Systems and methods for battery structure, interconnects, sensing, and balancing

A battery interconnect assembly for electrically coupling a plurality of cells of a battery pack, the battery interconnect assembly comprising:

• a first plate, the first plate comprising:
• a first window;
• and
• a first tab associated with the first window, the first tab configured to couple the first plate to a first terminal of a cell of the plurality of cells of the battery pack on a first side of the battery pack, the first side opposite a second side of the battery pack;
• and
• a second plate parallel to and at least partially overlapping the first plate, the second plate comprising:
• a second window aligned with the first window, wherein the first tab extends through the second window;
• and
• a second tab associated with the second window, the second tab configured to couple the second plate to a second terminal of the cell on the first side of the battery pack, wherein:
• the first window is configured to have a first shape;
• the second window is configured to have a second shape that is different from the first shape;
• the first tab is configured to have a third shape;
• the second tab is configured to have a fourth shape that is different from the third shape;
• the first plate is physically separated from the second plate;
• the first plate is electrically connected to the second plate through the cell;
• the first terminal has a first polarity;
• and
• the second terminal has a second polarity.

An interconnect assembly for electrically coupling a plurality of cells of a battery pack, the plurality of cells comprising a first group of cells, a second group of cells, and a third group of cells, the interconnect assembly comprising:

• a first plate;
• and
• a second plate, wherein:
• the first plate and the second plate are configured to be disposed on a first side of the battery pack;
• the first side being opposite a second side of the battery pack;
• the first plate forming a series coupling between the first group of cells and the second group of cells;
• the second plate forms a series coupling between the second group of cells and the third group of cells;
• the first and second plates are electrically coupled to the plurality of cells via tabs extending into windows in the respective plates;
• the windows in the first plate are configured to have a first shape;
• the windows in the second plate are configured to have a second shape different from the first shape;
• the tabs extending into the windows in the first plate are configured to have a third shape, and
• the tabs extending into the windows in the second plate are configured to have a fourth shape different from the third shape.

A conductive plate for a battery interconnect assembly, the conductive plate comprising:

• a main body including a conductive material;
• a plurality of first windows disposed in the main body, each first window having a first tab extending from the main body therein;
• and
• a plurality of second windows disposed in the main body, each second window having a second tab extending from the main body therein, wherein each first window has a first shape, and wherein each second window has a second shape different than the first shape.

A battery pack, comprising:

• a plurality of cells;
• a first interconnect assembly comprising a first current carrying plate and a first interconnect plate, the first current carrying plate coupled to the first interconnect plate, the first current carrying plate having a first thickness that is greater than a second thickness of the first interconnect plate;
• and
• a second interconnect assembly comprising a second current carrying plate and a second interconnect plate, the second current carrying plate coupled to the second interconnect plate, the first interconnect plate and the second interconnect plate being physically and electrically coupled to the plurality of cells.