A battery module includes a lower housing and a plurality of battery cells. The plurality of battery cells are electrically coupled together to produce a voltage. A lid assembly is disposed over the battery cells and is coupled to the lower housing. The lid assembly includes a lid and a plurality of bus bar interconnects mounted on the lid. A printed circuit board (PCB) assembly is disposed on and coupled to the lid assembly, and the PCB assembly includes a PCB. A cover is disposed over and coupled to the lower housing to hermetically seal the battery module.

A lithium ion secondary battery includes a positive electrode, a negative electrode, and an electrolyte provided between the positive electrode and the negative electrode. The positive electrode includes a positive electrode current collector and a positive electrode active material layer over the positive electrode current collector. The positive electrode active material layer includes a plurality of lithium-containing, composite oxides each of which is expressed by LiMPO.sub.4 (M is one or more of Fe (II), Mn (II), Co (II), and Ni (II)) that is a general formula. The lithium-containing composite oxide is a flat single crystal particle in which the length in the b-axis direction is shorter than each of the lengths in the a-axis direction and the c-axis direction. The lithium-containing composite oxide is provided over the positive electrode current collector so that the b-axis of the single crystal particle intersects with the surface of the positive electrode current collector.

A battery system having a bladed fuse connector and a method of operation of the bladed fuse connector are provided. The system may, in certain embodiments, include a printed circuit board (PCB) and a high current interconnect. The high current interconnect may be mounted to and extending upward from the PCB. The battery system may also include a fuse. The fuse may limit an amount of current flowing through the battery system. Additionally, the battery system may include a bladed fuse connector coupled between the high current interconnect and the fuse. The bladed fuse connector may carry a current between the high current interconnect and the fuse. To that end, the bladed fuse connector may include an S-shaped bend between the high current interconnect and the fuse.

Features for rechargeable lithium ion batteries, the batteries optionally employing vertically aligned carbon nanotube scaffolding, are described. Methods of manufacture and a solid polymer electrolyte are described for 3-dimensional battery architectures using the vertically aligned carbon nanotubes. Poly(ethylene)oxide bis(azide) and graphene poly(lactic acid) composite coatings are also described for use in such batteries or others.

A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

A method of manufacturing a battery module for use in a vehicle is presented. The method may include disposing battery cells into a lower housing and disposing a lid assembly over the battery cells. The lid assembly may include a lid and bus bar interconnects disposed on the lid. The method may also include disposing a printed circuit board (PCB) assembly onto the lid assembly and electrically coupling portions of the lid assembly, portions of the PCB assembly, and the battery cells to each other.

A printed circuit board (PCB) assembly includes a PCB and a high current interconnect mounted on the PCB. The high current interconnect is configured to electrically couple a first high current bladed component, a second high current bladed component, and a trace disposed on the PCB. The high current interconnect includes feet made of a conductive material that are coupled to the PCB. The trace is coupled to the feet via a weld.

A cell cathode compartment comprises a granule bed comprising metal granules, metal halide granules, and sodium halide granules, a separator adjacent to the granule bed, a liquid electrolyte dispersed in the granule bed, and a porous absorbent disposed in the granule bed, wherein a transverse cross-sectional distribution of the porous absorbent in the granule bed varies in a longitudinal direction from a first position to a second position. In another embodiment, a cell cathode compartment comprises a granule bed comprising metal granules, metal halide granules, and sodium halide granules, a separator adjacent to the granule bed, a liquid electrolyte dispersed in the granule bed, and a porous absorbent coating on a surface adjacent to the granule bed.

Battery electrodes are provided that can include a conductive core supported by a polymeric frame. Methods for manufacturing battery electrodes are provided that can include: providing a sheet of conductive material; and framing the sheet of conductive material with a polymeric material. Batteries are provided that can include a plurality of electrodes, with individual ones of the electrodes comprising a conductive core supported by a polymeric frame.

A lithium ion secondary battery includes a positive electrode, a negative electrode, and an electrolyte provided between the positive electrode and the negative electrode. The positive electrode includes a positive electrode current collector and a positive electrode active material layer over the positive electrode current collector. The positive electrode active material layer includes a plurality of lithium-containing composite oxides each of which is expressed by LiMPO.sub.4 (M is one or more of Fe (II), Mn (II), Co (II), and Ni (II)) that is a general formula. The lithium-containing composite oxide is a flat single crystal particle in which the length in the b-axis direction is shorter than each of the lengths in the a-axis direction and the c-axis direction. The lithium-containing composite oxide is provided over the positive electrode current collector so that the b-axis of the single crystal particle intersects with the surface of the positive electrode current collector.