Energy storage module cell assembly including pouch cell, compression element, thermal plate, and cell frame, and method for assembling the same

A cell sub-module comprising at least two cell assemblies, each of the at least two cell assemblies comprising:

• a cell frame, bus bars and a thermal plate, the bus bars and the thermal plate being integrated into the cell frame, the cell frame including a top wall and a bottom wall, the bus bars being in-molded into the top wall of the cell frame;
• a lithium-ion pouch cell comprising:
• a first face;
• and
• a second face opposite the first face;
• a positive cell terminal;
• and
• a negative cell terminal, the positive cell terminal and the negative cell terminal being arranged at a top end of the pouch cell, the positive cell terminal and the negative cell terminal each being pre-bent substantially at a right angle respective to the first face of the pouch cell;
• and
• a compression element;
• the cell frame being configured to receive and house the pouch cell and the compression element in a space defined by the thermal plate and the cell frame;
• the thermal plate including a bottom portion which extends through the bottom wall of the cell frame;
• the top wall of the cell frame including geometric features for supporting corresponding placement of the positive cell terminal and the negative cell terminal, the geometric features including a plurality of recesses, the plurality of recesses being shaped to receive the positive cell terminal and the negative cell terminal;
• and
• the at least two cell assemblies being stacked such that the thermal plate of a first cell assembly of the at least two cell assemblies contacts the compression element of an adjacent cell assembly of the at least two cell assemblies, and such that the cell terminals of each cell assembly are arranged on a first side of the cell sub-module.

An energy storage module, comprising:

• a housing having a thermal management feature;
• a plurality of cell sub-modules arranged in the housing, each sub-cell module of the plurality of cell sub-modules comprising:
• at least two cell assemblies, each of the at least two cell assemblies comprising:
• a cell frame, bus bars and a thermal plate, the bus bars and the thermal plate being integrated into the cell frame, the cell frame including a top wall and a bottom wall, the bus bars being in-molded into the top wall of the cell frame;
• a lithium-ion pouch cell comprising:
• a first face;
• and
• a second face opposite the first face;
• a positive cell terminal;
• and
• a negative cell terminal, the positive cell terminal and the negative cell terminal being arranged at a top end of the pouch cell, the positive cell terminal and the negative cell terminal each being pre-bent substantially at a right angle respective to the first face of the pouch cell;
• and
• a compression element;
• the cell frame being configured to receive and house the pouch cell and the compression element in a space defined by the thermal plate and the cell frame;
• the thermal plate including a bottom portion which extends through bottom wall of the cell frame;
• and
• the top wall of the cell frame including geometric features for supporting corresponding placement of the positive cell terminal and the negative cell terminal, the geometric features including a plurality of recesses, the plurality of recesses being shaped to receive the positive cell terminal and the negative cell terminal;
• and
• the at least two cell assemblies being stacked such that the thermal plate of a first cell assembly of the at least two cell assemblies contacts the compression element of an adjacent cell assembly of the at least two cell assemblies, and such that the cell terminals of each cell assembly are arranged on a first side of the cell sub-module;
• and
• the housing comprising a plurality of cavities, each configured to receive a corresponding one of the plurality of cell sub-modules, the cavities being defined by one of at least one wall of the housing and an internal partition of the housing by at least two internal partitions of the housing.