The present disclosure relates to a battery module framing assembly having battery cell stacks. More particularly, the present disclosure relates to the connection of side plates to end plates to form a compression frame on a battery cell stack.
Electric vehicles and hybrid vehicles employ a high voltage electric battery system that includes a number of battery cells. These electric and hybrid vehicles typically require several battery cells to provide enough power to meet vehicle power and energy requirements. The battery cells are often located under the vehicle body midway between the front and rear wheels.
To achieve the needed power, several battery cells are arranged in a stack and compressed together. Multiple battery cell stacks may be included in a battery module. In a battery module assembly, the connection between the end plate and side plate is a very critical joint that needs to be designed for ease of assembly, to maintain the cell compression over the life cycle, and to meet stringent load cases. Typically, adhesives and welding are used to connect end plates and side plates. While effective, there is a need in the art for improved assembly techniques that are easier to assembly, and that may be easily non-destructively disassembled to allow for module level serviceability and easy recycling.
A framing assembly for a battery module having at least one battery cell stack is provided. The framing assembly includes end plates for forming ends to the battery cell stack, each end plate having a battery side to face the battery cell stack and an exterior side opposite the battery side, the exterior side having studs extending away from the exterior side, side plates for forming sides to the battery cell stack, the side plates having opposite ends and a sidewall section that extends between the ends, the sidewall section having a battery side to face the battery cell stack and an exterior side opposite the battery side, each side plate end having a locking section that extends away from the sidewall section in a direction that the sidewall battery side faces, the locking section having an open ended slot and a pin that extends away from the locking section, locking plates for securing the side plates to the end plates, the locking plates having a stud opening and a pin opening and fasteners that engage with the studs. One of the end plates is positioned on each end of the battery cell stack, the side plates are positioned along opposite sides of the battery cell stack with each locking section disposed over the exterior side of an end plate and the stud disposed within the slot, the locking plates disposed on the locking sections with the stud in the stud opening and the pin in the pin opening, and wherein the fasteners are attached to the studs and secure the locking plates on the stud and pin, and the framing assembly maintains compression of the battery cell stack.
In one aspect, the end plates have side edges and a stud is adjacent to each side edge.
In another aspect, the end plate has studs adjacent each side edge, the side plate locking sections have pins and have an open ended slot for each stud adjacent the end plate side edge.
In another aspect, the locking plate has opposite end locking sections and an intermediate section that extends between the end locking sections, each locking plate end section having a stud opening and a pin opening, and the locking plate secures the side plate on each side of the battery cell stack to the end plate with each locking plate end section disposed on the side plate locking section with the stud in the stud opening and the pin in the pin opening.
In another aspect, the locking plate intermediate section has a rib portion that extends between the end locking sections.
In another aspect, a mid-beam for forming sides to adjacent battery cell stacks is included, the mid-beam having opposite ends and a mid-beam section that extends between the ends, the mid-beam section having opposite first and second sides to face the adjacent battery cell stacks, each mid-beam end having a dual locking section, the dual locking section having a first locking portion that extends away from the first mid-beam side and a second locking portion that extends away from the second mid-beam side, the first and second locking portions each having an open ended slot and a pin that extends away from the locking portion. One of the end plates is positioned on each end of adjacent battery cell stacks, the mid-beam is positioned between facing sides of adjacent battery cell stacks with each locking portion disposed over the exterior side of an end plate and the stud disposed within the slot, the side plates are positioned along non-facing sides of the adjacent battery cell stacks with each locking section disposed over the exterior side of an end plate and the stud disposed within the slot, the locking plates disposed on the locking portions with the stud in the stud opening and the pin in the pin opening and disposed on the locking sections with the stud in the stud opening and the pin in the pin opening, and wherein the fasteners are attached to the studs and secure the locking plates on the stud and pin, and the framing assembly maintains compression of the battery cell stacks.
In another aspect, a mid-beam locking plate is included having a first section with a stud opening and a pin opening and a second section with a stud opening and a pin opening, wherein the mid-beam locking plate is disposed on the first and second mid-beam locking portions with the studs in the stud openings and the pins in the pin openings, and the mid-beam locking plate secures the mid-beam to two end plates.
In another aspect, side beams are included having opposite ends, a rectangular cross section, and a sidewall surface, wherein each side plate has a side beam attached to the sidewall exterior side.
In another embodiment, a battery module is provided. The battery module includes a plurality of battery cells positioned in a battery cell stack, the battery cell stack having opposite ends and opposite sides that extend between the ends, end plates each having a battery side to face battery cells and an exterior side opposite the battery side, the exterior side having studs extending away from the exterior side, side plates each having opposite ends and a sidewall section that extends between the ends, the sidewall section having a battery side to face battery cells and an exterior side opposite the battery side, each side plate end having a locking section that extends away from the sidewall section in a direction that the sidewall battery side faces, the locking section having an open ended slot and a pin that extends away from the locking section, locking plates for securing the side plates to the end plates, the locking plates each having a stud opening and a pin opening, and fasteners that engage with the studs. One end plate is positioned on each end of the battery cell stack, one side plate is positioned along each side of the battery cell stack with each locking section being over the exterior side of one of the end plates and the stud disposed in the slot, the locking plates are disposed on the locking sections with the stud in the stud opening and the pin in the pin opening, the fasteners are attached to the studs and secure the locking plates on the stud and pin, and the side plates are secured to the end plates and maintain compression of the of battery cell stack.
In one aspect, the end plates have side edges and a stud is adjacent to each side edge.
In another aspect, the end plates have studs adjacent each side edge, the side plate locking sections have pins and have an open ended slot for each stud adjacent the end plate side edge.
In another aspect, the locking plate has opposite end locking sections and an intermediate section that extends between the end sections, each locking plate end locking section having a stud opening and a pin opening, and the locking plate secures the side plate on each side of the battery cell stack to the end plate with each locking plate end locking section disposed on the side plate locking section with the stud in the stud opening and the pin in the pin opening.
In another aspect, the locking plate intermediate section has a rib portion that extends between the end sections.
In another aspect, side beams are included having opposite ends, a rectangular cross section, and a sidewall surface, wherein each side plate has a side beam attached to the sidewall exterior side.
In yet another embodiment, a battery module is provided. The battery module includes a plurality of battery cells positioned in two battery cell stacks, each of the battery cell stacks having opposite ends and opposite sides that extend between the ends, the battery cell stacks are positioned adjacent with each battery cell stack having a facing side that faces the other battery cell stack and a non-facing side that faces opposite the facing side, end plates each having a battery side to face battery cells and an exterior side opposite the battery side, the exterior side having studs extending away from the exterior side, side plates each having opposite ends and a sidewall section that extends between the ends, the sidewall section having a battery side to face battery cells and an exterior side opposite the battery side, each side plate end having a locking section that extends away from the sidewall section in a direction that the sidewall battery side faces, the locking section having an open ended slot and a pin that extends away from the locking section, a mid-beam having opposite ends and a mid-beam section that extends between the ends, the mid-beam section having opposite first and second sides to face the adjacent battery cell stacks, each mid-beam end having a dual locking section, the dual locking section having a first locking portion that extends away from the first mid-beam side and a second locking portion that extends away from the second mid-beam side, the first and second locking portions each having an open ended slot and a pin that extends away from the locking portion, locking plates for securing the side plates and the mid-beam to the end plates, each of the locking plates having a stud opening and a pin opening, and fasteners that engage with the studs. One of the end plates is positioned on each end of the adjacent battery cell stacks, the mid-beam is positioned between the facing sides of the adjacent battery cell stacks with each locking portion disposed over the exterior side of an end plate and the stud disposed within the slot, the side plates are positioned along the non-facing sides of the adjacent battery cell stacks with each locking section disposed over the exterior side of an end plate and the stud disposed within the slot, the locking plates disposed on the locking portions with the stud in the stud opening and the pin in the pin opening and disposed on the locking sections with the stud in the stud opening and the pin in the pin opening, and wherein the fasteners are attached to the studs and secure the locking plates on the stud and pin, and the mid-beam and side plates are secured to the end plates and maintain compression of the battery cell stacks.
In one aspect, the end plates have side edges and a stud is adjacent to each side edge.
In another aspect, the end plates have studs adjacent each side edge, the side plate locking sections have pins and have an open ended slot for each stud adjacent the end plate side edge, and the mid-beam first and second locking portions each have pins and have an open ended slot for each stud adjacent the end plate side edge.
In another aspect, the locking plates have opposite end locking sections and a middle locking section between the end locking sections, each end locking section having a stud opening and a pin opening, the middle locking section having spaced apart stud openings and spaced apart pin openings, the locking plate secures the side plate on each side of the battery cell stacks to an end plate with each end locking section disposed on the side plate locking section with the stud in the stud opening and the pin in the pin opening, and the locking plate secures the mid-beam to end plates of both battery cell stacks with the middle locking section disposed on the locking portions of the dual locking section with the studs in the stud openings and the pins in the pin openings.
In another aspect, the locking plates include side locking plates that secure the side plates to the end plates and mid-beam locking plates that secure the mid-beam to two end plates, each side locking plate having a stud opening and a pin opening, each mid-beam locking plate having spaced apart stud openings and spaced apart pin openings, the side locking plates secure the locking section of a side plate on a side of the battery cell stacks to an end plate with the side locking plate disposed on the side plate locking section with the stud in the stud opening and the pin in the pin opening, and the mid-beam locking plate secures the mid-beam to end plates of both battery cell stacks with the mid-beam locking plate disposed on the locking portions of the dual locking section with the studs in the stud openings and the pins in the pin openings.
In another aspect, side beams are included having opposite ends, a rectangular cross section, and a sidewall surface, wherein each side plate has a side beam attached to the sidewall exterior side.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring to
The battery pack 12 generally includes a battery tray 20 connected to the vehicle 14. The battery tray 20 provides structural support to one or a plurality of battery modules 10 disposed within the battery pack 12. The battery modules 10 are preferably lithium-ion battery cells. However, it should be appreciated that any type of battery cell may be employed.
Referring now to
Framing assembly 24 is used to assemble the battery module 10 and secure and maintain compression of the battery cells 26 in the battery cell stacks 22 over the life cycle of the battery cells 26 as well as to meet stringent load cases. Framing assembly 24 provides a relatively easy assembly of the battery module 10 and enables the battery module 10 to be easily non-destructively disassembled to allow for battery module 10 level serviceability and easy recycling. The framing assembly 24 includes end plates 28 that form ends to the battery cell stack 22, side plates 30 that form sides to the battery cell stack 22, locking plates 32 that secure the side plates 30 to the end plates 28, and fasteners 34 that secure the locking plates 32 to the end plates 28. The locking plates 32, as described below with reference to
With reference to
With reference to
With reference to
With reference to
Referring to
Referring to
Referring to
Referring to
If a single battery cell stack 22 is being formed, side plates 30 are positioned on opposite sides of the battery cells 26 with the battery side 52 facing the battery cells 26 and the side plates 30 are moved toward the battery cells 26 and end plates 28. The locking sections 56 move relative to or slide over the exterior sides 42 of the end plates 28 and the studs 46 enter the open-ended slots 58. The locking plates 32 are then positioned with the studs 46 in the stud openings 90 and the pins 60 in the pin openings 92. The fasteners 34 are then attached to the studs 46 and secure the side plates 30 to the end plates 28. The engagement of the side plates 30 with the end plates 28 maintains the compression of the battery cells 26.
If two battery cell stacks 22 are being formed, the battery cell stacks 22 are positioned adjacent one another with each battery cell stack 22 having a facing side that faces the other battery cell stack 22 (the facing sides), and a non-facing side that faces away from the other battery cell stack 22 (the non-facing sides). A mid-beam 38 is positioned between the adjacent battery cell stacks 22 with the first side 66 facing the non-facing side of one of the battery cell stacks 22 and the second side 68 facing the non-facing side of the other battery cell stack 22. Side plates 30 are positioned on the non-facing sides of the battery cell stacks 22 with the battery sides 52 facing the battery cells 26. The side plates 30 are moved toward the battery cells 26 and end plates 28. The locking sections 56 move relative to or slide over the exterior sides 42 of the end plates 28 and the studs 46 enter the open-ended slots 58. The battery cell stacks 22 are moved toward the mid-beam 38. The first and second locking portions 72, 74 move relative to or slide over the exterior sides 42 of the end plates 28 and the studs 46 enter the open-ended slots 76. The locking plates 32 are then positioned with the studs 46 in the stud openings 90 and the pins 60 and pins 78 in the pin openings 92. The fasteners 34 are then attached to the studs 46 and secure the side plates 30 and mid-beam 38 to the end plates 28. The engagement of the side plates 30 and mid-beam 38 with the end plates 28 maintains the compression of the battery cells 26 in both battery cell stacks 22.
The use of the open-ended slots and pins and Bolted Anti-Slip Slip-Enabled Joints (BASSEJ) to mechanically join the side plate 30 and end plate 28 and mechanically join the mid-beam 38 and end plate 28 of the battery module 10 with a lockable slip plane offers several advantages. These include enabling an improved and easier assembly technique that meets structural needs and the battery module 10 may be easily non-destructively disassembled to allow for module level serviceability and easy recycling.
The description of the present disclosure is merely exemplary in nature and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.