Method for bonding thermoplastic components in a battery module

A lithium ion battery module housing comprising:

• a thermoplastic cover composed of a first transmissive or semi-transmissive layer configured to allow a transmission of an energy of a particular wavelength through the thermoplastic cover;
• a thermoplastic battery housing lid, composed of a second transmissive or semi-transmissive layer;
• an energy absorbing insert positioned between the thermoplastic cover and the thermoplastic battery housing lid, the energy absorbing insert composed of a material which absorbs the energy of the particular wavelength transferred through the thermoplastic cover and melts in response to the absorption, wherein the energy absorbing insert forms at least a part of a plastic weld joint between the thermoplastic cover and the thermoplastic battery housing lid;
• and
• an energy absorbing layer being a battery module housing separate from and adjacent to the thermoplastic battery housing lid and opposite the thermoplastic cover, the energy absorbing layer absorbs the energy of the particular wavelength directed at and initially contacting the energy absorbing layer and melts.

A lithium ion battery module comprising:

• a plurality of lithium ion battery cells held within an enclosure;
• a battery module housing coupled to a lid, the battery module housing and the lid forming the enclosure;
• and
• a plurality of electronics components held within an electronics compartment formed by the lid and a cover of the lithium ion battery module, wherein the plurality of electronics components are operatively coupled to the plurality of lithium ion battery cells;
• wherein the battery module housing and the lid are joined by a first weld to form a direct connection between the battery module housing and the lid, and the lid and the cover are joined by a second weld opposite the housing, wherein the second weld is formed between the lid and the cover via an energy absorbing insert in a laminar relationship with the lid and the cover having an increased absorbance in an infrared portion of an electromagnetic spectrum relative to the battery module housing and the cover through which the infrared portion travels.