SYSTEM FOR PROVIDING STRUCTURAL INTEGRITY OF A BATTERY MODULE

• US 20160093850A1
• Filed: 09/30/2014
• Published: 03/31/2016
• Est. Priority Date: 09/30/2014
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: DeKeuster, Richard M., Mack, Robert J.
• Granted Patent: US 9,608,245 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0411 Arrangement in the front part of the vehicle
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• 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: B60Y 2306/01 Reducing damages in case of crash, e.g. by improving battery protection
• CPC Class Codes: B60Y 2410/10 Housings
• 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 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 2200/00 Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• 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 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/505 comprising a single busbar
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A battery module includes a housing configured to receive a plurality of electrochemical cells, a skeletal frame coupled with the housing, and a framework disposed proximate to the skeletal frame. Moreover, the framework is substantially aligned with the skeletal frame and configured to transfer a force applied to the framework to the skeletal frame.

Claims

1. A battery module comprising:

a housing configured to receive a plurality of electrochemical cells;

a skeletal frame coupled with the housing; and

a framework disposed proximate to the skeletal frame, wherein the framework is substantially aligned with the skeletal frame and configured to transfer a force applied to the framework to the skeletal frame.

2. The battery module of claim 1 comprising a panel coupled to the housing, wherein the framework is integrally formed in the panel.

3. The battery module of claim 1 comprising a front cover disposed proximate to the framework, wherein the front cover is configured to enclose the framework within the battery module.

4. The battery module of claim 1 comprising an e-carrier configured to facilitate electrical connection between the plurality of electrochemical cells, wherein the framework is integrally formed with the e-carrier.

5. The battery module of claim 1, wherein the framework is positioned within a gap formed between the skeletal frame and a front side of the housing.

6. The battery module of claim 1, wherein the framework is formed from an elastomer, a polymer, a metal, or a combination thereof.

7. The battery module of claim 1, wherein the framework is configured to deform while enclosed within the housing.

8. The battery module of claim 1 comprising a cage configured to surround the housing, wherein the cage is configured to block the housing from external forces.

9. The battery module of claim 8, wherein the cage is configured to couple to the housing and aligned to transfer force to the skeletal frame.

10. The battery module of claim 8, wherein the cage comprises a crush assembly configured to deform when acted upon by a sufficient force, such that the energy from the sufficient force is substantially isolated from the housing.

11. The battery module of claim 1, wherein the framework is formed from a material with a lower modulus of elasticity than the skeletal frame.

12. The battery module of claim 1 comprising a housing lip extending beyond a front side of the housing and configured to couple to the panel.

13. The battery module of claim 1, wherein the skeletal frame is configured to provide structural support to the plurality of electrochemical cells.

14. A battery module comprising:

a housing configured to receive a plurality of electrochemical cells;

a skeletal frame of the housing;

a lid coupled to a top side of the housing, wherein the lid is configured to enclose components of the battery module within the housing;

a lip formed on the top side of the housing, wherein the lip extends away from the housing in a first direction and is integral with or engaged with the skeletal frame; and

a shoulder formed on the top side of the housing, wherein the shoulder is coupled to the lip and forms a recess configured to receive the lid.

15. The battery module of claim 14, comprising an arm coupled to the lip, wherein the arm extends laterally over the lid.

16. The battery module of claim 15, wherein the arm is configured to block movement of the lid in the first direction.

17. The battery module of claim 14, wherein the lips extends about a perimeter of the housing.

19. The battery module of claim 14, wherein the lip extends in the first direction above a top surface of the lid, thereby blocking the lid from forces applied to a side of the housing.

20. The battery module of claim 19, wherein the lip is configured to block movement of the lid in at least two directions.

18. The battery module of claim 124, comprising a lid space formed about a perimeter of the lid, wherein the lid space is configured to enable movement of the lid within the recess.

21. A battery module, comprising:

a housing configured to receive a plurality of electrochemical cells;

a housing lip formed on a front side of the housing, wherein the housing lip extends laterally away from the housing;

an e-carrier disposed proximate to the housing within a perimeter of the housing lip;

a bus bar configured to electrically couple the plurality of electrochemical cells to one another;

a framework integrally formed with or coupled to the e-carrier, wherein the framework is coupled to the bus bar and configured to substantially align with a skeletal frame of the housing; and

a front cover disposed proximate to the housing lip, wherein the front cover is configured to enclose the e-carrier, the bus bar, and the framework within the housing.

22. The battery module of claim 21, wherein the housing lip is configured to receive forces applied to the front cover and transfer the forces to the skeletal frame.

23. The battery module of claim 21, wherein the housing lip extends substantially about a perimeter of the housing and forms an opening configured to receive the e-carrier.

24. The battery module of claim 21, wherein the e-carrier is comprised of an elastomer, a polymer, a composite material, or a combination thereof.

25. The battery module of claim 21, wherein the housing comprises rigidity features disposed on a first side and a second side of the housing, the second side disposed opposite the first side, the rigidity features comprising extended members defined by recessed portions, wherein the extended members define triangles in a truss-like configuration.

26. The battery module of claim 25, wherein the extended members of the rigidity features couple together at hubs to form an integral framework along the first and second sides of the housing.