Current collector assembly with an elongated fuse

Patent metadata

Field	Value
Publication number	US-2025007131-A1
Application number	US-202418586356-A
Country	US
Kind code	A1
Filing date	Feb 23, 2024
Priority date	Jun 30, 2023
Publication date	Jan 2, 2025
Grant date	—

Abstract

A current collector assembly includes an electrically conductive layer with several tabs used to electrically couple with one or more battery cells. The tabs may connect to an interconnect of the electrically conductive layer by way of a fuse. Several fuses may include portions of difference sizes. For example, one portion of the fuse may be relatively longer and narrower, while another portion of the fuse may be shorter and wider. The narrower portion may be positioned between insulating layers of the current collector assembly, while the wider portion extends from the insulating layers. The wider portion of the fuse increases the likelihood of the fuse remaining intact when various forces are exerted on the fuse.

First claim

1 . An apparatus, comprising:
a current collector assembly comprising an electrically conductive layer, the electrically conductive layer comprising:
a first tab configured to be connected to a terminal of a battery cell; and
a first fuse comprising a first portion extending, from an interconnect of the electrically conductive layer, along a first axis and having a first width perpendicular to the first axis, the first fuse further comprising a second portion connected to the first tab and extending along a second axis and having a second width perpendicular with respect to the second axis, wherein the second axis is different from the first axis, and the first portion, measured along the first axis, is longer than the second portion.

2 . The apparatus of claim 1 , wherein:
the current collector assembly further comprises a first insulating layer, and the first insulating layer covers the first portion.

3 . The apparatus of claim 2 , further comprising a second insulating layer, wherein:
the second insulating layer is coupled with the first insulating layer, and the first insulating layer and the second insulating layer cover the first portion and partially cover the second portion.

4 . The apparatus of claim 3 , wherein:
the second insulating layer comprises an edge portion, and the second portion bends over the edge portion.

5 . The apparatus of claim 1 , wherein:
the first portion comprises a straight portion parallel with respect to the interconnect and disposed between the interconnect and the first tab, and the second portion is non-parallel with respect to the interconnect.

6 . The apparatus of claim 5 , wherein the first tab, the first fuse, and the interconnect form in part the current collector assembly configured to collect electrical current from one or more battery cells, including the battery cell, electrically coupled with the current collector assembly.

7 . The apparatus of claim 1 , wherein:
the first width is less than 1 millimeter (mm), and the second width is 3 to 5 mm.

8 . (canceled)

9 . A battery subassembly, comprising:
a current collector assembly electrically coupled with one or more battery cells, the currently collector assembly comprising an electrically conductive layer that comprises:
a first tab electrically coupled with a battery cell of the one or more battery cells; and
a fuse connected to the first tab, the fuse comprising a first portion extending along a first direction and having a first width, the fuse further comprising a second portion extending along a second direction different from the first direction and having a second width greater than the first width.

10 . The battery subassembly of claim 9 , further comprising a second tab, wherein:
the first tab is configured to electrically and mechanically couple with a positive terminal of the battery cell, and the second tab is configured to electrically and mechanically couple with a negative terminal of the battery cell.

11 . The battery subassembly of claim 9 , further comprising:
a first insulating layer; and a second insulating layer, wherein the first portion is enclosed by the first insulating layer and the second insulating layer.

12 . The battery subassembly of claim 11 , wherein the second portion gradually widens as the second portion extends away from the first insulating layer and the second insulating layer.

13 . The battery subassembly of claim 9 , wherein:
the currently collector assembly further comprises an interconnect, and the first portion of the first tab is connected to the interconnect.

14 . The battery subassembly of claim 13 , wherein:
the first portion is parallel with respect to the interconnect, and the second portion is perpendicular with respect to the interconnect.

15 . The battery subassembly of claim 13 , wherein the current collector assembly further comprises a thermal collector that extends from the interconnect, the thermal collector configured to receive thermal energy generated in the electrically conductive layer.

16 . The battery subassembly of claim 9 , wherein the second width is at least three times greater than the first width.

17 . A vehicle, comprising:
a battery subassembly comprising a current collector assembly electrically coupled with one or more battery cells, the currently collector assembly comprising:
a tab electrically coupled with a battery cell of the one or more battery cells; and
a fuse connected to the tab, the fuse comprising a first portion extending along a first direction and having a first width, the fuse further comprising a second portion extending along a second direction different from the first direction and having a second width greater than the first width;
a first insulating layer; and
a second insulating layer, wherein the first portion is enclosed by the first insulating layer and the second insulating layer, and the second portion extends from the first insulating layer and the second insulating layer, wherein the second portion widens from the second width as the second portion extends away from the first insulating layer and the second insulating layer.

18 . The vehicle of claim 17 , wherein:
the second insulating layer comprises an edge portion, and the second portion bends over the edge portion.

19 . The vehicle of claim 17 , wherein the first portion is perpendicular with respect to the second portion.

20 . The vehicle of claim 17 , wherein the tab is electrically coupled with a positive terminal of the battery cell.

21 . The apparatus of claim 1 , further comprising a second tab extending from a second fuse and configured to be connected to a second terminal of the battery cell, wherein the first fuse comprises a first shape and the second fuse comprises a second shape different than the first shape.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Patel Neil
• Butterfield Kyle
• Murkute Akshay Kishor
• Rahimi Najmeh
• Harris Kenton Robert

Classifications

• H01M50/588

  outside the batteries, e.g. incorrect connections of terminals or busbars · CPC title

• H01M50/593

  Spacers; Insulating plates · CPC title

• H01M50/583 Primary

  in response to current, e.g. fuses · CPC title

• H01M50/503

  characterised by the shape of the interconnectors · CPC title

• H01M50/507

  comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules · CPC title