STACKABLE REPEATING FRAME WITH INTEGRATED CELL SENSING CONNECTION

• US 20110293983A1
• Filed: 05/28/2010
• Published: 12/01/2011
• Est. Priority Date: 05/28/2010
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (General Motors Company)
• Inventors: Mituta, Andres V., Campbell, Kathleen M., Oury, Andrew P.
• Granted Patent: US 8,460,815 B2
• Time in Patent Office: Days
• US Class Current: 429/120
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• 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 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 2200/103 Fuse
• CPC Class Codes: H01M 50/463 Separators, membranes or diaphragms characterised by their shape
• CPC Class Codes: H01M 50/529 Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A module for a battery pack includes a cooling frame and a spacer frame. At least one of the first and second surfaces of the cooling frame is adapted to transfer heat to a coolant flow. A first battery cell having first and second electrically conductive tabs abuts a cooling frame member first surface. A second end of the cooling frame member includes a connection terminal for electrically connecting to the first electrically conductive tab. A spacer frame member first surface abuts the first battery cell, and a second surface abuts a second battery cell. A first end of the spacer frame member includes a connection terminal for electrically connecting to the second electrically conductive tab of the first battery cell and the first electrically conductive tab of the second battery cell.

Claims

1. An intermediate module for a battery pack having a plurality of battery cells, the intermediate module comprising:

a cooling frame member having a first surface and a second surface and a first end and a second end, at least one of the first surface and the second surface adapted to transfer heat to a cooling fluid, a first battery cell abutting at least a portion of the first surface and having a first electrically conductive tab and a second electrically conductive tab respectively adjacent the first end and the second end of the cooling frame member, the second end of the cooling frame member including a connection terminal for electrically connecting to the first electrically conductive tab, the first end of the cooling frame member including a support plate integrally formed therewith for supporting the second electrically conductive tab; and

a spacer frame member having a first surface, a second surface, a first end and a second end, the second surface of the spacer frame member abutting the first battery cell, the spacer frame member including a second battery cell abutting first surface of the spacer frame member, the second battery cell having a first electrically conductive tab and a second electrically conductive tab, the first end of the spacer frame member including a connection terminal for electrically connecting the second electrically conductive tab of the first battery cell and the first electrically conductive tab of the second battery cell.

2. The intermediate module for a battery pack of claim 1, wherein the connection terminal of the cooling frame member and the connection terminal of the spacer frame member include a voltage sensing lead integrally formed therewith.

3. The intermediate module for a battery pack of claim 2, wherein a current limiting device is interposed between the connection terminals of the cooling frame member and the spacer frame member and the voltage sensing leads of the cooling frame member and the spacer frame member.

4. The intermediate module for a battery pack of claim 1, wherein the first electrically conductive tab of the first battery is attached to the connection terminal of the cooling frame member and the second electrically conductive tab of the first battery cell and the first electrically conductive tab are attached to the connection terminal of the spacer frame member with one of resistance welding, laser welding, soldering and brazing.

5. The intermediate module for a battery pack of claim 1, wherein the first surface of the cooling frame member includes a cavity formed thereon adapted to receive the first battery cell, at least one perimeter wall formed along at least a portion of a perimeter of the cavity, the perimeter wall having a height substantially equal to a thickness of the first battery cell.

6. The intermediate module for a battery pack of claim 5, wherein the spacer frame member includes a first leg, a second leg, a third leg, and a fourth leg forming an opening therebetween to facilitate thermal communication between the first battery cell and the second battery cell.

7. The intermediate module for a battery pack of claim 1, wherein at least one of the first battery cell and the second battery cell is a prismatic lithium ion battery cell.

8. The intermediate module for a battery pack of claim 1, wherein the first electrically conductive tab of one of the first battery cell and the second battery cell extends outwardly from a perimeter of one of the first battery cell and the second battery cell substantially parallel to a plane defined by the first surface of the cooling frame member, and the second electrically conductive tab of the one of the first battery cell and the second battery cell extends outwardly from a perimeter of the one of the first battery cell and the second battery cell at an angle of between 45 degrees and 135 degrees in respect of the first surface of the cooling frame member.

9. A battery pack assembly comprising:

an end frame member having an inner surface for receiving a first battery cell, a first end of the end frame member including a connection terminal for electrically connecting to a first electrically conductive tab of the first battery cell;

a first cooling frame member having a first surface and a second surface, the second surface of the cooling frame member arranged adjacent the first battery cell, a second battery cell disposed adjacent the first surface of the first cooling frame, a second end of the first cooling frame member including a connection terminal for electrically connecting a second electrically conductive tab of the first battery cell and a first electrically conductive tab of the second battery cell;

a spacer frame member having a first surface and a second surface, the second surface of the spacer frame member disposed adjacent the second battery cell, a third battery cell arranged adjacent the first surface of the spacer frame member, a first end of the spacer frame member including a connection terminal for electrically connecting a second electrically conductive tab of the second battery cell and a first electrically conductive tab of the third battery cell;

a second cooling frame member having a first surface and a second surface, the second surface of the second cooling frame member disposed adjacent the third battery cell, a fourth battery cell disposed adjacent the first surface of the second cooling frame member, a second end of the second cooling frame member including a connection terminal for electrically connecting a second electrically conductive tab of the third battery cell and a first electrically conductive tab of the fourth battery cell; and

an end module member having a first surface and a second surface, the first surface of the end module member disposed adjacent the fourth battery cell, a first end of the end module member including a connection terminal for electrically connecting a second electrically conductive tab of the fourth battery cell.

10. The battery pack assembly of claim 9, wherein at least one of the connection terminal of the end frame member, the connection terminal of the first cooling frame member, the connection terminal of the spacer frame member, the connection terminal of the second cooling frame member, and the connection terminal of the end module member includes a voltage sensing lead in electrical communication therewith.

11. The battery pack assembly of claim 10, wherein a current limiting device is interposed between the voltage sensing lead and the at least one of the connection terminal of the end frame member, the connection terminal of the first cooling frame member, the connection terminal of the spacer frame member, the connection terminal of the second cooling frame member, and the connection terminal of the end module member.

12. The battery pack assembly of claim 9, wherein the first electrically conductive tab of the first battery is attached to the connection terminal of the end frame member, the second electrically conductive tab of the first battery and the first electrically conductive tab of the second battery are attached to the connection terminal of the first cooling frame member, the second electrically conductive tab of the second battery and the first electrically conductive tab of the third battery are attached to the connection terminal of the spacer frame member, the second electrically conductive tab of the third battery and the first electrically conductive tab of the fourth battery are attached to the connection terminal of the second cooling frame member, and the second electrically conductive tab of the fourth battery is attached to the connection terminal of the end module member with one of resistance welding, laser welding, soldering and brazing.

13. The battery pack assembly of claim 9, wherein the first electrically conductive tab of the one of the first, second, third and fourth battery cells extends outwardly from a perimeter of the one of the first, second, third and fourth battery cells substantially parallel to a plane defined by the first surface of the end frame member, and the second electrically conductive tab of the one of the first, second, third and fourth battery cells extends outwardly from the perimeter of the one of the first, second, third and fourth battery cells at an angle of between 45 degrees and 135 degrees in respect of the plane defined by the first surface of the end frame member.

14. The battery pack assembly of claim 9, wherein the first side of at least one of the end frame member, the first cooling frame member, the spacer frame member, and the second cooling frame member includes a cavity formed thereon to receive one of the first battery cell, the second battery cell, the third battery cell and the fourth battery cell respectively, at least one perimeter wall formed along at least a portion of a perimeter of the cavity, the perimeter walls having a height substantially equal to a thickness of the one of the first battery cell, the second battery cell, the third battery cell and the fourth battery cell.

15. The battery pack assembly of claim 9, wherein the spacer frame member includes a first leg, a second leg, a third leg, and a fourth leg forming an opening therebetween to facilitate thermal communication between the second battery cell and the third battery cell.

16. A battery pack assembly comprising:

an end frame member having an inner surface for receiving a first battery cell, a first end of the end frame member including a connection terminal for electrically connecting to a first electrically conductive tab of the first battery cell;

a plurality of intermediate modules, each module comprising;

a first cooling frame member having a first surface and a second surface, the second surface of the cooling frame member arranged adjacent the first battery cell, a second battery cell disposed adjacent the first surface of the first cooling frame, a second end of the first cooling frame member including a connection terminal for electrically connecting a second electrically conductive tab of the first battery cell and a first electrically conductive tab of the second battery cell; and

a spacer frame member having a first surface and a second surface, the second surface of the spacer frame member disposed adjacent the second battery cell, a third battery cell arranged adjacent the first surface of the spacer frame member, a first end of the spacer frame member including a connection terminal for electrically connecting a second electrically conductive tab of the second battery cell and a first electrically conductive tab of the third battery cell;

a second cooling frame member having a first surface and a second surface, the second surface of the second cooling frame member disposed adjacent the third battery cell, a fourth battery cell disposed adjacent the first surface of the second cooling frame member, a second end of the second cooling frame member including a connection terminal for electrically connecting a second electrically conductive tab of the third battery cell and a first electrically conductive tab of the fourth battery cell; and

an end module member having a first surface and a second surface, the first surface of the end module member disposed adjacent the fourth battery cell, a first end of the end module member including a connection terminal for electrically connecting a second electrically conductive tab of the fourth battery cell.

17. The battery pack assembly of claim 16, wherein the connection terminal of the end frame member, the connection terminal of the first cooling frame member, the connection terminal of the spacer frame member, the connection terminal of the second cooling frame member, and the connection terminal of the end module member includes a voltage sensing lead in electrical communication therewith, and a current limiting device interposed between each of the voltage sensing leads and the connection terminal of the first cooling frame member, the connection terminal of the spacer frame member, the connection terminal of the second cooling frame member, and the connection terminal of the end module member.

18. The battery pack assembly of claim 16, wherein the first battery cell, the second battery cell, the third battery cell, and the fourth battery cell are substantially similar, the first electrically conductive tabs of the first battery cell, the second battery cell, the third battery cell, and the fourth battery cell extending outwardly from a perimeter of the first battery cell, the second battery cell, the third battery cell, and the fourth battery cell substantially parallel to a plane defined in respect of the end frame member first surface, and the second electrically conductive tab of the first battery cell, the second battery cell, the third battery cell, and the fourth battery cell extending outwardly from the perimeter of the first battery cell, the second battery cell, the third battery cell, and the fourth battery cell battery cell at an angle of between 45 degrees and 135 degrees in respect of the plane defined by the first surface of the end frame member.

19. The battery pack assembly of claim 16, wherein the spacer frame member includes a first leg, a second leg, a third leg, and a fourth leg forming an opening therebetween to facilitate thermal communication between the second battery cell and the third battery cell.