Battery cover assembly

• US 9,123,944 B2
• Filed: 03/25/2010
• Issued: 09/01/2015
• Est. Priority Date: 03/25/2010
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Maguire, Patrick Daniel
• Primary Examiner(s): Laios, Maria J
• Application Number:
  US12/731,554
• Publication Number:
  US 20110177376A1
• Time in Patent Office: 1,986 Days
• Field of Search: 429/151, 429/153, 429/159, 429/100
• US Class Current: 1/1
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/6566 Means within the gas flow to guide the flow around one or more cells, e.g. manifolds, baffles or other barriers H01M10/6565 takes precedence
• CPC Class Codes: H01M 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/258 Modular batteries; Casings provided with means for assembling
• CPC Class Codes: H01M 50/262 with fastening means, e.g. locks
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/516 by welding, soldering or brazing
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

An end-to-end cell connection system for a battery assembly uses a conductive interconnector with an inner portion welded to an end of one cell, a standoff portion contiguous with the ring portion, tabs extending from the standoff portion, with the tabs welded to an end of another cell. By placing an insulator between the interconnector and the one cell, an electrical short is prevented in the event that a longitudinally coupled cell group is jostled. At the cell connections, there is a recess. To hold the cell group in place, the housing has a tab extending into the recess. The tab is at the center so that any dimensional variations are accommodated on each side of the tab. The interconnector also may include a receptacle for a thermistor to obtain a measure of battery assembly temperature. Diverter ribs may be provided in the housing to distribute flow to all cells.

Claims

1. A battery, comprising:

a plurality of cell groups, each group comprising a plurality of cells coupled longitudinally;

a plurality of cell housings each having at least one cell group within, the cell housings arranged in an array;

indexing tabs extending from an outside surface of each cell housing forming a channel along the array; and

a cover having a groove formed therein for mating with the channel when the cover is placed over the array.

2. The battery of claim 1 wherein the indexing tabs are configured to receive the groove and the groove is V-shaped.

3. The battery of claim 1 wherein the indexing tabs are configured to receive the groove and the groove is one of rectangular and semicircular.

4. The battery of claim 1, further comprising:

a first end plate coupled to a first end of the array, the first end being a side of the array adjacent to an end of the array onto which the cover is placed; and

a second end plate coupled to a second end of the array, the second end being opposite to the first end.

5. The battery of claim 4 wherein the first and second end plates define multiple clamping holes, the battery further comprising:

a nut coupled to the cover configured to align with the clamping hole when the array, cover, and end plates are assembled; and

a fastener passing through the clamping hole and engaged with the nut.

6. The battery of claim 5 wherein the cover further comprises a tab extending substantially perpendicularly from the cover, the tab defines an alignment hole, and the fastener further passes through the alignment hole.

7. The battery of claim 6 wherein the tab is proximate the groove and extends from a bottom of the groove to, at most, a top of the cover.

8. A battery, comprising:

a plurality of cell groups, each group comprising a plurality of cells coupled longitudinally;

a plurality of cell housings each having at least one cell group within, the cell housings arranged in an array and each housing having indexing tabs extending from an outside surface of each cell housing, the indexing tabs forming a channel along the array;

a first end plate coupled to a first end of the array;

a second end plate coupled to a second end of the array, the second end being opposite to the first end wherein the first and second end plates define clamping holes;

a cover placed on a side of the battery, the cover extending between the first end plate and the second end plate, the cover having a groove formed therein for mating with the channel when the cover is placed over the array;

an alignment hole defined in the cover and located near an edge of the cover; and

a fastener coupling the cover and the end plate via the alignment hole and the clamping hole.

9. The battery of claim 8, further comprising:

two pairs of indexing tabs extending from the outside surface of each cell housing wherein the cover has two grooves mating with the indexing tabs.

10. The battery of claim 8, further comprising:

a first pair of indexing tabs extending from the outside surface of each cell housing; and

a second pair of indexing tabs extending from an outside surface of each cell housing, wherein the cover has a first groove mating with the first pair of indexing tabs and a second groove mating with the second pair of indexing tabs.

11. The battery of claim 10 wherein the cover has two tabs proximate each end of the first groove and two tabs proximate each end of the second groove with the fastener passing therethrough.

12. The battery of claim 10 wherein the first pair of indexing tabs are aligned to form a first channel, the second pair of indexing tabs are aligned when arranged in the array to form a second channel, and the first and second grooves index with the first and second channels, respectively.

13. The battery of claim 8 wherein the cells are substantially cylindrical.

14. The battery of claim 8 wherein clamping holes defined in the first and second end plates are located near an edge of the first and second end plates proximate the cover.

15. A method to assemble a battery, the method comprising:

arranging a plurality of bricks each containing a plurality of cells in an array, the bricks having indexing tabs extending outwardly with the indexing tabs forming a channel when arranged in the array; and

placing a cover over a first side of the array such that a groove formed in the cover engages into the channel of the indexing tabs.

16. The method of claim 15 wherein the cover has tabs extending from the cover perpendicularly with an alignment hole in each tab, the method further comprising:

placing a first end plate having at least one clamping hole adjacent to a second side of the array with one of the clamping holes aligned with at least one the alignment holes; and

coupling the first end plate with the cover via the alignment hole and the clamping hole.

17. The method of claim 16, wherein a fastener couples the alignment hole and the clamping hole and the fastener is one of:

a bolt and a nut, a screw, a rivet, a stud, and a weld.

18. The method of claim 16 wherein the tabs are proximate the groove.

19. The method of claim 16 wherein the cover has two tabs which overlap proximate an end of the groove and a bolt is placed through both alignment holes, the method further comprising:

tightening a nut on the threads of the bolt.

20. The method of claim 15 wherein the cover is a first cover, the method further comprising:

placing a second cover over a side of the array opposite the first side of the array wherein first and second covers have tabs extending from the cover perpendicularly with an alignment hole in each tab;

placing a first end plate having at least one clamping hole adjacent to a second side of the array with one of the clamping holes aligned with at least one the alignment holes of the first cover and at least one of the alignment holes of the second cover; and

coupling the first end plate with the first and second covers via the alignment hole and the clamping hole.