320 may be manufactured (e.g., using injection molding, etc.) using at least one of a plurality of conductive materials (e.g., conductive plastics, thermal dissipation material, etc.) to promote thermal efficiency. Additionally, the cell barrier 320 may direct the thermal energy towards a heat sink (e.g., a cooling plate positioned proximate the bottom of the battery cell 270 and coupled to the cell separator 280, etc.). In some embodiments, the cell barrier 320 may be manufactured out of metallic materials (e.g., aluminum, steel, etc.).

According to an exemplary embodiment, the cell separator 280 may be configured to promote electrical isolation within the battery module 100. To be more precise, the cell separator 280 may reduce the potential of improper contact between the individual battery cells 270 to reduce the potential of shorting out at least one battery cell 270. Traditionally, battery cells 270 may have included a liner (e.g., metallic liner, insulated liner, etc.) to maintain energy storage within the battery cell 270 and to eliminate the potential of individual battery cells 270 shorting out by coming on contact with one another. In some embodiments, if the battery cells 270 are not properly assembled, arcing can occur between the battery cell 270 and a neighboring surface (e.g., another battery cell 270, metallic surface, etc.). The cell separator 280 mitigates at least one of (a) battery cell 270 shorting out and (b) battery cell 270 arcing by forming an individual barrier between each battery cell 270 in the battery module 100.

The support structure 330 may be a structure positioned along a vertical midpoint of the cell separator 280 (e.g., the support structure 330 separates the cell separator into two equal parts). The support structure 330 further includes a smooth flange or platform, shown as support structure platform 365. The support structure platform 365 may be configured to support a portion of the battery module cover 210, at the midpoint of the battery module cover 210. In some embodiments, the support structure platform 365 may be configured to provide structural rigidity to the battery cell 270.

The support structure 330 may be configured to provide (a) force dampening and (b) structural rigidity. By way of example, the support structure 330 may be configured to dampen forces (e.g., vibration, loading, impact, static, etc.) introduced to the battery module 100. To be more precise, the support structure 330 may be configured to dampen forces applied in at least one of the x-direction, y-direction, and z-direction. The support structures 330 may be further configured to withstand forces endured onto the battery module from external forces (e.g., force shock, crash, drop, crush, etc.). In such an embodiment, forces are routed, and dampened, through the support structures 330 instead of having direct contact with the battery cells 270.

The cell separator includes a plurality structures for retaining battery cells. For example, as shown in FIG. 6, the support structure 330 includes a number of flanges 370 extending therefrom, bottom walls 375, and the sidewalls 310. Together, the flanges 370, bottom walls 375, and sidewalls 310, as well as the cell barrier 320, each contact surfaces of the battery cells to retain such cell in place when assembled.

According to an example embodiment, the flanges 370 may be further configured to provide spacing between adjacent battery cells 270, which may also provide advantageous thermal separation. As shown in FIG. 6, the support structure 330 includes four flanges 370 substantially uniformly distributed along the length of the support structure 330. In some embodiments, the support structure 330 may include any number of flanges 370 needed to provide appropriate support to the battery module 100.

Referring still to FIG. 6, the cell separator 280 may be configured to advantageously provide at least one of decreased thermal prorogation and heat dissipation. Traditionally, battery cells 270 disposed within the battery module 100 are subject to high temperatures, with minimal methods of cooling. The cell separator 280, being disposed between battery cells 270, may have a lower temperature than the battery cells 270 thus allowing for heat to transfer from the battery cells 270 to the cell separator 280 (e.g., heat sink, etc.). This flow of heat between the battery cells 270 and the cell separator 280 may provide a cooling effect to the battery cells 270 such to prevent overheating. According to an example embodiment, the flow of heat between the battery cells 270 and the cell separator 280 may be at one of the flanges 370, the cell barrier 320, and the sidewalls 310, where heat flowing into the cell separator 280 is then routed out and away from the battery cells 270. Furthermore, the cell separator 280 may be configured as a barrier that is configured to prevent heat from transferring between adjacent battery cells 270.

Referring now to FIG. 7, the cell separator 280 includes a vertical axis, shown as Y-Y axis 380. The Y-Y axis 380 may be positioned along the support structure 330 and extend along the vertical midpoint of the cell separator 280. In some embodiments, the Y-Y axis 380 may extend vertically away from a vertical midpoint of the support structure 330. According to the example embodiment, the cell separator 280 may be configured as being geometrically similar over the Y-Y axis 380. Effectively, the Y-Y axis 380 separates the cell separator 280 into the respective first battery cell bank 250 and second battery cell bank 260.

Referring still to FIG. 7, the cell separator may include one or more features designed to allow coupling of adjacent cell separators to each other, which may advantageously provide a modular construction for the battery module (e.g., allowing a number of cell separators to couple to each other to allow variation in the number of battery cells included in the module). For example, at least one of the flanges 370 include a female portion or receptacle, shown as receptacle 390. The receptacle 390 may be configured to receive a male portion or member (shown in FIG. 8 as pins 395, which will be discussed more fully below) from an adjacent cell separator to couple the cell separators 280 to one another. According to an example embodiment, the receptacle 390 may be configured to receive a peg or extension from an adjacent cell separator. In some embodiments, the receptacle 390 may include a ridge where interaction between the receptacle 390 and the male portion create a snap (e.g., button, etc.) interaction. The cell separator 280 may include two receptacles 390, positioned equidistant to the top and bottom of the cell separator 280. To be more precise, the cell separator 280 may include a first receptacle positioned a first distance away from a top of the cell separator 280, and a second receptacle positioned a second distance away from a bottom of the cell separator 280, where the first distance is the same as the second distance. In some embodiments, the first receptacle 390 may be positioned closer to the top of the cell separator 280 such that the first distance is smaller than the second distance. In still other embodiments, the first receptacle 390 may be positioned further from the top of the cell separator 280 such that the first distance is larger than the second distance. According to still other embodiments, a different number of receptacles may be utilized.

Referring now to FIGS. 8 and 9, the cell separator 280 further comprises pins 395. The pins 395 may be configured to couple with the receptacles 390 to provide structural rigidity to the battery module 100 and to couple adjacent cell separators together. The pins 395 may be extruded bosses that extend horizontally from at least the support structure 330. In some embodiments, the pins 395 may be ribbed bosses where the ribs prevent the pins 395 from becoming out of contact with the receptacles 390. By way of example, the number of pins 395 coupled to the cell separator 280 is the same as the number of receptacles 390 on the adjacent cell separator. While the coupling members are illustrated herein as receptacles 390 and pins 395, it should be noted that other structures may be used for the purpose of coupling adjacent cell separators together.

The cell separator 280 further comprises a receiving flange, shown as cell receiving flange 400. The cell receiving flange 400 may be coupled to at least one of the sidewalls 310 and may further extend horizontally away from the cell separator 280. The cell receiving flange 400 may be an extruded rectangular boss, circular boss, or any extruded flange configuration. The cell receiving flange 400 may be configured to couple to at least one of the interlocking mechanisms 340 when the cell separators 280 abut one another. According to an example embodiment, the cell separator 280 includes two cell receiving flanges 400 positioned adjacent one another and coupled to the sidewalls 310.

As can be appreciated, the battery module 100 may include any number of cell separators 280 with any respective number of battery cells 270 disposed within, so as to create a customizable battery module. For example, for applications that may require additional power needs, more cell separators 280 can be added to allow for an increased number of battery cells 270. In some embodiments, if additional power is required, the cell separators 280 may include additional battery cell banks with additional support structures disposed between the additional battery cell banks. In still some embodiments, if additional power is required, the cell separators 280 may be coupled together at the interlocking mechanisms 340 such to extend the amount of battery cell banks disposed within the battery module 100.

To assemble the battery module 100, battery cells 270 are first placed in the associated cell separator 280, and then coupled to an adjacent battery cell/cell separator assembly. The process is then repeated until the battery module includes the desired number of battery cells 270. Once the layers of the battery module 100 are assembled, the end plates, side plates, and covers may be coupled to complete the battery module.

While the foregoing embodiments illustrate a configuration in which a battery module includes two “rows” or “banks” of cells, with each cell separator having a single support structure, other configurations are possible so as to allow a different number of rows of cells. By way of example, and referring now to FIG. 10, a cell separator 500 is shown according to another embodiment to allow the production of a battery module having three “rows” or “banks” of cells. The cell separator 500 is substantially similar to the cell separator 280 such that similar components may be used to describe the cell separator 500. The cell separator 500 includes a plurality of cell barriers 510 and a plurality of support structures 520 positioned between the plurality of cell barriers 510. The plurality of cell barriers 510 include a first cell barrier 530, a second cell barrier 540, and a third cell barrier 550. The plurality of cell barriers 510 may be configured to provide at least one of thermal propagation and heat dissipation to the cell separator 500. The plurality of support structures 520 include a first support structure 560 and a second support structure 570. The first support structure 560 may be positioned between the first cell barrier 530 and the second cell barrier 540. The second support structure 570 may be positioned between the second cell barrier 540 and the third cell barrier 550. The plurality of support structures 520 may be configured to (a) provide structural rigidity to the cell separator 500, (b) separate battery cells coupled to the cell separator 500, and (c) provide thermal propagation between battery cells coupled to the cell separator 500.

The cell separator 500 may be configured to accommodate an additional battery cell, coupled to the third cell barrier 550. By way of example, when the cell separators 500 are assembled into a battery module, the battery module will include an additional battery cell bank. The additional battery cell bank is configured to be substantially similar to the first battery cell bank 250 and the second battery cell bank 260. When the cell separators 500 are assembled into the battery module, the battery module may effectively have more power than the battery module 100.

According to an example embodiment, at least one of the plurality of end plates 290 and 300 and the cell separator 280 may include additional structural components. To be more precise, at least one of the plurality of end plates 290 and 300 and the cell separator may include increased ribbing or structural supports configured to further stiffen the battery module 100. The ribbing or structural supports may be configured to dampen loading force applied to the battery module in the vertical direction, the horizontal direction, or a combination of the horizontal and vertical direction.

Referring now to FIG. 11, a cell separator 600 is shown, according to an example embodiment, which allows for construction of a battery module having four “rows” or “banks” of cells. The cell separator 600 is configured to be substantially similar to the cell separators 280 and 500 such that similar components may be used to describe the cell separator 600. The cell separator 600 includes a plurality of cell barriers 610 and a plurality of support structures 620 positioned between the plurality of cell barriers 610. The plurality of cell barriers 610 include a first cell barrier 630, a second cell barrier 640, a third cell barrier 650, and a fourth cell barrier 660. The plurality of cell barriers 610 may be configured to provide at least one of thermal propagation and heat dissipation to the cell separator 600. The plurality of support structures 620 include a first support structure 670, a second support structure 680, and a third support structure 690. The first support structure