar to the first PCBA onto the second carrier; and installing a second top cover on the second bottom housing to form a second energy storage device; wherein the assembly line is configured to form both the first energy storage device having the first voltage and the second energy storage device having the second voltage.

2. An energy storage device, comprising: a housing; a carrier comprising a plurality of slot features forming a slot pattern; a printed circuit board assembly (“PCBA”); a cover; and a cell pack disposed within the housing, the cell pack comprising: a plurality of cells comprising a cell count, wherein each cell comprises an anode tab and a cathode tab, and wherein a plurality of cathode tabs and anode tabs form a tab pattern on a first side of the cell pack; wherein the cell count and the tab pattern are configured to operate the cell pack at an operating voltage; wherein a cathode tab and an anode tab of the cell pack are in electrical communication with the plurality of slot features and a tab pattern of the cell pack matches the slot pattern; and wherein the carrier is positioned over the first side of a cell pack, and the PCBA is positioned over the carrier.

3. The energy storage device of Claim 2, wherein each of the plurality of cells comprise at least a portion of a surface that forms the first side of the cell pack.

4. The energy storage device of Claim 2 or 3, wherein the tab pattern and the slot pattern are configured to operate the energy storage device at an operating voltage.

5. The energy storage device of Claim 4, wherein each of the plurality of cells comprise at least a portion of a surface that forms the first side of the cell pack.

6. The energy storage device of any one of Claims 2-5, wherein the PCBA comprises a plurality of heating resistors.

7. The energy storage device of Claim 6, further comprising a thermally conductive material disposed between the cathode and anode tabs and the PCBA.

8. The energy storage device of Claim 7, further comprising a temperature sensor dispose on a surface of the cell pack.

9. The energy storage device of any one of Claims 2-8, wherein the carrier further comprises a busbar arrangement.

10. A method of forming the energy storage device of claim 2, comprising: selecting and orienting the plurality of cells to form the cell pack; disposing the cell pack within the housing; selecting the carrier configured to operate the energy storage device at the operating voltage; and electrically connecting the carrier to the cell pack.

11. A method of assembling an energy storage device, comprising: selecting a first cell pack array comprising a first cell pack arrangement; and on an assembly line: installing the first cell pack array in a first cell carrier to form a first cell pack; adhering the first cell pack into a first bottom housing; installing a first carrier, with a first busbar arrangement disposed thereon, over the first cell pack; attaching a plurality of cell tabs of the first cell pack to the first carrier; installing a first PCBA onto the first carrier; and installing a first top cover on the first bottom housing.

12. The method of Claim 11, further comprising selecting the first carrier based on the first busbar arrangement disposed thereon.

13. The method of Claim 11 or 12, wherein attaching the plurality of cell tabs of the first cell pack to the first carrier comprises: bending and flattening one or more cell tabs on the first carrier; and creasing the one or more cell tabs onto the first carrier.

14. The method of any one of Claims 11-13, wherein the first PCBA comprises one or more heat resistors.

15. The method of any one of Claims 11-14, further comprising: selecting a second cell pack array comprising a second cell pack arrangement, wherein the second cell pack arrangement is different than the first cell pack arrangement; and on the assembly line: installing the second cell pack array in a second cell carrier to form a second cell pack; adhering the second cell pack into a second bottom housing; installing a second carrier, a second busbar arrangement disposed thereon, over the second cell pack; attaching a plurality of cell tabs of the second cell pack to the second carrier; installing a second PCBA onto the second carrier; and installing a second top cover on the second bottom housing.

16. The method of Claim 15, wherein attaching the plurality of cell tabs of the first cell pack to the first carrier comprises: bending and flattening one or more cell tabs on the first carrier via a bending and flattening apparatus; and creasing the one or more cell tabs onto the first carrier via a rolling apparatus.

17. The method of Claim 16, wherein attaching the plurality of cell tabs of the second cell pack to the second carrier comprises: bending and flattening one or more cell tabs on the second carrier via the bending and flattening apparatus; and creasing the one or more cell tabs onto the second carrier via the rolling apparatus.

18. The method of any one of Claims 15-17, wherein the first PCBA and the second PCBA are substantially the same.

19. The method of any one of Claims 15-18, wherein the first cell pack has a first voltage and the second cell pack has a second, different voltage.

20. The method of Claim 19, wherein the first cell pack has a voltage selected from a group consisting of 12V or 16V and the second cell pack has a voltage of 48V.