U.S. patent application number 14/448441 was filed with the patent office on 2014-11-20 for battery cell system with interconnected frames.
The applicant listed for this patent is EnerDel, Inc.. Invention is credited to Ed Cates, Bruce Silk, Tom Tople, Len Wolf.
Application Number | 20140342207 14/448441 |
Document ID | / |
Family ID | 45493880 |
Filed Date | 2014-11-20 |
United States Patent
Application |
20140342207 |
Kind Code |
A1 |
Tople; Tom ; et al. |
November 20, 2014 |
BATTERY CELL SYSTEM WITH INTERCONNECTED FRAMES
Abstract
A battery cell assembly includes a plurality of sub-assemblies.
Each sub-assembly includes a heat sink and a first frame and a
second frame disposed on opposite sides of the heat sink. The
sub-assemblies are stacked to form a plurality of cell pockets that
receive a battery cell. The battery cell assembly further includes
a plurality of tie rods for fixing the plurality of sub-assemblies
together. The first frame is formed with a plurality of through
holes, and the second frame is formed with a plurality of
protrusions with a hole extending therethrough. The frames are
brought together such that each protrusion is at least partially
received in a respective through hole. The interior surfaces of
corresponding protrusions and through holes of the stack of frames
form a passage for one of the tie rods to extend through.
Inventors: |
Tople; Tom; (Indianapolis,
IN) ; Cates; Ed; (Anderson, IN) ; Wolf;
Len; (Indianapolis, IN) ; Silk; Bruce;
(Indianapolis, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EnerDel, Inc. |
Greenfield |
IN |
US |
|
|
Family ID: |
45493880 |
Appl. No.: |
14/448441 |
Filed: |
July 31, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12843667 |
Jul 26, 2010 |
8795872 |
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14448441 |
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Current U.S.
Class: |
429/99 |
Current CPC
Class: |
H01M 10/0481 20130101;
H01M 10/0486 20130101; H01M 10/613 20150401; H01M 10/6555 20150401;
H01M 10/02 20130101; Y02E 60/10 20130101; H01M 10/647 20150401;
H01M 10/0525 20130101 |
Class at
Publication: |
429/99 |
International
Class: |
H01M 10/613 20060101
H01M010/613; H01M 10/6555 20060101 H01M010/6555; H01M 10/647
20060101 H01M010/647; H01M 10/04 20060101 H01M010/04 |
Claims
1. A battery assembly comprising: a plurality of sub-assemblies,
each of the sub-assemblies including a cell support, a first frame
and a second frame, the first frame including an upper side and a
lower side, a plurality of holes extending through the first frame
from the upper side to the lower side, the second frame including
an upper side and a lower side, a plurality of protrusions
extending from the upper side thereof to an outer tip surface, a
plurality of holes extending through the second frame from the
lower side to a respective one of the outer tip surfaces, the first
and second frames being disposed on opposite sides of the cell
support such that at least a portion of the heat sink is sandwiched
between the lower side of the first frame and the upper side of the
second frame and such that each of the protrusions is at least
partially received in a respective one of the holes in the first
frame, whereby the first and second frames are interlockingly
engaged, the plurality of sub-assemblies being stacked to form a
plurality of cell pockets, each cell pocket being formed between
two adjacent sub-assemblies, the holes in the second frame of each
of the sub-assemblies being substantially aligned so as to
collectively form a plurality of passages for receiving an
elongated fastener therein to fix the plurality of sub-assemblies
together.
2. The assembly of claim 1 further including a plurality of battery
cells, wherein each battery cell is received in a respective one of
the plurality of cell pockets and wherein portions of each battery
cell are sandwiched between adjacent sub-assemblies.
3. The assembly of claim 2 wherein the battery cells are
lithium-ion battery cells.
4. The assembly claim 1 further including two end plates, the end
plates being disposed on opposite ends of the plurality of
sub-assemblies such that the plurality of sub-assemblies are
sandwiched between the two end plates.
5. The assembly of claim 1 wherein the first and second frames have
a substantially rectangular shape and an open middle portion.
6. The assembly of claim 5 wherein the frames have a plurality of
corner regions, wherein each hole in the first frame is located in
a corner region thereof, and wherein each protrusion of the second
frame is located in a corner region thereof.
7. The assembly of claim 5 wherein each of the first frames
includes a protrusion for being received into a hole in the second
frame of an adjacent one of the plurality of sub-assemblies,
wherein the protrusion extends from the upper side of each of the
first frames to an outer tip surface, wherein a hole extends
through the first frame from the lower side to the outer tip
surface, wherein the protrusion is located in one of the corner
regions of the first frame proximate to one of the holes.
8. The assembly of claim 1 wherein the cell support is a heat
sink.
9. The assembly of claim 1 wherein at least one of the protrusions
has a substantially circular cross-sectional shape.
10. The assembly of claim 1 wherein each protrusion has an
associated height, wherein the height of each protrusion is less
than or equal to the depth of a corresponding through hole into
which the protrusion is received.
11. The assembly of claim 1 wherein, in a first one of the
sub-assemblies, the height of at least one of the protrusions of
the second frame is greater than the depth of a corresponding
through hole into which the protrusion is received such that the at
least one of the protrusions extends beyond the upper side of the
first frame and into a recess provided in the lower side of the
second frame of an adjacent second one of the sub-assemblies.
12. The assembly of claim 1 further including a plurality of
elongated fasteners, each elongated fastener being received in a
respective one of the passages, whereby the plurality of elongated
fasteners fix the plurality of sub-assemblies together.
13. The assembly of claim 12 wherein the elongated fasteners are
tie rods.
14. A battery assembly comprising: a plurality of sub-assemblies,
each of the sub-assemblies including a cell support, a first frame
and a second frame, the first frame including an upper side and a
lower side, a plurality of holes extending through the first frame
from the upper side to the lower side, the second frame including
an upper side and a lower side, a plurality of protrusions
extending from the upper side thereof to an outer tip surface, a
plurality of holes extending through the second frame from the
lower side to a respective one of the outer tip surfaces, the first
and second frames being disposed on opposite sides of the cell
support such that at least a portion of the cell support is
sandwiched between the lower side of the first frame and the upper
side of the second frame and such that each of the protrusions is
at least partially received in a respective one of the holes in the
first frame, whereby the first and second frames are interlockingly
engaged, the plurality of sub-assemblies being stacked to form a
plurality of cell pockets, each cell pocket being formed between
two adjacent sub-assemblies, the holes in the second frame of each
of the sub-assemblies being substantially aligned so as to
collectively form a plurality of passages, a plurality of battery
cells, wherein each battery cell is received in a respective one of
the plurality of cell pockets and wherein portions of each battery
cell are sandwiched between adjacent sub-assemblies; and a
plurality of elongated fasteners, each elongated fastener being
received in a respective one of the passages, whereby the plurality
of elongated fasteners fix the plurality of sub-assemblies
together.
15. The assembly of claim 14 wherein the elongated fasteners are
tie rods.
16. The assembly of claim 14 wherein the cell support is a heat
sink.
17. A battery assembly comprising: a plurality of sub-assemblies,
each of the sub-assemblies including a first frame and a second
frame, the first frame including an upper side and a lower side, a
plurality of holes extending through the first frame from the upper
side to the lower side, the second frame including an upper side
and a lower side, a plurality of protrusions extending from the
upper side thereof to an outer tip surface, a plurality of holes
extending through the second frame from the lower side to a
respective one of the outer tip surfaces, each of the protrusions
being at least partially received in a respective one of the holes
in the first frame, a plurality of battery cells, the plurality of
sub-assemblies being alternatingly stacked with the plurality of
battery cells such that portions of each battery cell are
sandwiched between adjacent sub-assemblies, the holes in the second
frame of each of the sub-assemblies being substantially aligned so
as to collectively form a plurality of passages; and a plurality of
elongated fasteners, each elongated fastener being received in a
respective one of the passages, whereby the plurality of elongated
fasteners fix the plurality of sub-assemblies together.
18. The assembly of claim 17 wherein the elongated fasteners are
tie rods.
19. The assembly of claim 17 wherein, in a first one of the
sub-assemblies, the height of at least one of the protrusions of
the second frame is greater than the depth of a corresponding
through hole in the first frame into which the protrusion is
received such that the at least one of the protrusions extends
beyond the upper side of the first frame and into a recess provided
in the lower side of the second frame of an adjacent second one of
the sub-assemblies.
20. The assembly of claim 17 wherein each protrusion has an
associated height, wherein the height of each protrusion is less
than or equal to the depth of a corresponding through hole into
which the protrusion is received.
Description
FIELD
[0001] Embodiments relate in general to batteries and, more
particularly, to multi-cell battery systems.
BACKGROUND
[0002] A battery is a device that converts chemical energy directly
to electrical energy. In some applications, multiple battery cells,
such as lithium battery cells, are assembled together to form a
battery cell assembly so as to provide sufficient power for various
applications. In order to assemble a plurality of battery cells,
the cells are arranged in a stack along with generally planar
frames. Portions of the battery cells are sandwiched between the
battery frames. Tie rods can be used to hold the stack of battery
cells together under slight compression. Each tie rod can extend
through a passage collectively formed by aligned holes in the
frames. Each tie rod can be fixed in place by, for example, a
threaded nut, at each end of the tie rod.
[0003] However, this type of assembly does not provide sufficient
stability and rigidity to the stack. For example, while the tie
rods may fix the frames relative to each other in one direction (in
the axial direction of the tie rod), they may move relative to one
another in one or more directions transverse to the axial direction
of the tie rod. This lack of stability and rigidity can preclude
the suitability of this type of assembly to stacks having a large
number of cells. Moreover, this type of assembly does not
sufficiently isolate the tie rods from the battery cells. Indeed,
in some instances, it may be possible for the tie rods and the
battery cells to come into contact with each other, such as when
the battery cells are oversized or not properly aligned in the
stack. In such cases, the battery cell and the tie rod may contact
each other in the spaces between adjacent frame members where
portions of the battery cell are sandwiched. Consequently, a short
can develop, which can adversely affect battery performance,
shorten the battery life span and endanger people who may handle
the battery.
[0004] Therefore, there is a need for a system that can minimize
such concerns.
SUMMARY
[0005] In a first respect, embodiments are directed to battery
assembly. The assembly includes a plurality of sub-assemblies. Each
sub-assembly includes a cell support, a first frame and a second
frame. The cell support can be a heat sink.
[0006] The first frame has an upper side and a lower side. A
plurality of holes extends through the first frame from the upper
side to the lower side. The second frame has an upper side and a
lower side. A plurality of protrusions extends from the upper side
thereof to an outer tip surface. The protrusions can have any
suitable cross-sectional shape. In one embodiment, one or more of
the protrusions can have a substantially circular cross-sectional
shape. A plurality of holes extends through the second frame from
the lower side to a respective one of the outer tip surfaces.
[0007] The first and second frames are disposed on opposite sides
of the cell support. At least a portion of the heat sink is
sandwiched between the lower side of the first frame and the upper
side of the second frame. Each of the protrusions is at least
partially received in a respective one of the holes in the first
frame. As a result, the first and second frames are interlockingly
engaged.
[0008] The plurality of sub-assemblies is stacked to form a
plurality of cell pockets. Each cell pocket is formed between two
adjacent sub-assemblies. The holes in the second frame of each of
the sub-assemblies are substantially aligned so as to collectively
form a plurality of passages. Such passages can receive an
elongated fastener so as to fix the plurality of sub-assemblies
together.
[0009] The assembly can further include a plurality of battery
cells. Each battery cell can be received in a respective one of the
plurality of cell pockets. Portions of each battery cell can be
sandwiched between adjacent sub-assemblies. In one embodiment, the
battery cells can be lithium-ion battery cells.
[0010] The assembly can also include two end plates. The end plates
can be disposed on opposite ends of the plurality of
sub-assemblies. Thus, the plurality of sub-assemblies can be
sandwiched between the two end plates.
[0011] The first and second frames can have a substantially
rectangular shape and an open middle portion. The frames can have a
plurality of corner regions. Each hole in the first frame can be
located in a corner region of the first frame. Each protrusion of
the second frame can be located in a corner region of the second
frame. Each of the first frames can include a protrusion. The
protrusion can be received into a hole in the second frame of an
adjacent one of the plurality of sub-assemblies. The protrusion can
extend from the upper side of each of the first frames to an outer
tip surface. A hole extends through the first frame from the lower
side to the outer tip surface. The protrusion can be located in one
of the corner regions of the first frame proximate to one of the
holes.
[0012] Each protrusion can have an associated height. The height of
each protrusion can be less than or equal to the depth of a
corresponding through hole into which the protrusion is
received.
[0013] In a first one of the sub-assemblies, the height of at least
one of the protrusions of the second frame can be greater than the
depth of a corresponding through hole into which the protrusion is
received. In such case, the protrusion can extend beyond the upper
side of the first frame and into a recess provided in the lower
side of the second frame of an adjacent second one of the
sub-assemblies.
[0014] The assembly can include a plurality of elongated fasteners.
Each elongated fastener can be received in a respective one of the
passages. The plurality of elongated fasteners can fix the
plurality of sub-assemblies together. In one embodiment, the
elongated fasteners can be tie rods.
[0015] In another respect, embodiments are directed to a battery
assembly. The assembly includes a plurality of sub-assemblies. Each
of the sub-assemblies includes a cell support, a first frame and a
second frame.
[0016] The first frame has an upper side and a lower side. A
plurality of holes extends through the first frame from the upper
side to the lower side. The second frame has an upper side and a
lower side. A plurality of protrusions extends from the upper side
thereof to an outer tip surface. A plurality of holes extends
through the second frame from the lower side to a respective one of
the outer tip surfaces. The cell support can be a heat sink.
[0017] The first and second frames are disposed on opposite sides
of the cell support. As a result, at least a portion of the cell
support is sandwiched between the lower side of the first frame and
the upper side of the second frame. In addition, each of the
protrusions is at least partially received in a respective one of
the holes in the first frame. In this way, the first and second
frames are interlockingly engaged.
[0018] The plurality of sub-assemblies is stacked to form a
plurality of cell pockets. Each cell pocket is formed between two
adjacent sub-assemblies. The holes in the second frame of each of
the sub-assemblies are substantially aligned so as to collectively
form a plurality of passages.
[0019] The assembly also includes a plurality of battery cells.
Each battery cell is received in a respective one of the plurality
of cell pockets. Portions of each battery cell are sandwiched
between adjacent sub-assemblies.
[0020] The assembly includes a plurality of elongated fasteners. In
one embodiment, the elongated fasteners can be tie rods. Each
elongated fastener is received in a respective one of the passages.
As a result, the plurality of elongated fasteners fixes the
plurality of sub-assemblies together.
[0021] In still another respect, embodiments are directed to a
battery assembly. The battery assembly includes a plurality of
sub-assemblies. Each sub-assembly includes a first frame and a
second frame.
[0022] The first frame has an upper side and a lower side. A
plurality of holes extends through the first frame from the upper
side to the lower side. The second frame has an upper side and a
lower side. A plurality of protrusions extends from the upper side
thereof to an outer tip surface. A plurality of holes extends
through the second frame from the lower side to a respective one of
the outer tip surfaces. Each of the protrusions is at least
partially received in a respective one of the holes in the first
frame.
[0023] The assembly includes a plurality of battery cells. The
plurality of sub-assemblies is alternatingly stacked with the
plurality of battery cells such that portions of each battery cell
are sandwiched between adjacent sub-assemblies. The holes in the
second frame of each of the sub-assemblies are substantially
aligned so as to collectively form a plurality of passages.
[0024] The assembly includes a plurality of elongated fasteners,
which can be, for example, tie rods. Each elongated fastener can be
received in a respective one of the passages. The plurality of
elongated fasteners fixes the plurality of sub-assemblies
together.
[0025] In a first one of the sub-assemblies, the height of one or
more of the protrusions of the second frame can be greater than the
depth of a corresponding through hole in the first frame into which
the protrusion is received. As a result, the one or more
protrusions can extend beyond the upper side of the first frame and
into a recess provided in the lower side of the second frame of an
adjacent second one of the sub-assemblies.
[0026] Each protrusion can have an associated height. In one
embodiment, the height of each protrusion can be less than or equal
to the depth of a corresponding through hole into which the
protrusion is received.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is an exploded perspective view of a
sub-assembly.
[0028] FIG. 2 is a perspective view of the sub-assembly of FIG. 1
in an assembled state.
[0029] FIG. 3 is a perspective view of an exemplary battery cell
assembly.
[0030] FIG. 4 is a side elevation cross-sectional view of the
battery cell assembly, showing frames with interconnecting
features.
[0031] FIG. 5 is perspective partial cross-sectional view of the
battery cell assembly, showing battery cells being received in
respective cell pockets.
DETAILED DESCRIPTION
[0032] Embodiments are directed to a battery assembly with
interlocking features. Aspects will be explained in connection with
one possible system and method, but the detailed description is
intended only as exemplary. Embodiments are shown in FIGS. 1-5, but
the embodiments are not limited to the illustrated structure or
application. It will be appreciated that for simplicity and clarity
of illustration, where appropriate, reference numerals have been
repeated among the different figures to indicate like elements.
[0033] A battery assembly can comprise a plurality of
sub-assemblies. Referring to FIG. 1, an exploded view of an example
of a sub-assembly 100 is shown. In one arrangement, the
sub-assembly 100 can include a cell support, a first frame 110 and
a second frame 130. The first and second frames 110, 130 are
disposed on opposite sides of the cell support. In one embodiment,
the cell support can be a heat sink 120, which can dissipate heat
generated by the battery cells so as to prevent degradation of the
battery cells due to overheating. The heat sink 120 can be made of
any suitable heat dissipating material, including, for example,
copper or aluminum. The heat sink 120 can have any suitable
conformation. In one embodiment, the heat sink 120 can be generally
rectangular. However, other conformations are possible, depending
on the particular application at hand. The heat sink 120 can be a
generally flat, planar structure. The heat sink 120 can have
various other features, such as holes, slots and projections, as
may be needed.
[0034] The first and second frames 110, 130 can be made of any
suitable material. For instance, the first and second frames 110,
130 can be made of plastic. The first and second frames 110, 130
can have any suitable conformation. In one embodiment, the first
and second frames 110, 130 can be generally rectangular. However,
other conformations are possible, depending on the particular
application at hand. The first and second frames 110, 130 can have
generally the same conformation as the heat sink 120. The first and
second frames 110, 130 can have an open middle portion 111, 131,
respectively.
[0035] The first and second frames 110, 130 can be substantially
identical to each other, except for certain structures described
herein. The first frame 110 can have an upper side 122 and a lower
side 124. The second frame 130 can have an upper side 126 and a
lower side 128. The terms "upper" and "lower" are used for
convenience to facilitate the discussion and are used to denote
their relative orientation in FIG. 2; however, it will be
understood that the use of these terms is not intended to be
limiting, as the first and second frames 110, 130 and their
associated sides 122, 124, 126, 128 can have any suitable
orientation when assembled and in use.
[0036] The first and second frames 110, 130 can include features to
allow for a greater degree of engagement between them, besides the
mere abutment of the lower surface 124 of the first frame 110 and
the upper surface 126 of the second frame 130. For instance, as
shown in FIG. 1, the first frame 110 can include a plurality of
holes 116 extending through the thickness of the first frames 110
from the upper side 122 to the lower side 124. The holes 116 can
have any suitable conformation. In one embodiment, the holes 116
can be substantially circular in cross-sectional shape, but other
cross-sectional shapes are possible, including, for example,
substantially rectangular, oval, triangular, polygonal and
trapezoidal. The plurality of holes 116 can be substantially
identical to each other, or at least one of the holes 116 can be
different from the other holes 16 in at least one respect including
any of those described above.
[0037] There can be any suitable quantity of holes 116. In one
embodiment, there can be four holes 116. However, there may be
greater or fewer holes 116. The holes 116 can be arranged in any
suitable manner. For example, there can be at least one hole 116 in
each corner region 142 of the first frame 110. The corner region
142 includes the area where two portions of the first frame 110
meet to form a corner and neighboring areas thereof.
[0038] The second frame 130 can include a plurality of protrusions
112 extending outwardly from the upper side 126. Each protrusion
112 can culminate in an outer tip surface 113. The protrusions 112
can have any suitable conformation. In one embodiment, the
protrusions 112 can be substantially circular in cross-sectional
shape, but other conformations are possible, including, for
example, substantially rectangular, oval, triangular, polygonal and
trapezoidal. The cross-sectional size of the protrusions 112 can be
substantially constant or it can vary along the length of the
protrusion 112. The protrusions 112 can extend from the upper side
126 of the second frame 130 at any suitable angle. In one
embodiment, the protrusions 112 can be substantially orthogonal to
the upper side 126 of the second frame 130.
[0039] The protrusions 112 can be relatively large and simple
structures, as they must be able to withstand the compressive
forces that they will be subject to in the battery assembly. Thus,
it is preferred if the protrusions 112 do not include small and
fine features, such as a plurality of thin walls or a double-wall,
because such features may not withstand exposure to compressive
forces in the final assembly, in addition to being more expensive
and difficult to manufacture.
[0040] The plurality of protrusions 112 can be substantially
identical to each other, or at least one of the protrusions 112 can
be different from the other protrusions 112 in one or more respects
including any of those described herein. The holes 116 and the
protrusions 112 can be sized such that each protrusion 112 can be
received in a respective one of the holes 116. In one embodiment,
the holes 116 and the protrusions 112 can be sized such that each
protrusion 112 can be received in a respective one of the holes 116
with a snug fit therebetween.
[0041] There can be any suitable quantity of protrusions 112. In
one embodiment, there can be four protrusions 112 on the second
frame 130. However, there may be greater or fewer protrusions 112
on the second frame 130. The quantity of protrusions 112 provided
in the second frame 130 can be equal to the quantity of holes 116
provided in the first frame 110. The protrusions 112 can be
arranged in any suitable manner. Generally, the protrusions 112 can
be arranged on the upper side 126 of the second frame 130 such that
each protrusion 112 is substantially aligned with a respective one
of the holes 116 in the first frame 110. In one embodiment, there
can be at least one protrusion 112 in each corner region 143 of the
second frame 130. The corner region 143 includes the area where two
portions of the second frame 130 meet to form a corner and
neighboring areas thereof.
[0042] A plurality of holes 114 can extend through the thickness of
the second frame 130 and the protrusion 112, from the lower side
126 to the outer tip surface 113 of each protrusion 112. The holes
114 can have any suitable conformation. In one embodiment, the
holes 114 can be substantially circular in cross-sectional shape,
but other cross-sectional shapes are possible, including, for
example, substantially rectangular, oval, triangular, polygonal and
trapezoidal. The cross-sectional size of the holes 114 can be
substantially constant or it can vary along the length of the holes
114. The plurality holes 114 can be substantially identical to each
other, or at least one of the holes 114 can be different from the
other holes 114 in one or more respects including any of those
described herein. The holes 114 can be sized and shaped to receive
an elongated fastener, such as a tie rod, therein.
[0043] The height of each of the protrusion 112, as measured from
the upper side 126 to the outer tip surface 113, can be configured
relative to the depth of a corresponding hole 116 into which the
protrusion 112 fits. In one embodiment, the outer tip surface 113
of the protrusion 112 can be substantially flush with the upper
side 122 of the first frame 110. In another embodiment, the outer
tip surface 113 of the protrusion 112 can be recessed from the
upper side 122 of the first frame 110. In still another embodiment,
the outer tip surface 113 of the protrusion 112 can project
outwardly beyond the upper side 122 of the first frame 110.
Additional details of such a possible configuration will be
described below.
[0044] There may be more than one hole 116 and/or protrusion 112 in
at least one of the corner regions 142 of the first and second
frames 110, 130. For example, as is shown in FIG. 1, each corner
region 142 of the first frame 110 can include a hole 116 and a
protrusion 112', and each corner region 143 of the second frame can
include a corresponding protrusion 112 as well as a hole 116'. In
such case, each protrusion 112' in the first frame 110 can be
received in a respective hole (not shown) in an adjacent second
frame (not shown). Similarly, each hole 116' in the second frame
130 can receive a respective protrusion (not shown) from an
adjacent first frame (not shown). In this way each sub-assembly 100
can be interconnected with neighboring sub-assemblies 100. The
above discussion of the holes 116 and the protrusions 112 applies
equally to the protrusions 112' and holes 116'.
[0045] It is noted that embodiments are not limited to the
particular arrangement of holes 116 and protrusions 112 shown in
FIG. 1. For example, the quantity and the location of the holes 116
can vary depending on, for example, the size, quantity, and/or the
shape of the cells to be assembled. Further, one or more of the
corner regions 142, 143 of each frame 110, 130 may include only
protrusions 112 or only holes 116. Other suitable arrangements can
include only one hole 116 or only one protrusion 112 at one or more
of the corner regions 142 of the frames 110, 130. Alternatively or
in addition, different corner regions 142, 143 can have different
quantities of holes 116 and/or protrusions 112. Further,
embodiments are not limited to the protrusions 112 and holes 116
being provided in the corner regions 142, 143 of the frames 110,
130. Indeed, in some embodiment, there may be no protrusions 112
and frames 116 provided in any of the corner regions 142, 143.
[0046] It should be noted that, in some instances, that one or more
protrusions (not shown) can extend from the lower side 124 of the
first frame 110. Each of such protrusions can be received into a
respective hole (not shown) in the second frame 130. Such a
configuration can be provided as an alternative or in combination
to the protrusion/hole configurations described above. Further, the
above discussion of the protrusions 112 and holes 116 can apply
equally here.
[0047] The first frame 110 and the second frame 130 can be brought
together about the heat sink 120 such that the protrusions 112 of
the second frame 130 are received in the holes 116 in the first
frame 110. In this way, the holes 116 and protrusions 112 can act
as alignment guides or locators to facilitate assembly. The holes
116 and protrusions 112 can also minimize lateral movement of the
first and second frames 110, 130 relative to each other.
[0048] The heat sink 120 can be held in place by engagement with
the first and second frames 110, 130, generally along a perimeter
region of the heat sink 120. As a result, a sub-assembly 100 is
formed, as is shown in FIG. 2. A plurality of such assemblies 100
can be stacked to together. Adjacent sub-assemblies 100 can
collectively form a cell pocket 140 (see FIG. 5). A cell pocket 140
can be formed on each side of the heat sink 120 of each
sub-assembly 100. A battery cell 150, such as a lithium-ion battery
cell, can be received in the pocket 140. The heat sink 120 can
provide a surface on which a battery cell 150 (see FIG. 5) can be
supported.
[0049] Referring to FIG. 3, an exemplary battery cell assembly 200
is shown. By alternatively stacking sub-assemblies 100 and battery
cells 150 (see FIG. 5) on one another, a battery cell stack 230 can
be formed. The battery cell stack 230 can then be assembled into a
battery cell assembly 200, as shown in FIG. 3, by sandwiching the
cell stack 230 between two end plates 210, 220. Elongated
fasteners, such as tie rods 240, can be used to fix the cell stack
230 and the end plates 210 and 220 together. The quantity of tie
rods 240 used can depend on a number of considerations, including,
for example, the number of cells to be assembled, the required
stability and/or available space. In the exemplary arrangement
shown in FIG. 3, two tie rods 240 are used at each corner region
241 of the assembly 200. However, other suitable arrangements may
also be used and embodiments are not limited to the particular
arrangement shown. In one embodiment, there can be the same number
of tie rods 240 used at each corner region 241 of the assembly;
however, one or more of the corner regions 241 may have a different
quantity of tie rods relative to the other corner regions 241.
[0050] An example of the interconnecting arrangement of the frames
110, 130 can be seen in FIG. 4. The battery cell assembly 200
includes a plurality of sub-assemblies 100 stacked together and
sandwiched between two end plates 210, 220 (only end plate 210 is
shown in FIG. 4). At least a portion of each of the protrusions 112
formed on the lower frames 130 can be received in a respective one
of the through holes 116 formed in the adjacent upper frame 110
such that each protrusion is nested therein. In one embodiment, the
protrusions 112 can fit snuggly fit into corresponding through
holes 116 formed in adjacent upper frames 110. The nested
protrusions 112 and through holes 116 can collectively form a
continuous passage 250 for receiving a tie rod 240 (see FIG. 3).
Similarly, the protrusions 112' formed on the upper frames 110 can
snuggly fit into corresponding through holes 116 formed in adjacent
lower frames 130 to form another continuous passage 260 for another
tie rod 240 (see FIG. 3) to extend through. The tie rods 240 can
extend longitudinally through the stack 230 with the tie rods 240
passing through the holes 114.
[0051] It will be appreciated that one or both of the end plates
210, 220 can include any suitable features to allow passage of the
tie rods 240 and to accommodate any features of the adjacent frames
110 or 130 in the stack 230. For instance, one or both of the end
plates 210, 230 can include recess 260 to accommodate the
protrusion 112 in a neighboring frame 110 or 130, as shown in FIG.
4. In addition, the end plate 210 can include an aperture 262 to
allow insertion of a tie rod. The tie rods are not shown in FIG. 4
in order to more clearly show the interlocking arrangement.
[0052] In another possible arrangement, a recess is provided in a
side of one of the frames with a protrusion on the opposite side of
the frame. For instance, FIG. 4 shows a recess 270 provided in the
lower side 124 of the first frame 110. The recess 270 can extend to
any suitable depth in the first frame 110. The recess 270 can be
sized and shaped to receive a protrusion 112. For instance, the
protrusion 112 on the upper side 122 of the first frame 110 can
have a height that is greater than the depth of a corresponding
through hole 116' of the second frame 130 into which the protrusion
112 is received. As a result, the protrusion 112 can extend beyond
the upper side 126 of the second frame 130 and into the recess 270
provided in the lower side 124 of the first frame 110 of an
adjacent one of the sub-assemblies. In this way, even greater
interconnection between the frames can be achieved and a greater
degree of isolation of the tie rod or other fastener can be
provided. While the embodiment in FIG. 4 shows the recess 270 as
being provided in the lower side 124 of the first frame 110, it
will be appreciated that the recess 270 can be provided in the
upper side 122 of the first frame 110, the lower side 124 of the
first frame 110 and/or the upper side 122 of the first frame 110.
Corresponding protrusions 112 can be provided as appropriate.
[0053] FIG. 5 is another partial sectional view of the battery cell
assembly 200, showing cell pockets 140, each formed between two
adjacent sub-assemblies 100. A battery cell 150 can be accommodated
in each cell pocket 140 and supported by the heat sink 120. The
battery cell 150 can have lateral portions 151, which can be the
battery contacts, that are sandwiched between the first and second
frames 110, 130. Embodiments of systems herein can be used in
connection with any type of battery cells, including lithium-ion
battery cells. Embodiments are particularly suitable for assembling
prismatic cells which are normally difficult to package into a
larger grouping of cells.
[0054] The interconnected arrangement described herein can provide
the battery cell assembly 200 with stability and rigidity because
the protrusions prevent the adjacent frames from moving laterally
relative to one another. The stability and rigidity can be further
improved by providing pairs of fasteners in each corner region. Due
to the improved stability and rigidity, the battery cell assembly
200 can include a greater number of cells, if desired, than was
available in previous cell assemblies. The nested arrangement of
the protrusions 112 and the holes 116 can also prevent the cells
150 from contacting the tie rods 240, thus preventing a short and
also improving safety of the battery. Further, the protrusions 112
and the holes 116 can also facilitate alignment of the frames
during assembly.
[0055] The foregoing description is provided in the context of one
possible application for a battery cell assembly. Thus, it will of
course be understood that embodiments are not limited to the
specific details described herein, which are given by way of
example only, and that various modifications and alterations are
possible within the scope of the following claims.
* * * * *