BATTERY MODULE AND METHOD INCORPORATING EXTERIOR CASING AND LINER

• US 20120247107A1
• Filed: 03/29/2012
• Published: 10/04/2012
• Est. Priority Date: 03/31/2011
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology LLC (Johnson Controls International plc)
• Inventors: DeKeuster, Richard M., Balk, Mikhail S., Fan, Binbin
• Granted Patent: US 9,859,532 B2
• Time in Patent Office: Days
• US Class Current: 60/718
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/231 having a layered structure
• CPC Class Codes: H01M 50/233 characterised by physical properties of casings or racks, e.g. dimensions
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• 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 50/289 characterised by spacing elements or positioning means within frames, racks or packs spacing elements inside cells other than separators, membranes or diaphragms H01M50/471
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A battery module includes a rigid external casing made, for example, of a metallic sheet material. Securement features, tabs, and so forth may be formed in the material of the casing. The casing may be made by stamping and bending metallic sheet. A liner is disposed in the casing, and one or more battery cells are disposed in the liner. The liner may comprise an insulative sheet material that is cut and folded to generally conform to the casing. The structure may include a bus bar assembly, compression members, a thermal component and other structural and functional elements.

Claims

1. An xEV electric vehicle battery module comprising:

a cage-like metallic external casing;

an insulative, sheet-like liner disposed in the external casing; and

at least one prismatic energy storage cell disposed in the liner and configured to provide power for operation of the electric vehicle.

2. The battery module of claim 1, wherein the external casing comprises a thin metallic material formed by stamping and bending.

3. The battery module of claim 2, wherein the external casing has a nominal thickness or between approximately 0.5 mm and 1.5 mm.

4. The battery module of claim 1, wherein the external casing comprises at least one open face through which the liner and energy storage cell are inserted.

5. The battery module of claim 1, wherein the external casing comprises an opening in at least one face to reduce weight of the casing.

6. The battery module of claim 1, wherein the external casing comprise at least one tab configured to facilitate securement of the battery module in an application or to other battery modules of similar configuration.

7. The battery module of claim 6, wherein the external casing comprises at least one aperture configured to receive the at least one tab to allow for securement of the battery module to a self-similar battery module.

8. The battery module of claim 1, wherein the liner is made of a single sheet of insulative material.

9. The battery module of claim 1, wherein the liner comprises polypropylene.

10. The battery module of claim 1, wherein the liner has a nominal thickness of between approximately 0.2 mm and 1.0 mm.

11. The battery module of claim 1, wherein the liner is formed by cutting a sheet of insulative material and folding the cut sheet to conform generally to the external casing.

12. The battery module of claim 1, comprising a plurality of energy storage cells disposed in the casing and liner.

13. The battery module of claim 12, comprising a bus structure configured to interface with terminals of the energy storage cells to at least partially combine outputs of the energy storage cells.

14. The battery module of claim 12, comprising at least one compression element disposed between the casing and the energy storage cells and configured to urge the energy storage cells towards one another.

15. The battery module of claim 1, comprising a thermal component configured to remove heat from and/or inject heat into the at least one cell.

16. The battery module of claim 15, wherein the thermal component is secured to the casing.

17. The battery module of claim 16, wherein the casing comprises a retaining structure configured to allow the thermal component to be slid into an assembled position.

18. The battery module of claim 17, wherein the retaining structure comprises a groove.

19. An xEV electric vehicle battery module comprising:

a stamped and bent cage-like metallic external casing;

an insulative, sheet-like liner disposed in the external casing;

a plurality of prismatic lithium technology energy storage cells disposed in the liner and configured to provide power for operation of the electric vehicle;

a bus structure configured to interface with terminals of the energy storage cells to at least partially combine outputs of the energy storage cells; and

a compression element disposed between the casing and the energy storage cells and configured to urge the energy storage cells towards one another.

20. The battery module of claim 19, wherein the external casing has a nominal thickness or between approximately 0.5 mm and 1.5 mm.

21. The battery module of claim 19, wherein the external casing comprises at least one open face through which the liner and energy storage cells are inserted.

22. The battery module of claim 19, wherein the external casing comprises an opening in at least one face to reduce weight of the casing.

23. The battery module of claim 19, wherein the external casing comprise at least one tab configured to facilitate securement of the battery module in an application or to other battery modules of similar configuration.

24. The battery module of claim 23, wherein the external casing comprises at least one aperture configured to receive the at least one tab to allow for securement of the battery module to a self-similar battery module.

25. The battery module of claim 19, wherein the liner is made of a single sheet of insulative material.

26. The battery module of claim 19, wherein the liner comprises polypropylene.

27. The battery module of claim 19, wherein the liner has a nominal thickness of between approximately 0.2 mm and 1.0 mm.

28. The battery module of claim 19, wherein the liner is formed by cutting a sheet of insulative material and folding the cut sheet to conform generally to the external casing.

29. A method for making a battery module, comprising:

forming cage-like metallic external casing having apertures and ribs defining an interior volume;

inserting an insulative, sheet-like liner into the interior volume of the external casing; and

inserting a plurality of prismatic energy storage cells into the liner.

30. The method of claim 29, comprising forming on the casing at least one tab configured to facilitate securement of the battery module in an application or to other battery modules of similar configuration.

31. The method of claim 30, comprising forming in the casing at least one aperture configured to receive the at least one tab to allow for securement of the battery module to a self-similar battery module.

32. An xEV electric vehicle, comprising:

drive train configured to propel the vehicle in operation; and

an energy storage assembly coupled to the drive train and comprising at least one battery module comprising a cage-like metallic external casing, an insulative, sheet-like liner disposed in the external casing, and at least one prismatic energy storage cell disposed in the liner and configured to provide power for propulsion of the electric vehicle.

33. The electric vehicle of claim 32, comprising an internal combustion engine coupled either to the energy storage assembly, to the drive train, or both.

34. A lithium technology battery module comprising:

a metallic external casing;

an insulative, sheet-like liner disposed in the external casing;

a plurality of prismatic lithium technology energy storage cells disposed in the liner and configured to power for operation of the electric vehicle;

a bus structure configured to interface with terminals of the energy storage cells to provide power for operation of the electric vehicle;

a bus structure configured to interface with terminals of the energy storage cells to at least partially combine outputs of the energy storage cells; and

a compression element disposed between the casing and the energy storage cells and configured to urge the energy storage cells towards one another.