BATTERY PACK WITH INTEGRAL COOLING AND BUSSING DEVICES
First Claim
1. A battery assembly for a vehicle having a device for introducing fluid therein thereby affecting temperature of said battery assembly, said battery assembly presenting at least one battery pack comprising:
- a plurality of prismatic cells having side edges;
a plurality of heat transfer elements extending between said prismatic cells with each heat transfer element presenting terminal ends and thermal transfer edges with at least one of said thermal transfer edges of extending beyond said edges of said prismatic cell with said heat sinks and said prismatic cells being removable interconnected with one another thereby applying pressure to said prismatic cells; and
a mechanical connection between said prismatic cells and said heat transfer elements defined by a first bend extending from one of said side edges of each said prismatic cell and a second bend extending from opposite side edge of each said prismatic cell in an opposite direction from said first bend with said first bend of each of said prismatic cells engaging one of said terminal ends of one of said heat transfer elements and said second bend of each of said prismatic cells engaging terminal end of another said heat transfer element with each said first bends connecting with one another and each said second bends connecting with one another.
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Accused Products
Abstract
A battery module of the present invention is adaptable to be utilized in various configurations including and not limited to an overlapping battery cell packaging configuration and a vertical stack battery cell packaging configuration used in an automotive vehicle. The battery module has a plurality of battery heatsink assemblies with the cells disposed therebetween. A plurality of rods extend through the each heatsink assemblies to secure the heatsink assemblies and the cell with one another to form the battery module.
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Citations
56 Claims
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1. A battery assembly for a vehicle having a device for introducing fluid therein thereby affecting temperature of said battery assembly, said battery assembly presenting at least one battery pack comprising:
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a plurality of prismatic cells having side edges; a plurality of heat transfer elements extending between said prismatic cells with each heat transfer element presenting terminal ends and thermal transfer edges with at least one of said thermal transfer edges of extending beyond said edges of said prismatic cell with said heat sinks and said prismatic cells being removable interconnected with one another thereby applying pressure to said prismatic cells; and a mechanical connection between said prismatic cells and said heat transfer elements defined by a first bend extending from one of said side edges of each said prismatic cell and a second bend extending from opposite side edge of each said prismatic cell in an opposite direction from said first bend with said first bend of each of said prismatic cells engaging one of said terminal ends of one of said heat transfer elements and said second bend of each of said prismatic cells engaging terminal end of another said heat transfer element with each said first bends connecting with one another and each said second bends connecting with one another. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method of forming a battery assembly having a plurality of battery packs for a vehicle having a device for introducing fluid therein thereby affecting temperature of the battery assembly, said method comprising the steps of:
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placing a plurality of prismatic cells having side edges between a plurality of heat transfer elements extending between the prismatic cells with each heat transfer element presenting terminal edges and terminal sides with at least one of the terminal edges extending beyond the edges of the cell; removably connecting the heat transfer elements and the prismatic cells with one another to at least increase and decrease the size of the battery pack and to apply pressure to the prismatic cells; and forming a mechanical connection between the prismatic cells and the heat transfer elements by extending a first bend from one of the side edges of each prismatic cell and extending a second bend from another side edge of each prismatic cell in an opposite direction from the first bend; engaging the first bend of each prismatic cell with one of the terminal ends of one of the heat transfer elements and engaging the second bend of each prismatic cell with the terminal end of another heat transfer element. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
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36. A battery assembly for a vehicle having a device for introducing fluid therein thereby affecting temperature of said battery assembly, said battery assembly comprising:
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a pair of battery packs each having a plurality of prismatic cells having side edges a plurality of spacers extending between said cells with each spacer presenting terminal edges and terminal sides with at least one of said terminal edges of said spacers extending beyond said edges of said cell with said spacers and said cells being removable and mechanically interconnected with one another thereby applying pressure to said cells; and at least one member connecting said battery packs with one another with said at least one member presenting a stress relief element for reducing stress of said battery packs as the vehicle is in motion. - View Dependent Claims (37, 38, 39, 40, 41, 42, 43, 44, 45, 46)
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47. A battery assembly for a vehicle having a device for introducing fluid therein thereby affecting temperature of said battery assembly, said battery assembly comprising:
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a plurality of prismatic cells having terminal edges of opposite current and a plurality of spacers extending between said prismatic cells with each spacer presenting terminal edges with at least one of said terminal edges of said spacers extending beyond said edges of said prismatic cell with said spacers and said prismatic cells being removable interconnected with one another thereby applying pressure to said prismatic cells; a housing encapsulating said prismatic cells and said spacer; and a temperature affecting element supported by and continuously extending over said terminal edges in a substantially parallel relationship with said housing thereby selectively increasing and decreasing temperature if said prismatic cells. - View Dependent Claims (48, 49, 50, 51, 52, 53, 54, 55)
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56. A battery assembly for a vehicle having a device for introducing fluid therein thereby affecting temperature of said battery assembly, said battery assembly comprising:
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at least one battery pack; a plurality of prismatic lithium cells of said at least one battery pack, each prismatic lithium cell having side edges and first and second bends presents an L-shaped configuration defining an angle of at least ninety degrees and extending from said side edges in opposite directions and at least one of circular openings and semi-circular openings defined in each of said first and second bends; a plurality of spacers extending between said prismatic lithium cells with each spacer presenting terminal ends and terminal edges with at least one of said terminal edges of said spacers extending beyond said side edges of said prismatic lithium cell with said spacers and said prismatic lithium cells being removable interconnected with one another thereby applying pressure to said prismatic lithium cells; each said spacer defined by a plate from at least one of heat insulating material and heat absorbing material with said plate defining said terminal edges and said terminal sides wherein at least one of said terminal edges of said spacer presents a corrugated configuration wherein at least one of said terminal edges of said spacer presents a hook; a cut out portion defined in each terminal end of said spacer; a pair bracket engaging said cut out portions of each said spacer wherein one of said brackets includes at least one pin extending therefrom and the other of said brackets includes at least one concave portion to receive a sensor for sensing temperature of said prismatic lithium cells; each of said spacers includes a plurality of holes and a plurality of rods extending therethrough to interconnect said spacers with said prismatic cells disposed between said spacer thereby applying pressure to said prismatic cells and retaining said prismatic cells between said spacers; at least one pin extending from at least one of said brackets to engage said at least one of said receive said at least one of circular openings and semi-circular openings defined in each of said first and second bends as said prismatic lithium cells are assembled with said spacers whereby one of said bends extending from one of said side edges of each said prismatic lithium cell and another bend extending from another side edge of each said prismatic lithium cell in an opposite direction with said bend of each of said prismatic lithium cells engaging one of said terminal ends of one of said spacers and said another bends of each of said prismatic lithium cells engaging terminal end of another said spacer; at least one member connecting said battery packs with one another with said at least one member presenting a stress relief element for reducing stress of said battery packs as the vehicle is in motion; a pair of terminal plates engaging said spacers with said prismatic cells disposed therebetween to form said battery pack; a circuit bus connected to each of said negative terminals and said positive terminals and extending to a positive extremity and a negative extremity; a plurality of segments connected to said pins extending from said brackets for forcing said circuit bus to said positive terminals and said negative terminals; a housing formed from a polymeric material, said housing having a first portion for supporting said battery packs and a second portion for enclosing said battery packs; a foam disposed inside said housing and covering said battery packs to expose said at least one of said terminal edges of said spacers beyond said foam and exposed by said housing to receive at least one of cooling fluid and heating fluid thereby heating and cooling said prismatic cells; and at least one of a current sensor, a power contractor, a pair of power bus bars each connected to said battery packs, a battery electronic controller, a power contractor, a short circuit protection, a pre-charge circuit presenting operative communication with one another and said prismatic cells and said spacers.
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Specification