WO2008106641A1

WO2008106641A1 - Battery system

Info

Publication number: WO2008106641A1
Application number: PCT/US2008/055487
Authority: WO
Inventors: Steven J. Wood; Gary P. Houchin-Miller; Dale B. Trester; Anthony Pacheco; Steven J. Esshaki
Original assignee: Johnson Controls - SAFT Advanced Power Solutions, LLC
Priority date: 2007-03-01
Filing date: 2008-02-29
Publication date: 2008-09-04
Also published as: EP2132803A1

Abstract

A battery module includes a plurality of cells arranged in a battery pack. The battery pack includes a first tray configured to receive a first row of cells and a second row of cells. A second tray is provided over the first tray, the first row of cells, and the second row of cells. The second tray is configured to receive a third row of cells and a fourth row of cells. A third tray is provided over the second tray, the third row of cells, and the fourth row of cells. The first row of cells and the second row of cells are arranged between the first tray and the second tray and the third row of cells and the fourth row of cells are arranged between the second tray and third tray.

Description

BATTERY SYSTEM

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Patent Application 60/904,180, filed March 1, 2007 and U.S. Patent Application 60/924,395 filed May 11, 2007, both of which are incorporated herein by reference in their entirety.

BACKGROUND

[0002] The present application relates generally to the field of batteries and battery systems. More specifically, the present application relates to a system for packaging and cooling and/or heating batteries (e.g., in a cell assembly or module).

[0003] It is known to provide batteries for use in vehicles such as automobiles. For example, lead-acid batteries have been used in starting, lighting, and ignition applications. More recently, hybrid vehicles have been produced which utilize a battery (e.g., a nickel metal hydride (NiMH) battery, a lithium-ion battery) in combination with other systems (e.g., an internal combustion engine) to provide power for the vehicle. Additionally, vehicles have been produced which utilize only a battery (e.g., a NiMH battery, a lithium-ion battery) to provide power for the vehicle.

[0004] The design and management of a battery system and/or module that can be advantageously utilized in a hybrid or electric vehicle may involve considerations such as battery arrangement, electrical performance monitoring, thermal management, and containment of effluent (e.g., gases that may be vented from a battery cell).

[0005] It would be desirable to provide an improved battery module or system for use in vehicles. It would also be desirable to provide a system for efficiently and effectively cooling and/or heating battery cells used in the module. It would also be desirable to provide an improved system and method for assembling and arranging a battery module. It would be desirable to provide a battery system that includes any one or more of these or other advantageous features as will be apparent from the present disclosure.

SUMMARY

[0006] According to an embodiment of the invention, a battery module includes a plurality of cells arranged in a battery pack. The cells have a first terminal and a second terminal at a first end thereof. The battery pack includes a first tray configured to receive a first row of cells and a second row of cells. A second tray is provided over the first tray, the first row of cells, and the second row of cells. The second tray is configured to receive a third row of cells and a fourth row of cells. A third tray is provided over the second tray, the third row of cells, and the fourth row of cells. The first row of cells and the second row of cells are arranged between the first tray and the second tray with the terminals of the first row of cells facing away from the terminals of the second row of cells and the third row of cells and the fourth row of cells are arranged between the second tray and third tray with the terminals of the third row of cells facing away from the terminals of the fourth rows of cells.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. l is a perspective view of a vehicle having a battery module provided therein.

[0008] FIG. 2 is a perspective view of a vehicle according to another exemplary embodiment.

[0009] FIG. 3 is a perspective view of a battery module or system according to an exemplary embodiment.

[0010] FIG. 4 is a perspective view of a housing or cover for use with a battery module such as that shown in FIG. 3.

[0011] FIG. 5 is an exploded perspective view of a battery module or system according to an exemplary embodiment. [0012] FIG. 6 is a perspective view of a battery pack for use with a battery module or system such as that shown in FIG. 5.

[0013] FIG. 7 is an exploded perspective view of the battery pack of FIG. 6.

[0014] FIG. 8 is a partially exploded perspective view of a battery pack for use in a battery module according to an exemplary embodiment.

[0015] FIG. 9 is a perspective view of the assembled battery pack of FIG. 8.

[0016] FIG. 10 is a front elevation view of the assembled battery pack of FIG. 8.

[0017] FIG. 11 is an exploded perspective view of the battery pack of FIG. 8 with three rows of cells omitted.

[0018] FIG. 12 is a perspective view of a tray of the battery pack of FIG. 7.

[0019] FIG. 13 is a detailed perspective view of the tray of FIG. 12.

[0020] FIG. 14 is a plan view of the buss bar assemblies and cell supervisory controllers of the battery module shown in FIG. 6.

[0021] FIG. 15 is a detailed perspective view of the buss bar assembly of FIG. 14.

[0022] FIG. 16 is a perspective view of a high voltage link cover for the buss bar assembly according to an exemplary embodiment.

[0023] FIG. 17 is an exploded perspective view of the high voltage link cover of FIG. 16.

[0024] FIG. 18 is a rear perspective view of the high voltage link cover of FIG. 16.

[0025] FIG. 19 is an exploded perspective view of the high voltage link cover of FIG. 18.

[0026] FIG. 20 is a partially exploded view of the battery module of FIG. 4.

[0027] FIG. 21 is another perspective view of the battery module of FIG. 4. [0028] FIG. 22 is a cross sectional view of the battery pack of FIG. 9.

[0029] FIG. 23 is a detailed cross sectional view of the battery pack of FIG. 22.

[0030] FIG. 24 is a partial cut away cooling flow diagram of the battery pack of FIG. 9.

[0031] FIG. 25 is a perspective view of a battery module or system according to another exemplary embodiment.

[0032] FIG. 26 is a top view of the battery module of FIG. 25.

DETAILED DESCRIPTION

[0033] The batteries and systems described herein may be used in any of a variety of applications, including, for example, vehicles such as hybrid electric vehicles, plug-in electric vehicles, and electric vehicles. FIG. 1 is a perspective view of a vehicle 8 (e.g., a hybrid-electric vehicle (HEV), plug-in HEV (PHEV), or electric vehicle (EV)) having a battery module provided therein according to an exemplary embodiment. The size, shape, and location of the battery module or system and the type of vehicle may vary according to a variety of other exemplary embodiments. It should be understood that the module 10 may be oriented in any suitable direction as may be appropriate in a given vehicle application.

[0034] One example of the manner in which the battery system or module is integrated within a vehicle is illustrated according to an exemplary embodiment illustrated in FIG. 2. As shown therein, a vehicle 200 (e.g., an HEV) is shown according to an exemplary embodiment. Vehicle 200 includes a battery system 210 (e.g., lithium-ion battery system), an internal combustion engine 220, an electric motor 230, a power split device 240, a generator 250, and a fuel tank 260. Vehicle 200 may be powered or driven by just the battery system 210, by just the engine 220, or by both the battery system 210 and engine 220. It should be noted that other types of vehicles and configurations for the vehicle electrical system may be used according to other exemplary embodiments. [0035] Referring to FIGS. 3-5, a battery system or module 10 is shown to include a housing 40, a battery pack 42, a battery disconnect unit 44, a base member shown as base plate 46, a support member shown as support frame 48, and a cover member shown as under mount cover 54. The housing 40 is configured to encase or enclose the battery pack 42 and the battery disconnect unit 44. The housing 40 may be constructed of a single sheet of material (e.g., sheet metal) or may be constructed of various combinations of different types of materials (e.g., metal, plastic, etc.). As shown in FIG. 5, the housing 40 is closed on five sides and open on a bottom side, hi other embodiments, housing 40 may be closed on the bottom side and have an opening on a side elsewhere on housing 40. Connectors 11, 13 (e.g., a low voltage 16-pin connector, a low voltage 24-pin connector, etc.) are provided coupled to module 10.

[0036] Provided in battery pack 42 are a plurality of batteries or cells 12 (as shown, for example, in FIG. 3). Cells 12 are shown in FIG. 3 as being provided in a generally horizontal manner. Alternatively, cells 12 may be provided in a generally vertical manner (as shown in FIG. 25).

[0037] Referring to FIGS. 6 and 7, battery pack 42 is shown to include a plurality of cells 12, a plurality of trays 14, 16, 18, 20 and 22, a first cell supervisory controller (CSC) 24, a second cell supervisory controller 26, a member shown as top tray plate 28, a plurality of buss bar assemblies 56, a plurality of buss bar covers 58, and a plurality of high voltage link cover assemblies 60.

[0038] Referring to FIGS. 8-11, a battery pack 42 (only one-half of battery pack 42 is shown for clarity) includes a plurality of batteries or cells 12 and a plurality of members or elements shown as trays 14, 16, 18, 20, and 22. Between each of the trays 14, 16, 18, 20, and 22 is provided a row of cells 12 (as shown, for example, in FIG. 11, where one row of cells 12 is provided in tray 14; the other rows of cells have are not shown between the trays for clarity) such that the trays sandwich the cells therebetween. [0039] Each of the trays 14, 16, 18, 20, and 22 are configured to receive a row of battery cells 12. Each of the batteries 12 in the row fit into or are received by a depression, valley, trough, cradle, or channel 15 and an upper portion, protrusion, ridge or peak 17 defined by the trays 14, 16, 18, 20, and 22 (see, for example, tray 20 in FIG. 11 - similar configurations are provided for each of the trays).

[0040] The tray 16, which has a different configuration than tray 14 as shown in FIG. 11, is provided on top of the first row of cells 12 and is configured for coupling or mating with the tray 14 to retain the row of cells 12 in place. A second row of cells 12 is then provided on tray 16 in the depressions or channels defined by the tray 16.

[0041] The tray 18 is configured for mating or coupling both with tray 16 and to sandwich the second row of cells between the trays 16 and 18. A third row of cells 12 is provided on tray 18.

[0042] Tray 20 is configured for coupling or mating with the tray 18 and for sandwiching the third row of cells between the trays 18 and 20. A fourth row of cells 12 is provided on tray 20.

[0043] Tray 22, which has a similar or identical configuration to the tray 14, is configured for coupling or mating with the tray 20 and for sandwiching the fourth row of cells 12 between the trays 20 and 22.

[0044] According to an exemplary embodiment, the trays 14 and 22 have a similar or identical configuration. According to an exemplary embodiment, the trays 16, 18, and 20 have a similar or identical configuration. As shown in FIG. 11, the trays 16, 18, and 20 are arranged in alternating orientations (i.e., the trays are arranged as mirror images of each other in the battery pack 42).

[0045] It should be understood that according to other exemplary embodiments, the battery module may include any suitable number of rows of batteries or cells and any suitable number of trays of any desired configuration. [0046] The terminals 30, 32 of cells 12 (as shown in FIG. 10) are exposed for relatively easy access for connecting to a load or to each other. The opposite end of each battery or cell 12 is exposed on the opposite side of the trays as a pathway for the expulsion of gases in the event that a cell 12 should expel gasses or effluent.

[0047] Each tray 14, 16, 18, 20, and 22 also defines a number of cutouts, openings or grooves 27 (shown in FIGS. 11-13) for the terminals 30, 32 (shown in FIG. 10) of each cell 12 to be exposed when module 10 is assembled. Cutouts, openings, or grooves 27 are typically of a specific shape to facilitate proper polarity of the terminals 30, 32 when laying down a row of cells 12 (for example, since the terminals have different sizes and/or shapes, the cells must be oriented in a particular manner in order for the terminals to be properly received in the grooves in a Poka-Yoke manner). In other exemplary embodiments, grooves 27 may be of shapes that are capable of receiving a plurality of different shapes of terminals regardless of polarity.

[0048] Each tray 14, 16, 18, 20, and 22 includes one or more cutouts or openings 26 that are configured to facilitate a flow of a fluid 36 (for example, air, liquid, etc.) between the cells 12 of battery pack 42. Openings 26 of trays 14, 16, 18, 20, and 22, when stacked or assembled, define paths or channels 34 (as shown in FIG. 22). Channels 34 are located both before and aft the cells 12 to aid in either cooling or heating the cells 12.

[0049] Referring now to FIGS. 12-13, a tray 18 is shown according to another exemplary embodiment to include a sealing member 19. Any of the above described trays may further include sealing member 19 as shown in FIGS. 12-13. According to one exemplary embodiment, sealing member 19 is an overmolded silicone seal that is configured to resist high temperatures. Sealing member 19 facilitates isolating fluid 36 in discrete channels and keeps the fluid 36 isolated from the terminals 30, 32 of the cells 12 and any gasses that might be vented from the cells 12. Sealing member 19 may also aid in dampening any vibrations the battery module 10 is exposed to, thus protecting individual cells 12. [0050] FIG. 7 illustrates a battery pack 42 capable of retaining eighty-eight cells 12. It should be understood that in other exemplary embodiments, a different number of cells may be utilized in the module, depending on the number of trays 14, 16, 18, 20, and 22 used and other factors. For example, a base tray (such as tray 14) may be combined with a top tray (such as tray 22) while omitting other trays (for example trays 16, 18, and 20) resulting in a module 10 with a single row of cells 12. In another example, a base tray (such as tray 14) may be combined with a single tray (for example, tray 16) and a top tray (such as tray 22), resulting in a module 10 with two rows of cells 12. In still other examples, modules of greater size than shown in FIGS. 7-13 may be assembled by adding alternating layers of trays such as those shown in FIGS. 7-13 as appropriate. Likewise, trays 14, 16, 18, 20, and 22 may be of different sizes and have capacity for more or fewer than eleven cells in each row. Additionally, each individual tray 14, 16, 18, 20, and 22 may be able to receive more then one or two rows of cells. For instance, each individual tray 14, 16, 18, 20, and 22 may be able to receive three or more rows of cells. It should be noted that FIG. 7 shows trays 14, 16, 18, 20, and 22 that are not shown interspersed between cells 12 for clarity. Trays 14, 16, 18, 20, and 22 may be interspersed between cells 12 as discussed above.

[0051] Trays 14, 16, 18, 20, and 22 may be made of any generally electrically insulating material (e.g., an injected molded polymeric material such as polyethylene or polypropylene) capable of supporting the cells 12 in a configuration similar to that shown in FIGS. 7-13. Additionally, while the cells shown in FIGS. 7-11 are shown as having a generally cylindrical shape, according to other exemplary embodiments, cells may have other forms (for example, oval, prismatic, polygonal, etc.). According to still other exemplary embodiments, cells may be lithium-ion, nickel cadmium, nickel metal hydride (NiMH), or any other suitable types of electrochemical cells.

[0052] Referring to FIGS. 14-15, the plurality of buss bar assemblies 56 are shown arranged to be assembled to the battery pack 42. The buss bar assembly 56 is shown to include a plurality of holes to be inserted over the terminals 30, 32 of the cells 12. Buss bar assembly 56 includes a plurality of connectors or buss bars that are riveted or otherwise coupled to a generally nonconductive substrate by fastening members (not shown). The buss bars are configured to couple the terminals of adjacent cells together or to an outside connector. Buss bar assembly 56 may further include sensors (e.g., voltage sensors, temperature sensors, etc.) that are coupled to the substrate of the buss bar assembly and are in communication with the cells 12 via sensor wires that are integrated onto the substrate of the buss bar assembly 56. The sensors may be electrically coupled to the buss bars and may monitor battery pack 42. Buss bar assembly 56 may also include one or more connectors (e.g., the connector shown as multi-pin connector 62 in FIG. 15).

[0053] The integrated nature of the buss bar assembly 56 (i.e., combining the buss bars, sensors, sensor wires, and connectors into a single component) reduces the overall parts count of the battery pack 42 (and the battery module 10) and simplifies assembly of the battery pack 42. For example, instead of having to assemble multiple components (e.g., individual buss bars, sensors, wires, etc.) to the battery pack 42, a single buss bar assembly 56 (having all the individual components attached to the buss bar assembly) is instead coupled to a battery pack 42 in a single action.

[0054] Also shown in FIG. 14 is a first cell supervisory controller 24 and a second cell supervisory controller 26. The cell supervisory controllers 24, 26 are shown to include a member shown as trace board 64, 66. The function of the cell supervisory controller is to monitor the cell voltage, perform cell balancing and provide (redundant) overvoltage protection. The cell supervisory controller is in electrical communication with the plurality of cells 12 via connector 62 shown in FIG. 15.

[0055] Referring to FIGS. 16-19, a high voltage link cover 60 is shown according to an exemplary embodiment. The high voltage link cover 60 is shown to include fastener 68, 74, washers 70, and buss bars 38. The function of high voltage cover 60 is to cover the high voltage terminals of the battery pack 42.

[0056] Referring to FIGS. 20 and 21, housing 40 is shown to include a first opening 76, a second opening 78, and a member shown as terminal cover 80. The terminal cover 80 covers the main terminal of battery module 10 (shown as first terminal 84 and second terminal 86), a service disconnect 82 and a high voltage charger connector 90. Also provided on housing 40 is a raised member shown as protrusion 88. Protrusion 88 may be shaped in the general shape of a numeral 3. The function of protrusion 88 is to keep main terminals 84, 86 separated from one another while connecting main terminals of battery module 10 to a vehicle. Protrusion 88 is helpful in guiding connecting cables (not shown) when connecting battery module 10 to a vehicle.

[0057] Referring to FIGS. 22-24, an assembled battery pack 42 defines a number of discrete channels, pathways, or passages 34 (through openings in the trays as described above) for the flow of a fluid 36 (for example, air, liquid, etc.) near and around cells 12. As shown specifically in FIG. 24, fluid 36 may be provided to battery pack 42 to aid in cooling or heating the cells 12. Fluid 36 may enter battery pack 42 as represented by arrow 50 in FIG. 24. Alternatively, fluid 36 may enter battery pack 42 in the reverse direction to that shown in FIG. 24 (i.e. fluid 36 may enter battery pack 42 at arrow 52 and exit at arrow 50). Fluid 36 may be at a high velocity or any other suitable velocity.

[0058] As shown in more detail in FIG. 23, the fluid 36 flows from a plenum airspace 33 through features shown as openings, inlets or bottlenecks 35 to a multitude of discrete channels, pathways, or passages 34 formed between cells 12 and trays 14, 16, 18, 20, and 22. The bottlenecks 35 form a restricted opening that creates a pressure drop as the fluid 36 leaves the plenum airspace 33. Having bottlenecks 35 ensures that fluid reaches all the discrete channels 34 at substantially the same temperature. As the fluid 36 flows over cells 12, heat transfer takes place (i.e., the fluid 36 absorbs heat from cells 12 or the fluid 36 provides heat to the cells 12) and the fluid 36 exits battery pack 42. Confining the fluid 36 to discrete channels reduces the chance of the fluid or taking unpredictable or undesirable paths through the module 10. Additionally, confining the fluid 36 to discrete channels further allows greater control of the heat transfer characteristics of the system.

[0059] During cooling, exiting fluid 36 may be at a higher temperature than entering fluid 36 due to the heat transfer that takes place between the cells 12 and the fluid 36. Alternatively, during heating, exiting fluid 36 may be at a lower temperature than entering fluid 36 due to the heat transfer that takes place between the cells 12 and the fluid 36. It is noted that according to various exemplary embodiments, fluid 36 may be pushed into (blown into) or pulled through (sucked out) of module 10 (for example, by a fan, by a pressure difference, by a vacuum pump, etc.).

[0060] It is noted that while a specific shape of pathways 34 is shown, pathways of other shapes may be defined based on alternative tray structures and shapes. As shown previously, cells 12 lie in or make contact with trays 14, 16, 18, 20, and 22. In an exemplary embodiment where trays 12, 16, 18, 20, and 22 are at least partially thermally conductive, contact with the material may transport heat from the cells to a state of equilibrium, thus moderating the temperature of individual cells 12 with the temperature of other cells.

[0061] Referring to FIGS. 25 and 26, a battery module 110 is shown according to an exemplary embodiment. Battery module 110 is shown to include a plurality of batteries or cells 112 arranged in a generally vertical configuration. A central plenum 118 is provided between a first grouping of cells 112 and a second grouping of cells 112. A first exterior plenum 120 is provided exterior the first grouping of cells 112 and a second exterior plenum 122 is provided exterior a second grouping of cells 112. A duct 114 is shown connected to a central plenum 118. A duct 116 is shown connected to the external plenums 120, 122 via ports or openings 126, 128. Duct 114 has an opening 130 and duct 116 has an opening 132.

[0062] As shown in FIG. 26 a heater 124 is provided in central plenum 118. Alternatively, heater 124 may be provided in a different location other than that shown in FIG. 26, or not at all. For instance, a heater may be placed in duct 114 or in duct 116. Fluid flow through battery module 110 may be from duct 114, into the central plenum 118, and then through the cells 112 (in both directions). Fluid will then exit through external plenums 120, 122 and out duct 116. Alternatively, fluid flow may begin at duct 116 and enter battery module 110 through the external plenums 120, 122. Fluid will then flow through the cells 112 and then exit through the central plenum 118 and out duct 114. A fluid may be used to either heat or cool battery module 110. [0063] It should be noted that references to "front," "rear," "top," and "base" in this description are merely used to identify various elements as are oriented in the FIGURES, with "front" and "rear" being relative to the environment in which the device is provided.

[0064] For the purpose of this disclosure, the term "coupled" means the joining of two members directly or indirectly to one another. Such joining may be stationary or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

[0065] It is important to note that the construction and arrangement of the battery system as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (for example, variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present embodiments.

Claims

WHAT IS CLAIMED IS:

L A battery module comprising: a plurality of cells arranged in a battery pack, the cells having a first terminal and a second terminal at a first end thereof; wherein the battery pack comprises: a first tray configured to receive a first row of cells and a second row of cells; a second tray provided adjacent the first tray, the first row of cells, and the second row of cells, the second tray configured to receive a third row of cells and a fourth row of cells; a third tray provided adjacent the second tray, the third row of cells, and the fourth row of cells; wherein the first row of cells and the second row of cells are arranged between the first and second trays with the terminals of the first row of cells facing away from the terminals of the second row of cells and the third row of cells and fourth row of cells are arranged between the second tray and the third tray with the terminals of the third row of cells facing away from the terminals of the fourth rows of cells.

2. The battery module of Claim 1 further comprising a buss bar assembly coupled to the terminals of the plurality of cells and comprising a plurality of buss bars for connecting the terminals of the cells to each other; and a cell supervisory controller configured to monitor the plurality of cells and coupled to the battery pack and in electrical communication with the buss bar assembly.

3. The battery module of Claim 2 further comprising a housing configured to enclose the battery pack, the buss bar assembly, and the cell supervisory controller.

4. The battery module of Claim 1 wherein the trays have a plurality of alternating depressions and ridges configured to receive the plurality of cells.

5. The battery module of Claim 1 wherein the trays comprise a plurality of grooves provided on an edge of the tray that are configured to receive the terminals of the plurality of cells, wherein the grooves are configured to receive the cells only in the correct orientation.

6. The battery module of Claim 1 further comprising a fourth tray provided between the first tray and second tray and configured to receive a plurality of cells both above and below the fourth tray and a fifth tray provided in between the second tray and third tray and configured to receive a plurality of cells both above and below the fifth tray.

7. The battery module of Claim 4 wherein the trays further comprise at least one opening that is configured to facilitate a flow of a fluid between the plurality of cells and trays.

8. The battery module of Claim 7 wherein the fluid is a gas.

9. The battery module of Claim 7 wherein the housing has a first opening and a second opening and wherein the fluid enters the first opening and enters a first plenum space located adjacent the first row of cells and exits the housing through the second opening after traveling through the at least one opening in the trays and around the plurality of cells.

10. The battery module of Claim 9 wherein the first plenum space has a plurality of features intended to balance the flow of the fluid through the plurality of cells.

11. The battery module of Claim 4 further comprising a sealing member coupled to the trays to seal the fluid path.

12. The battery module of Claim 11 wherein the sealing member comprises silicone.

13. The battery module of Claim 11 wherein the sealing member is overmolded on the trays.

14. The battery module of Claim 3 wherein the housing further comprises a protrusion configured to isolate a first main terminal of the battery module from a second main terminal of the battery module.

15. The battery module of Claim 14 wherein the protrusion is shaped so as to at least partially separate each of the main terminals from one another.

16. The battery module of Claim 1 wherein the plurality of cells in the battery pack are arranged in a generally horizontal configuration.

17. The battery module of Claim 1 wherein the plurality of cells in the battery pack are arranged in a generally vertical configuration.

18. The battery module of Claim 17 wherein the battery pack comprises a first exterior plenum air space adjacent a first grouping of cells, a second exterior plenum air space adjacent a second grouping of cells and a central plenum air space provided in between the two groupings of cells.