US 11,909,061 B2
Modular approach for advanced battery modules having different electrical characteristics
Richard M. DeKeuster, Racine, WI (US); Robert J. Mack, Milwaukee, WI (US); and Stephen D. Cash, Cary, IL (US)
Assigned to CPS Technology Holdings LLC, New York, NY (US)
Filed by CPS Technology Holdings LLC, New York, NY (US)
Filed on Nov. 4, 2020, as Appl. No. 17/089,540.
Application 17/089,540 is a division of application No. 14/501,095, filed on Sep. 30, 2014, abandoned.
Prior Publication US 2021/0057695 A1, Feb. 25, 2021
Int. Cl. H01M 50/26 (2021.01); H01M 50/267 (2021.01); H01M 10/0525 (2010.01); H01M 10/42 (2006.01); H01M 4/505 (2010.01); H01M 4/485 (2010.01); H01M 4/525 (2010.01); H01M 50/271 (2021.01); H01M 10/6563 (2014.01); H01M 10/625 (2014.01); H01M 10/613 (2014.01); H01M 50/249 (2021.01); B60L 50/64 (2019.01); H01M 50/209 (2021.01)
CPC H01M 50/267 (2021.01) [H01M 4/485 (2013.01); H01M 4/505 (2013.01); H01M 4/525 (2013.01); H01M 10/0525 (2013.01); H01M 10/425 (2013.01); H01M 50/271 (2021.01); B60L 50/64 (2019.02); H01M 10/613 (2015.04); H01M 10/625 (2015.04); H01M 10/6563 (2015.04); H01M 50/209 (2021.01); H01M 50/249 (2021.01); H01M 2220/20 (2013.01); Y02E 60/10 (2013.01); Y02P 70/50 (2015.11); Y02T 10/70 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of manufacturing lithium ion battery modules, the method comprising:
providing a first battery module subassembly on a first manufacturing path, the first battery module subassembly including a first housing having a first dimension, a second dimension, and a third dimension;
providing a second battery module subassembly on a second manufacturing path different from the first manufacturing path, the second battery module subassembly including a second housing having the first dimension, the second dimension, and a fourth dimension different than the third dimension;
converging the first manufacturing path and the second manufacturing path to a battery cell positioning region that includes a common battery cell source;
at the battery cell positioning region,
placing a first plurality of battery cells from the common battery cell source in the first battery module subassembly, and
placing a second plurality of battery cells from the common battery cell source in the second battery module subassembly, wherein a number of the second plurality of battery cells is different from a number of the first plurality of battery cells;
diverging the first manufacturing path from the second manufacturing path after the battery cell positioning region;
at a first component integration region in the first manufacturing path, the first component integration region having a first component source, assembling a first component of the first component source with the first battery module subassembly;
at a second component integration region in the second manufacturing path, the second component integration region having a second component source different from the first component source, assembling a second component of the second component source with the second battery module subassembly; and
concluding the first manufacturing path and the second manufacturing path to result in a first battery module and a second battery module.