Battery assembly and method of making same

• US 20050031946A1
• Filed: 08/06/2003
• Published: 02/10/2005
• Est. Priority Date: 08/06/2003
• Status: Active Grant

• Current Assignee: Dynavair LLC (IP Edge LLC)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Kruger, Duane D., Beer, Robert C.
• Granted Patent: US 7,118,827 B2
• Time in Patent Office: Days
• US Class Current: 429/159
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/528 Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/55 on the same side of the cell
• CPC Class Codes: H01M 50/557 Plate-shaped terminals
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery assembly is designed to include a plurality of cells positioned parallel to each other. A frame including end supports position the cells appropriately. Each of the cells includes a first terminal and a second terminal. Two buses are positioned over all of the first terminals and all of the second terminals. Each of the buses includes slots allowing the terminals to extend therethrough. Once through, the terminals are bent over the bus bar. A slide is then positioned over the terminals protecting the terminals and maintaining the terminals in electrical contact with each other. This battery assembly allows more than three cells to be connected to each other and is versatile enough to allow the removal of certain cells to enhance the airflow through the battery assembly.

Claims

1. A battery assembly for storing electric energy comprising:

a frame defining a plurality of channels;

a plurality of cells having first and second terminals extending out therefrom, each of said plurality of cells being received and positioned by one of said plurality of channels such that said first terminals are aligned and said second terminals are aligned; and

a bus bar positioned over said first and second terminals such that said bus provides electrical contact for each of said first terminals to electrical contact each other and said bus bar provides electrical contact for each of said second terminals to electrical contact each other to allow said battery assembly to provide the electric potential from said plurality of cells.

2. A battery assembly as set forth in claim 1 wherein said frame defines a bus support for receiving said bus bar therein.

3. A battery assembly as set forth in claim 2 including a slide receivable by said bus support to maintain said first and second terminals in electrical contact with said bus bar.

4. A battery assembly as set forth in claim 3 wherein said bus support includes a guide for receiving said slide therein.

5. A battery assembly as set forth in claim 4 wherein said bus bar includes a plurality of slots allowing each of said first and second terminals to pass therethrough when said bus is mounted to said frame.

6. A battery assembly as set forth in claim 5 wherein said guide extends along said bus support at an angle.

7. A battery assembly as set forth in claim 6 wherein said angle is acute.

8. A battery assembly as set forth in claim 7 wherein said bus includes a terminal receiving surface for receiving said first and second terminals thereagainst.

9. A battery assembly as set forth in claim 8 wherein said bus includes an electrical conductor to contact each of said first and second terminals.

10. A battery assembly as set forth in claim 9 wherein said housing includes a front side support extending across one of said plurality of cells to protect said plurality of cells.

11. A battery assembly as set forth in claim 10 wherein said housing includes a back side support extending across another of said plurality of cells to protect said plurality of cells.

12. A battery assembly as set forth in claim 11 including end supports defining said plurality of channels, said end supports extending between said front and back side supports on either of said plurality of cells.

13. A battery assembly as set forth in claim 12 including protrusions extending out of each of said front and back side supports.

14. A battery assembly as set forth in claim 13 wherein said bus supports include apertures for receiving said protrusions therethrough to snap lock said frame together.

16. A battery assembly as set forth in claim 14 wherein said bus support includes a guide for receiving said slide therein.

18. A battery assembly as set forth in claim 16 wherein said angle is acute.

20. A battery assembly as set forth in claim 18 wherein said bus includes an electrical conductor to contact each of said first and second terminals.

21. A battery assembly as set forth in claim 18 wherein said housing includes a front side support extending across one of said plurality of cells to protect said plurality of cells.

15. A battery assembly for storing electric energy comprising:

a frame defining a plurality of channels and a bus support;

a plurality of cells less than said plurality of channels having first and second terminals extending out therefrom, each of said plurality of cells being received and positioned by one of said plurality of channels such that said first terminals are aligned and said second terminals are aligned;

a bus bar defining a plurality of slots greater than said plurality of cells allowing each of said first and second terminals to pass therethrough when said bus is mounted to said frame, said bus bar positioned over said first and second terminals such that said bus provides electrical contact for each of said first terminals to electrical contact each other and said bus bar provides electrical contact for each of said second terminals to electrical contact each other to allow said battery assembly to provide the electric potential from said plurality of cells; and

a slide receivable by said bus support to maintain said first and second terminals in electrical contact with said bus bar.

17. A battery assembly as set forth in claim 15 wherein said guide extends along said bus support at an angle.

19. A battery assembly as set forth in claim 17 wherein said bus includes a terminal receiving surface for receiving said first and second terminals thereagainst.