System for providing structural integrity of a battery module

• US 10,361,411 B2
• Filed: 03/27/2017
• Issued: 07/23/2019
• Est. Priority Date: 09/30/2014
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: CPS Technology Holdings, LLC
• Inventors: DeKeuster, Richard M., Mack, Robert J.
• Primary Examiner(s): Cantelmo, Gregg
• Application Number:
  US15/470,294
• Publication Number:
  US 20170200931A1
• Time in Patent Office: 848 Days
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0411 Arrangement in the front part of the vehicle
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60Y 2306/01 Reducing damages in case of crash, e.g. by improving battery protection
• CPC Class Codes: B60Y 2410/10 Housings
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 2200/00 Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/505 comprising a single busbar
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A battery module includes a housing configured to receive a plurality of electrochemical cells, a skeletal frame coupled with the housing, and a framework disposed proximate to the skeletal frame. Moreover, the framework is substantially aligned with the skeletal frame and configured to transfer a force applied to the framework to the skeletal frame.

Claims

1. A battery module comprising:

a housing;

a plurality of lithium ion electrochemical cells disposed within the housing;

a skeletal frame of the housing;

a lid coupled to a top side of the housing, wherein the lid encloses components of the battery module within the housing;

a lip formed on the top side of the housing, wherein the lip extends away from the housing in a first direction and is integral with or engaged with the skeletal frame;

a shoulder formed on the top side of the housing, wherein the shoulder is coupled to the lip and forms a recess configured to receive the lid; and

a lid space formed about at least a portion of a perimeter of the lid, wherein the lid space is configured to enable movement of the lid within the recess.

2. The battery module of claim 1, comprising an arm coupled to the lip, wherein the arm extends laterally over the lid.

3. The battery module of claim 2, wherein the arm is configured to block movement of the lid in the first direction.

4. The battery module of claim 1, wherein the lip extends about a perimeter of the housing.

5. The battery module of claim 1, wherein the lid space enables expansion, contraction, or both, of the lid, the housing, or both, without creating stress points along the lid.

6. The battery module of claim 1, wherein the lid space provides room for the lip to be deformed toward the lid without initiating contact with the lid.

7. The battery module of claim 1, wherein the lid space extends about an entire perimeter of the lid.

8. The battery module of claim 1, wherein the lip extends in the first direction above a top surface of the lid, thereby blocking the lid from forces applied to a side of the housing.

9. The battery module of claim 8, wherein the lip is configured to block movement of the lid in at least two directions.

10. A system comprising:

a battery module having a housing, a plurality of lithium ion electrochemical cells disposed within the housing, and a lid coupled to a side of the housing, wherein the lid encloses components of the battery module within the housing; and

a cage surrounding the battery module and configured to absorb impact from external forces to limit or eliminate a transfer of the external forces to the battery module;

wherein the housing of the battery module comprises a skeletal frame, a lip and a shoulder, wherein the lip and the shoulder are formed on the side of the housing where the lid is positioned, and wherein the lip extends away from the housing in a first direction and is integral with or engaged with the skeletal frame, and wherein the shoulder is coupled to the lip and forms a recess configured to receive the lid; and

wherein the cage is coupled to the skeletal frame.

11. The system of claim 10, wherein the cage is made of a metal or metal alloy.

12. The system of claim 10, wherein the cage is made of a polymer, or a composite material.

13. The system of claim 10, wherein the cage includes crush assemblies configured to deform when acted upon by a sufficient force, the sufficient force being a force capable of plastically deforming the cage.