Integrated battery cell module

A battery module of a battery pack for electric vehicles, the battery module comprising:

• a housing having a length, a width and a height, a first surface of the housing defining a plurality of openings to a plurality of cavities extending along the height of the housing;
• a plurality of electrode structures positioned within the plurality of cavities, each electrode structure including a first tab terminal and a second tab terminal;
• a cover having a length equal to the length of the housing, having a height less than the height of the housing, and having a width equal to the width of the housing, the cover disposed over the first surface of the housing, the cover including a plurality of first junction connectors extending along a height of the cover between a first surface of the cover and an opposing second surface of the cover, the plurality of first junction connectors welded to respective first tab terminals of the plurality of electrode structures;
• and
• a plurality of second junction connectors extending between respective cavity base surfaces of the plurality of cavities and a second surface of the housing, the second surface of the housing opposing the first surface of the housing, the plurality of second junction connectors welded to respective second tab terminals of the plurality of electrode structures.

A method of providing battery modules for battery packs of electric vehicles, comprising:

• forming a housing having a length, width and a height, a first surface of the housing defining a plurality of openings to a plurality of cavities extending along the height of the housing;
• positioning a plurality of electrode structures within the plurality of cavities, each electrode structure including a first tab terminal and a second tab terminal;
• and
• disposing a cover having a length equal to the length of the housing, having a height less than the height of the housing, and having a width equal to the width of the housing, over the first surface of the housing, the cover including a plurality of first junction connectors extending along a height of the cover between a first surface of the cover to and an opposing second surface of the cover, an insulation layer positioned between at least a portion of the first surface of the housing and at least a portion of the second surface of the cover, the insulation layer positioned along at least a portion of a periphery of the first surface of the housing, the plurality of first junction connectors welded to respective first tab terminals of the plurality of electrode structures.

A method of providing battery modules for battery packs of electric vehicles, comprising:

• forming a housing having a length, width and a height, a first surface of the housing defining a plurality of openings to a plurality of cavities extending along the height of the housing;
• positioning a plurality of electrode structures within the plurality of cavities, each electrode structure including a first tab terminal and a second tab terminal;
• disposing a cover having a length equal to the length of the housing, having a height less than the height of the housing, and having a width equal to the width of the housing, over the first surface of the housing, the cover including a plurality of first junction connectors extending along a height of the cover between a first surface of the cover to and an opposing second surface of the cover;
• providing a plurality of second junction connectors extending between cavity base surfaces of the plurality of cavities and a second surface of the housing, the second surface of the housing opposing the first surface of the housing;
• and
• welding the plurality of second junction connectors to respective second tab terminals of the plurality of electrode structures.

A method, comprising:

• providing a battery module for a battery pack of an electric vehicle, the battery module including:
• a housing having a length, a width and a height, a first surface of the housing defining a plurality of openings to a plurality of cavities extending along the height of the housing;
• a plurality of electrode structures positioned within the plurality of cavities, each electrode structure including a first tab terminal and a second tab terminal;
• a cover having a length equal to the length of the housing, having a height less than the height of the housing, and having a width equal to the width of the housing, the cover disposed over the first surface of the housing, the cover including a plurality of first junction connectors extending along a height of the cover between a first surface of the cover and an opposing second surface of the cover, the plurality of first junction connectors welded to respective first tab terminals of the plurality of electrode structures, and
• an insulation layer positioned between at least a portion of the first surface of the housing and at least a portion of the second surface of the cover, the insulation layer positioned along at least a portion of a periphery of the first surface of the housing.