Patent ID: 11967673
Assignee: BETA AIR LLC
Field: Electrical machinery, apparatus, energy (Electrical engineering)
Classification: CPC H  B | IPC B  H

Claim 0:
1. A method for manufacturing a battery pack of an electric aircraft, the method comprising:
vertically stacking a plurality of battery cells to create a stack of battery cells;
applying a compressive force on the stack of battery cells using a plurality of pneumatic cylinders;
applying a cell cover comprising a material with insulating properties to the stack of battery cells as a first and a last layer of the stack of battery cells, wherein the cell cover is configured to further compress the stack of battery cells to generate a compressed stack of battery cells, wherein the material is configured to thermally insulate the stack of battery cells;
inserting a first portion of the compressed stack of battery cells into a container prior to releasing any of the plurality of pneumatic cylinders;
engaging each battery cell of the plurality of battery cells with an end cap of the container, wherein the end cap is configured to:
maintain a predetermined arrangement of the plurality of battery cells, wherein the end cap includes an electrical bus;
couple to a back plate using a first snap attachment mechanism comprising a first protruding boss configured to be captured by a first receptable disposed on the back plate;
couple to a sense board using a second snap attachment mechanism comprising a second protruding boss configured to be captured by a second receptable disposed on the sense board; and
rest on top of a lip, wherein the lip comprises a flange located on a longer side of the lip, wherein the flange is configured to wrap around the end cap;

releasing the first portion of the stack of battery cells from a first portion of the plurality of pneumatic cylinders while a second portion of the stack of battery cells remains compressed by one or more other pneumatic cylinders of the plurality of pneumatic cylinders; and
connecting the container to an electrical system of a vehicle through the electrical bus of the end cap, wherein the electrical bus includes a sensor designed to monitor a status of at least one battery cell of the plurality of battery cells connected to the electrical bus.