Battery module housing and method of making the same

• US 9,985,268 B2
• Filed: 03/31/2014
• Issued: 05/29/2018
• Est. Priority Date: 09/06/2013
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Houchin-Miller, Gary P., Balk, Mikhail S., DeKeuster, Richard M., Cash, Stephen D.
• Primary Examiner(s): Dignan, Michael L
• Application Number:
  US14/231,329
• Publication Number:
  US 20150072206A1
• Time in Patent Office: 1,520 Days
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 1/14 to electric lighting circuits
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/15 : Preventing overcharging
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/24 : for controlling the temperature of batteries
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60R 16/03 : for supply of electrical power to vehicle subsystems or for circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60R 16/033 : characterised by the use of electrical cells or batteries for propulsion puposes B60K1/04; supplying batteries to, or removing batteries from, vehicles B60S5/06; testing of charge state G01R31/36
• CPC Class Codes: G01R 31/3835 : involving only voltage measurements
• CPC Class Codes: G01R 31/385 : Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: G01R 31/52 : Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H01H 47/325 : by switching regulator
• 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 10/058 : Construction or manufacture
• CPC Class Codes: H01M 10/425 : Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/4257 : Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• 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 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 2010/4271 : Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2010/4278 : Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2200/103 : Fuse
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2250/20 : Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/661 : Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/665 : Composites
• CPC Class Codes: H01M 50/20 : Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders structural combination of accumulators with charging apparatus H01M10/46
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/264 : for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/287 : Fixing of circuit boards to lids or covers
• CPC Class Codes: H01M 50/291 : characterised by their shape
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/308 : Detachable arrangements, e.g. detachable vent plugs or plug systems
• CPC Class Codes: H01M 50/342 : Non-re-sealable arrangements
• CPC Class Codes: H01M 50/35 : Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages
• CPC Class Codes: H01M 50/358 : External gas exhaust passages located on the battery cover or case
• CPC Class Codes: H01M 50/367 : Internal gas exhaust passages forming part of the battery cover or case; Double cover vent systems
• CPC Class Codes: H01M 50/50 : Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/502 : Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
• CPC Class Codes: H01M 50/507 : comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
• CPC Class Codes: H01M 50/528 : Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/529 : Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: H01M 50/543 : Terminals
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/571 : Methods or arrangements for affording protection against corrosion; Selection of materials therefor
• CPC Class Codes: H01M 50/572 : Means for preventing undesired use or discharge
• CPC Class Codes: H01M 50/583 : in response to current, e.g. fuses
• CPC Class Codes: H01M 50/597 : Protection against reversal of polarity
• CPC Class Codes: H01R 12/716 : Coupling device provided on the PCB
• CPC Class Codes: H02H 7/18 : for batteries; for accumulators
• CPC Class Codes: H05K 1/0218 : by printed shielding conductors, ground planes or power plane H05K1/0236 takes precedence
• CPC Class Codes: H05K 1/0262 : Arrangements for regulating voltages or for using plural voltages
• CPC Class Codes: H05K 1/0263 : High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 1/0298 : Multilayer circuits
• CPC Class Codes: H05K 1/18 : Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/0715 : provided by an outer layer of PCB
• CPC Class Codes: H05K 2201/09327 : Special sequence of power, ground and signal layers in multilayer PCB
• CPC Class Codes: H05K 2201/10492 : Electrically connected to another device mounted components directly electrically connected to each other H05K2201/1053
• CPC Class Codes: H05K 2201/1053 : Mounted components directly electrically connected to each other, i.e. not via the PCB
• CPC Class Codes: H05K 2201/10545 : Related components mounted on both sides of the PCB
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding

Abstract

A battery module includes a housing configured to hold prismatic battery cells within a space defined by four interior walls of the housing. The housing includes a first interior wall that includes partitions extending upwards from a bottom of the housing and a second interior wall that includes partitions extending upwards from the bottom of the housing. The first interior wall faces opposite the second interior wall. The partitions disposed on the first interior wall and the partitions disposed on the second interior wall define slots between adjacent partitions, where each of the slots increases in width between the adjacent partitions from the bottom of the housing upwards. Each of the slots is configured to retain one of the prismatic battery cells.

Claims

1. A battery module, comprising:

a housing configured to hold a plurality of prismatic battery cells within a space defined by four interior walls of the housing, the housing comprising a cover configured to be sealed over the housing, and;

a first interior wall comprising a first plurality of partitions extending upwards from a bottom of the housing and disposed in a first row along a first length of the first interior wall; and

a second interior wall comprising a first plurality of partitions extending upwards from the bottom of the housing and disposed in a second row along a second length of the second interior wall, wherein the second interior wall faces the first interior wall, wherein the first and second lengths are parallel with one another, and wherein the first plurality of partitions and the second plurality of partitions are aligned with and extend toward one another;

wherein the plurality of partitions disposed on the first interior wall and the second plurality of partitions disposed on the second interior wall define a first plurality partitions and adjacent second partitions of the second plurality of partitions, respectively, wherein the first slot of the first plurality of slots and each second slot of the second plurality of slots increases in a width from the bottom of the housing upwards as measured along the first and second length of the first and second interior walls respectively, wherein a gap separates the first plurality of partitions from the second plurality of partitions, and wherein each of the first plurality of slots and each of the second plurality of slots is configured to retain one of the plurality of prismatic battery cells.

2. The battery module of claim 1, wherein the housing comprises a third interior wall that couples the first and second interior walls at a first end of the housing, wherein an additional first slot of the plurality of first slots is defined between the third interior wall and one first partition of the first plurality of partitions adjacent to the third interior wall, wherein an additional second slot of the second plurality of slots is defined between the third interior wall and one second partition of the second plurality of partitions adjacent to the third interior wall, and wherein the first and second additional slots are configured to retain one of the plurality of prismatic battery cells.

3. The battery module of claim 1, wherein each first slot of the first plurality of slots and each second slot of the second plurality of slots comprises a first width at the bottom of the housing and measured along the first and second lengths of the first and second interior walls, respectively, wherein the first width is large enough to accomodate a cell width of any one of the plurality of prismatic battery cells.

4. The battery module of claim 3, wherein each first slot of the first plurality of slots and each second slot of the second plurality of slots comprises a second width proximate to a top of the housing and measured along the first and second lengths of the first and second interior walls, respectively, wherein the second width is greater than the first width and larger than the cell width of any one of the plurality of prismatic battery cells.

5. The battery module of claim 1, wherein each first partition of the first plurality of partitions and each second partition of the second plurality of partitions is tapered inwards from the bottom of the housing upwards and along the first and second lengths of the first and second interior walls, respectively, such that each of the plurality of slots gradually increases in width from the bottom of the housing upwards.

6. The battery module of claim 1, wherein the first plurality of partitions extend in an upward direction perpendicular to the first and second lengths of the first and second interior walls, respectively, from the interior wall toward the second interior wall, and wherein the first plurality of partitions of the first interior wall are tapered along the inward direction, from the bottom of the housing upwards, such that an inward width of each of the first plurality of partitions along the inward direction gradually decreases from the bottom of the housing upwards.

7. The battery module of claim 1, wherein the housing comprises a truss structure configured to counteract forces in the housing caused by swelling of one or more battery cells.

8. The battery module of claim 7, wherein the housing comprises a third interior wall that couples the first and second interior walls at a first end of the housing, a fourth interior wall that couples the first and second interior walls at a second end of the housing opposite the first end, wherein the housing is configured to hold the plurality of prismatic battery cells in an orientation such that the prismatic battery cells of the plurality of prismatic battery cells are stacked from the third interior wall to the fourth interior wall, and wherein the truss structure is disposed adjacent the third interior wall, adjacent the fourth interior wall, or both.

9. The battery module of claim 1, wherein the housing comprises a plurality of extensions disposed on an outer surface of the housing, wherein the plurality of extensions is configured to transfer heat from the plurality of battery cells in the housing to ambient air outside the battery module.

10. The battery module of claim 1, comprising a lid structure configured to be held between the cover and the housing, wherein the lid structure holds internal components of the battery module, wherein the housing comprises an attachment feature for coupling with the lid structure on the housing and a sealing feature formed along a circumference of the housing, and wherein the sealing feature is configured to mate with a complementary sealing feature of the cover to hermetically seal the cover to the housing.