U.S. patent application number 14/501095 was filed with the patent office on 2016-03-31 for modular approach for advanced battery modules having different electrical characteristics.
The applicant listed for this patent is Johnson Controls Technology Company. Invention is credited to Stephen D. Cash, Richard M. DeKeuster, Robert J. Mack.
Application Number | 20160093848 14/501095 |
Document ID | / |
Family ID | 53546696 |
Filed Date | 2016-03-31 |
United States Patent
Application |
20160093848 |
Kind Code |
A1 |
DeKeuster; Richard M. ; et
al. |
March 31, 2016 |
MODULAR APPROACH FOR ADVANCED BATTERY MODULES HAVING DIFFERENT
ELECTRICAL CHARACTERISTICS
Abstract
Present embodiments include a series of lithium battery modules
having a plurality of electrochemical cells having different
electrical characteristics such as voltages and/or capacities. The
battery modules are each constructed using components,
architectures, production methods, among other things, in common
with each other. The lithium ion battery modules may include a
first battery module type having a first capacity and a first
voltage, a second battery module type having a second capacity and
a second voltage, and, in some embodiments, additional battery
module types (e.g., a third battery module type having a third
capacity and a third voltage) having different voltages and/or
capacities. The lithium ion battery modules may all have the same
footprint.
Inventors: |
DeKeuster; Richard M.;
(Racine, WI) ; Mack; Robert J.; (Milwaukee,
WI) ; Cash; Stephen D.; (Cary, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson Controls Technology Company |
Holland |
MI |
US |
|
|
Family ID: |
53546696 |
Appl. No.: |
14/501095 |
Filed: |
September 30, 2014 |
Current U.S.
Class: |
429/71 ; 29/825;
429/151 |
Current CPC
Class: |
H01M 10/425 20130101;
H01M 10/6563 20150401; H01M 4/525 20130101; H01M 10/0525 20130101;
H01M 4/485 20130101; H01M 10/613 20150401; Y02E 60/10 20130101;
H01M 2/1077 20130101; Y02P 70/50 20151101; Y02T 10/70 20130101;
H01M 4/505 20130101; H01M 10/625 20150401; H01M 2220/20
20130101 |
International
Class: |
H01M 2/10 20060101
H01M002/10; H01M 2/30 20060101 H01M002/30; H01M 4/525 20060101
H01M004/525; H01M 10/42 20060101 H01M010/42; H01M 4/505 20060101
H01M004/505; H01M 4/485 20060101 H01M004/485; H01M 10/0525 20060101
H01M010/0525; H01M 10/6563 20060101 H01M010/6563 |
Claims
1. A lithium ion battery module product portfolio, comprising: a
first lithium ion battery module product comprising a first housing
configured to receive a first set of prismatic electrochemical
cells, the housing including a base having a first footprint; a
second lithium ion battery module product comprising a second
housing configured to receive a second set of prismatic
electrochemical cells, the second housing including a base having a
second footprint that is substantially the same as the first
footprint, wherein a vertical profile opposing the base of the
first and second housings is different for each of the first and
second lithium ion battery module products; each prismatic
electrochemical cell of the first and second sets of prismatic
electrochemical cells conforming to the same manufacturing
specifications, wherein the first housing of the first lithium ion
battery module product is sized to fit a first number of the
prismatic electrochemical cells, the second housing of the second
lithium ion battery module product is sized to fit a second number
of the prismatic electrochemical cells, and the first and second
numbers of the prismatic lithium ion electrochemical cells are
different; and a component configured to interchangeably couple
with a first region of the first housing of the first lithium ion
battery module product and a second region of the second housing of
the second lithium ion battery module product, the first and second
regions having corresponding locations on the first and second
housings.
2. The lithium ion battery module product portfolio of claim 1,
wherein the first and second housings each comprise a pair of
terminal regions and a pair of terminals located in the pair of
terminal regions, the respective pairs of terminal regions of the
first lithium ion battery module product and the second lithium ion
battery module product have the same size and are located in
corresponding locations on the respective first and second
housings.
3. The lithium ion battery module product portfolio of claim 1,
wherein the component is a relay configured to interchangeably
couple with both of the first and second lithium ion battery module
products, wherein the first region comprises a first relay region
and the second region comprises a second relay region, and the
first and second relay regions each comprises a set of connectors
configured to mechanically couple to the relay.
4. The lithium ion battery module product portfolio of claim 1,
wherein the component is a control board having control circuitry
configured to control operational parameters of the first and
second lithium ion battery module products, wherein the first
region comprises a first control board region and the second region
comprises a second control board region, and the first and second
control board regions each comprises a set of connectors configured
to mechanically couple to the control board, and wherein the first
and second control board regions are positioned on corresponding
top portions of the first and second housings, the corresponding
top portions being located opposite the respective bases of the
first and second lithium ion battery module products.
5. The lithium ion battery module product portfolio of claim 1,
wherein the component is a barbed fitting configured to interface
with a vent hose of an xEV, wherein the first region comprises a
first vent region located on a side of the first housing of the
first lithium ion battery module product and the second region
comprises a second vent region located on a side of the housing of
the second lithium ion battery module product, the first and second
vent regions are configured to mechanically couple to the barbed
fitting, and are each positioned on a corresponding side portion of
the respective housing, the corresponding side portion being
located between the respective base and a respective top portion
opposite the respective base.
6. The lithium ion battery module product portfolio of claim 1,
wherein the component is a fan assembly having a fan, a fan cover,
a fan filter, and a fan filter cover, wherein the first and second
housings of the first and second lithium ion battery module
products each comprise a top portion configured to mechanically
couple to the fan assembly, and the fan cover is shaped to conform
around a section of the respective top portions.
7. The lithium ion battery module product portfolio of claim 1,
wherein the first and second housings comprise respective top
portions opposite the bases, the top portions having electrical
layouts comprising regions configured to mechanically couple with a
control board and a relay, and the component comprises a top cover
configured to interchangeably cover the top portion of the first
and second lithium ion battery module products.
8. The lithium ion battery module product portfolio of claim 1,
wherein the first housing and the second housing each have a layout
comprising a plurality of regions, each region of the plurality of
regions having a particular location on the respective housing and
being configured to mechanically couple to a particular component,
and the particular locations and particular components of the
plurality of regions of the first and second lithium ion battery
module products are matching.
9. The lithium ion battery module product portfolio of claim 8,
wherein the first and second lithium ion battery module products
each comprise a respective set of the particular components, the
particular components representing between 60% and 95% of a total
part count of the first and second lithium ion battery module
products.
10. The lithium ion battery module product portfolio of claim 9,
wherein the particular components of each of the first and second
lithium ion battery module products comprise a relay configured to
couple a voltage output of the respective number of prismatic
electrochemical cells with a terminal of the respective battery
module product, a top cover for a corresponding top portion of the
first and second housings positioned opposite their respective
bases, a control board comprising circuitry configured to control
operational parameters of the first and second lithium ion battery
module products, a low voltage connector configured to couple the
relay with an xEV, and terminals configured to provide a voltage
output of the first and second lithium ion battery module
products.
11. The lithium ion battery module product portfolio of claim 10,
wherein the first housing comprises a first cell receptacle region,
and wherein the second housing comprises a second cell receptacle
region that is larger than the first cell receptacle region, and
the first and second cell receptacle regions are configured to hold
the first and second numbers of prismatic electrochemical cells in
the first and second lithium ion battery module products,
respectively.
12. The lithium ion battery module product portfolio of claim 11,
wherein the first number of the prismatic electrochemical cells of
the first lithium ion battery module product are electrically
coupled as a group such that the first lithium ion battery module
product has a first voltage output and a first capacity, and
wherein the second number of the prismatic electrochemical cells of
the second lithium ion battery module product are electrically
coupled as a group such that the second lithium ion battery module
product has a second voltage output and a second capacity, wherein
the second voltage output is the same as the first voltage output,
and the second capacity is larger than the first capacity.
13. The lithium ion battery module product portfolio of claim 12,
wherein the first and second voltage outputs are 12 volts (V), the
first capacity is 10 amp-hours (Ah), and the second capacity is 20
Ah.
14. The lithium ion battery module product portfolio of claim 1,
comprising a third lithium ion battery module product comprising a
third housing configured to receive a third set of prismatic
electrochemical cells, the third housing having a respective base
with a third footprint as the first and second lithium ion battery
module products, and a respective vertical profile of the third
housing is different than the respective vertical profiles of the
first and second lithium ion battery module products; wherein the
third housing is sized to fit a third number of the prismatic
electrochemical cells, and the third number of the prismatic
electrochemical cells is greater than the first and second numbers;
and wherein the third housing comprises a third region, and the
component is configured to interchangeably couple with the first,
second, and third regions.
15. The lithium ion battery module product portfolio of claim 1,
wherein the prismatic electrochemical cells each have a cathode
including lithium nickel cobalt manganese oxide (NMC) (e.g.,
LiNi.sub.1/3Co.sub.1/3Mn.sub.1/3O.sub.2) as a cathode active
material, and an anode including LTO (Li.sub.4Ti.sub.5O.sub.12) as
an anode active material.
16. A method of manufacturing lithium ion battery modules,
comprising: producing a first lithium ion battery module by a first
process comprising: disposing a first number of prismatic
electrochemical cells having a set of standardized dimensions in a
first housing, the first housing having a first base with a length
and a width; and electrically connecting the first number of
prismatic electrochemical cells such that the first lithium ion
battery module has a first voltage and a first capacity; producing
a second battery module by a second process comprising: disposing a
second number of prismatic electrochemical cells having the set of
standardized dimensions in a second housing different from the
first housing, the second housing having a second base with the
length and the width; and electrically connecting the second number
of prismatic electrochemical cells such that the second lithium ion
battery module has a second voltage and a second capacity; wherein
the first process and the second process collectively comprise
using a type of component configured to interchangeably couple with
a first region of the first housing of the first lithium ion
battery module and a second region of the housing of the second
lithium ion battery module, the first and second regions having the
same location on their first and second housings, respectively.
17. The method of manufacturing lithium ion battery modules of
claim 16, wherein electrically connecting the first number of
prismatic electrochemical cells such that the first lithium ion
battery module has the first voltage and the first capacity
comprises connecting the first number of prismatic electrochemical
cells serially to provide a 12 volt (V) output, and a 10 amp-hour
(Ah) capacity, and wherein electrically connecting the second
number of prismatic electrochemical cells such that the second
lithium ion battery module has the second voltage and the second
capacity comprises connecting the second number of prismatic
electrochemical cells in a combination of serial and parallel
connections to provide a 12 V output, and a 20 Ah capacity.
18. The method of manufacturing lithium ion battery modules of
claim 16, comprising: producing a third lithium battery module by a
third process comprising: disposing a third number of prismatic
electrochemical cells having the standardized dimensions in a third
housing different from the first and second housings, the third
housing having a third base with the length and the width; and
electrically connecting the third number of prismatic
electrochemical cells such that the third lithium ion battery
module has a third voltage and a third capacity; and wherein the
first, second, and third number of prismatic electrochemical cells
are different, and the first base, the second base, and the third
base all have the same length and width.
19. The method of manufacturing lithium ion battery modules of
claim 18, comprising performing the first and second processes
using a plurality of components that are each configured to
interchangeably couple with the first and second lithium ion
battery modules and third lithium ion battery modules, but not the
third lithium ion battery module.
20. The method of manufacturing lithium ion battery modules of
claim 19, wherein the components comprise a relay configured to
couple a voltage output of the respective number of prismatic
electrochemical cells with a terminal of the respective battery
module, a top cover for a top portion of the respective housings
positioned opposite the respective bases, a control board
comprising circuitry configured to control operational parameters
of the first and second lithium ion battery modules, a low voltage
connector configured to couple the relay with an xEV, and terminals
configured to provide a voltage output of the first and second
lithium ion battery modules.
21. The method of manufacturing lithium ion battery modules of
claim 19, comprising performing the first, second, and third
processes using a plurality of components that are each configured
to interchangeably couple with the first, second, and third lithium
ion battery modules.
22. The method of manufacturing lithium ion battery modules of
claim 18, wherein the prismatic electrochemical cells each have a
cathode including lithium nickel cobalt manganese oxide (NMC)
(e.g., LiNi.sub.1/3Co.sub.1/3Mn.sub.1/3O.sub.2) as a cathode active
material, and an anode including LTO (Li.sub.4Ti.sub.5O.sub.12) as
an anode active material.
23. The method of manufacturing lithium ion battery modules of
claim 16, wherein the first and second processes collectively
comprise: conveying the first and second housings along a first
path and a second path, respectively, in a manufacturing system;
converging the first and second paths in a first module integration
region of the manufacturing system where a source of the component
configured to interchangeably couple with the first and second
lithium ion battery modules is located; integrating a first one of
the component with the first housing and a second one of the
component with the second housing; converging the first and second
paths in an additional module integration region of the
manufacturing system where a source of an additional component
configured to interchangeably couple with the first and second
lithium ion battery modules is located; and integrating a first one
of the additional component with the first housing and a second one
of the additional component with the second housing.
24. A lithium ion battery module product portfolio, comprising: a
first lithium ion battery module product having a first layout,
comprising: a first module housing configured to house a first set
of electrochemical cells, wherein the first module housing
comprises: a first top portion having terminals configured to
provide a voltage output of the first lithium ion battery module
product; a first base disposed opposite the top portion and having
a set of dimensions; and a first cell receptacle region disposed
between the first top portion and the first base, the first cell
receptacle region being configured to receive the first set of
electrochemical cells in an orientation; and a second lithium ion
battery module product having a second layout, comprising: a second
module housing configured to house a second set of electrochemical
cells, the second set of electrochemical cells having a greater
number of electrochemical cells compared to the first set of
electrochemical cells, wherein the second module housing comprises:
a second top portion having terminals configured to provide a
voltage output of the second lithium ion battery module product; a
second base disposed opposite the second top portion and having the
same set of dimensions as the first base; and a second cell
receptacle region disposed between the second top portion and the
second base, the second cell receptacle region being configured to
receive the second set of electrochemical cells in the orientation;
and a plurality of components configured to interchangeably couple
with a plurality of corresponding first regions of the first
battery module housing and a plurality of corresponding second
regions of the second module housing, and the first and second
layouts are such that the corresponding first and second regions
have the same location on their respective housings.
Description
BACKGROUND
[0001] The present disclosure relates generally to the field of
batteries and battery modules. More specifically, the present
disclosure relates to water management features for Lithium-ion
(Li-ion) battery modules.
[0002] This section is intended to introduce the reader to various
aspects of art that may be related to various aspects of the
present disclosure, which are described and/or claimed below. This
discussion is believed to be helpful in providing the reader with
background information to facilitate a better understanding of the
various aspects of the present disclosure. Accordingly, it should
be understood that these statements are to be read in this light,
and not as admissions of prior art.
[0003] A vehicle that uses one or more battery systems for
providing all or a portion of the motive power for the vehicle can
be referred to as an xEV, where the term "xEV" is defined herein to
include all of the following vehicles, or any variations or
combinations thereof, that use electric power for all or a portion
of their vehicular motive force. For example, xEVs include electric
vehicles (EVs) that utilize electric power for all motive force. As
will be appreciated by those skilled in the art, hybrid electric
vehicles (HEVs), also considered xEVs, combine an internal
combustion engine propulsion system and a battery-powered electric
propulsion system, such as 48 Volt (V) or 130V systems. The term
HEV may include any variation of a hybrid electric vehicle. For
example, full hybrid systems (FHEVs) may provide motive and other
electrical power to the vehicle using one or more electric motors,
using only an internal combustion engine, or using both. In
contrast, mild hybrid systems (MHEVs) disable the internal
combustion engine when the vehicle is idling and utilize a battery
system to continue powering the air conditioning unit, radio, or
other electronics, as well as to restart the engine when propulsion
is desired. The mild hybrid system may also apply some level of
power assist, during acceleration for example, to supplement the
internal combustion engine. Mild hybrids are typically 96V to 130V
and recover braking energy through a belt or crank integrated
starter generator. Further, a micro-hybrid electric vehicle (mHEV)
also uses a "Stop-Start" system similar to the mild hybrids, but
the micro-hybrid systems of a mHEV may or may not supply power
assist to the internal combustion engine and operates at a voltage
below 60V. For the purposes of the present discussion, it should be
noted that mHEVs typically do not technically use electric power
provided directly to the crankshaft or transmission for any portion
of the motive force of the vehicle, but an mHEV may still be
considered as an xEV since it does use electric power to supplement
a vehicle's power needs when the vehicle is idling with internal
combustion engine disabled and recovers braking energy through an
integrated starter generator. In addition, a plug-in electric
vehicle (PEV) is any vehicle that can be charged from an external
source of electricity, such as wall sockets, and the energy stored
in the rechargeable battery packs drives or contributes to drive
the wheels. PEVs are a subcategory of EVs that include all-electric
or battery electric vehicles (BEVs), plug-in hybrid electric
vehicles (PHEVs), and electric vehicle conversions of hybrid
electric vehicles and conventional internal combustion engine
vehicles.
[0004] xEVs as described above may provide a number of advantages
as compared to more traditional gas-powered vehicles using only
internal combustion engines and traditional electrical systems,
which are typically 12V systems powered by a lead acid battery. For
example, xEVs may produce fewer undesirable emission products and
may exhibit greater fuel efficiency as compared to traditional
internal combustion vehicles and, in some cases, such xEVs may
eliminate the use of gasoline entirely, as is the case of certain
types of EVs or PEVs.
[0005] As technology continues to evolve, there is a need to
provide improved power sources, particularly battery modules, for
such vehicles and other implementations. For example, traditional
battery modules may be constructed on an individually-designed
basis, meaning that each traditional battery module may be designed
for a specific implementation (e.g., voltage and capacity).
Accordingly, each type of traditional battery module may use
components specifically selected for that module. It is now
recognized that in traditional approaches, it may be difficult to
construct battery modules for different applications, but using a
shared approach and source of components for the modules. Indeed,
it is now recognized that it may be desirable to provide battery
modules that utilize a set of common (shared) components, and other
shared features.
SUMMARY
[0006] A summary of certain embodiments disclosed herein is set
forth below. It should be understood that these aspects are
presented merely to provide the reader with a brief summary of
these certain embodiments and that these aspects are not intended
to limit the scope of this disclosure. Indeed, this disclosure may
encompass a variety of aspects that may not be set forth below.
[0007] Present embodiments are directed toward a series of battery
modules having a plurality of electrochemical cells (which may also
be referred to as battery cells herein) having different voltages
and/or capacities, where the battery modules are each constructed
using components, architectures, production methods, among other
things, in common with each other. For example, in certain
implementations of the present approach, the battery modules may
include a first battery module type having a first capacity and a
first voltage, a second battery module type having a second
capacity and a second voltage, and, in some embodiments, additional
battery module types (e.g., a third battery module type having a
third capacity and a third voltage) having different voltages
and/or capacities.
[0008] For example, in one aspect, the present disclosure relates
to a lithium ion battery module product portfolio, including a
first lithium ion battery module product having a first housing
configured to receive a first set of prismatic electrochemical
cells, the housing including a base having a first footprint; a
second lithium ion battery module product having a second housing
configured to receive a second set of prismatic electrochemical
cells, the second housing including a base having a second
footprint that is substantially the same as the first footprint. A
vertical profile opposing the base of the first and second housings
is different for each of the first and second lithium ion battery
module products, and each prismatic electrochemical cell of the
first and second sets of prismatic electrochemical cells conforming
to the same manufacturing specifications. The first housing of the
first lithium ion battery module product is sized to fit a first
number of the prismatic electrochemical cells, the second housing
of the second lithium ion battery module product is sized to fit a
second number of the prismatic electrochemical cells, and the first
and second numbers of the prismatic lithium ion electrochemical
cells are different. The lithium ion battery module product
portfolio also includes a component configured to interchangeably
couple with a first region of the first housing of the first
lithium ion battery module product and a second region of the
second housing of the second lithium ion battery module product,
the first and second regions having corresponding locations on the
first and second housings.
[0009] In another aspect, the present disclosure also relates to a
method of manufacturing lithium ion battery modules. The method
includes producing a first lithium ion battery module by a first
process that includes disposing a first number of prismatic
electrochemical cells having a set of standardized dimensions in a
first housing, the first housing having a first base with a length
and a width, and electrically connecting the first number of
prismatic electrochemical cells such that the first lithium ion
battery module has a first voltage and a first capacity. The method
also includes producing a second battery module by a second
process, the second process including disposing a second number of
prismatic electrochemical cells having the set of standardized
dimensions in a second housing different from the first housing,
the second housing having a second base with the length and the
width, and electrically connecting the second number of prismatic
electrochemical cells such that the second lithium ion battery
module has a second voltage and a second capacity. The first
process and the second process collectively comprise using a type
of component configured to interchangeably couple with a first
region of the first housing of the first lithium ion battery module
and a second region of the housing of the second lithium ion
battery module, the first and second regions having the same
location on their first and second housings, respectively.
[0010] In yet another aspect, the present disclosure also relates
to a lithium ion battery module product portfolio, including a
first lithium ion battery module product having a first layout. The
first layout includes a first module housing configured to house a
first set of electrochemical cells. The first module housing
includes a first top portion having terminals configured to provide
a voltage output of the first lithium ion battery module product, a
first base disposed opposite the top portion and having a set of
dimensions; and a first cell receptacle region disposed between the
first top portion and the first base, the first cell receptacle
region being configured to receive the first set of electrochemical
cells in an orientation. The system also includes a second lithium
ion battery module product having a second layout, the layout
including a second module housing configured to house a second set
of electrochemical cells, the second set of electrochemical cells
having a greater number of electrochemical cells compared to the
first set of electrochemical cells. The second module housing
includes a second top portion having terminals configured to
provide a voltage output of the second lithium ion battery module,
a second base disposed opposite the second top portion and having
the same set of dimensions as the first base, and a second cell
receptacle region disposed between the second top portion and the
second base, the second cell receptacle region being configured to
receive the second set of electrochemical cells in the orientation.
The system further includes a plurality of components configured to
interchangeably couple with a plurality of corresponding first
regions of the first battery module housing and a plurality of
corresponding second regions of the second module housing, and the
first and second layouts are such that the corresponding first and
second regions have the same location on their respective
housings.
DRAWINGS
[0011] FIG. 1 is a perspective view of an xEV having a battery
system configured in accordance with present embodiments to provide
power for various components of the xEV, in accordance with an
aspect of the present disclosure;
[0012] FIG. 2 is a cutaway schematic view of an embodiment of the
xEV having a start-stop system that utilizes the battery system of
FIG. 1, the battery system having a lithium ion battery module, in
accordance with an aspect of the present disclosure;
[0013] FIG. 3 is a schematic representation of a layout of an
embodiment of the lithium ion battery module of FIG. 2, in
accordance with an aspect of the present disclosure;
[0014] FIG. 4 is a perspective view of an embodiment of the lithium
ion battery module of FIG. 2 having various components that may be
used in other versions of a lithium ion battery module, in
accordance with an aspect of the present disclosure;
[0015] FIG. 5 is a perspective view of an embodiment of the lithium
ion battery module of FIG. 2 having various components that may be
used in other versions of a lithium ion battery module, in
accordance with an aspect of the present disclosure;
[0016] FIG. 6 is a perspective view of an embodiment of the lithium
ion battery module of FIG. 2 having various components that may be
used in other versions of a lithium ion battery module, in
accordance with an aspect of the present disclosure;
[0017] FIG. 7 is a block diagram representing an embodiment of a
manufacturing system configured to produce a set of lithium ion
battery modules having a plurality of common components, in
accordance with an aspect of the present disclosure;
[0018] FIG. 8 is a block diagram representing an embodiment of a
region of the manufacturing system of FIG. 7 in which various
shared components may be incorporated into a variety of different
lithium ion battery modules, in accordance with an aspect of the
present disclosure;
[0019] FIG. 9 (FIGS. 9A and 9B) is a combined exploded perspective
view of the embodiments of the lithium ion battery modules of FIGS.
4 and 5 and highlighting various shared components between the
modules, in accordance with an aspect of the present
disclosure;
[0020] FIG. 10 (FIGS. 10A and 10B) is a combined exploded
perspective view of the embodiments of the lithium ion battery
modules of FIGS. 4 and 6 and highlighting various shared components
between the modules, in accordance with an aspect of the present
disclosure.
DETAILED DESCRIPTION
[0021] One or more specific embodiments will be described below. In
an effort to provide a concise description of these embodiments,
not all features of an actual implementation are described in the
specification. It should be appreciated that in the development of
any such actual implementation, as in any engineering or design
project, numerous implementation-specific decisions must be made to
achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which may vary
from one implementation to another. Moreover, it should be
appreciated that such a development effort might be complex and
time consuming, but would nevertheless be a routine undertaking of
design, fabrication, and manufacture for those of ordinary skill
having the benefit of this disclosure.
[0022] When introducing elements of various embodiments of the
present disclosure, the articles "a," "an," and "the" are intended
to mean that there are one or more of the elements. The terms
"comprising," "including," and "having" are intended to be
inclusive and mean that there may be additional elements other than
the listed elements. Additionally, it should be understood that
references to "one embodiment" or "an embodiment" of the present
disclosure are not intended to be interpreted as excluding the
existence of additional embodiments that also incorporate the
recited features.
[0023] The battery systems described herein may be used to provide
power to various types of electric vehicles (xEVs) and other high
voltage energy storage/expending applications (e.g., electrical
grid power storage systems). Such battery systems may include one
or more battery modules, each battery module having a housing and a
number of battery cells (e.g., Lithium-ion (Li-ion) electrochemical
cells) arranged within the housing to provide particular voltages
and/or currents useful to power, for example, one or more
components of an xEV. As another example, battery modules in
accordance with present embodiments may be incorporated with or
provide power to stationary power systems (e.g., non-automotive
systems).
[0024] Present embodiments are directed toward a lithium ion
battery module product portfolio including a series of battery
module products having a plurality of electrochemical cells (which
may also be referred to as battery cells) having different
electrical characteristics such as voltages and/or capacities,
where the battery module products are each constructed using
components, architectures, production methods, among other things,
in common with each other. For example, in certain implementations
of the present approach, the battery module products (also referred
to herein individually as a "battery module" and collectively as
"battery modules") may include a first battery module type (e.g., a
first battery module product) having a first capacity and a first
voltage, a second battery module type (e.g., a second battery
module product) having a second capacity and a second voltage, and,
in some embodiments, additional battery module types (e.g., a third
battery module type or product having a third capacity and a third
voltage) having different voltages and/or capacities.
[0025] Again, the battery module types (e.g., a battery module
products) may differ in voltage and/or capacity, but may have a
number of similar components that may be utilized in any of the
different designs in a modular fashion. For instance, these modular
components may include, but are not limited to, battery cells,
terminals, bus bar connections, shunt bridges, side plugs, fans,
low voltage connectors, relays, printed circuit boards (PCBs), and
fan filters.
[0026] Not only are the same types of components used across the
different battery module types or products, but the battery module
types also include housings that, while different in terms of the
number of battery cells they may hold, ultimately include features
that perform the same functions in substantially the same way. That
is, the different battery module types include similar design
concepts for their respective housings, including similar
receptacles for the similar components and, in some embodiments, a
similar layout.
[0027] Though there may be two, three, or more different battery
module types depending, for example, on the number of battery cells
utilized in the battery module and the manner in which they are
connected, the present embodiments are described in the context of
two or three battery modules (which are also battery module
products as described herein). For example, two battery modules may
have a similar voltage rating but different capacities, and a third
battery module may have a different voltage but the same capacity
as one of the other two battery modules. However, any combination
of overlapping voltages and/or capacities is encompassed by the
present disclosure.
[0028] As set forth above, in certain xEV contexts (among others,
such as non-automotive or stationary energy expending
applications), a 12 V output from a lithium ion battery module may
be desirable to power certain types of components (e.g., similar
types of components traditionally powered by a traditional lead
acid battery in traditional vehicles), while a 48 V output may be
more suitable to power other types of components that may require a
higher voltage, such as an air conditioning system. With this in
mind, it is now recognized that the present battery module
embodiments may be particularly applicable to such types of battery
modules.
[0029] By way of non-limiting example, the different battery
modules constructed in accordance with the modular approaches
described herein may include a first battery module type having a
voltage of 12V and a capacity of 10 Amp hours (Ah), a second
battery module type having a voltage of 12V and a capacity of 20
Ah, and a third battery module type having a voltage of 48V and a
capacity of 10 Ah.
[0030] To help illustrate, FIG. 1 is a perspective view of an
embodiment of a vehicle 10, which may utilize a regenerative
braking system. Although the following discussion is presented in
relation to vehicles with regenerative braking systems, the
techniques described herein are adaptable to other vehicles that
capture/store electrical energy with a battery, which may include
electric-powered and gas-powered vehicles.
[0031] It is now recognized that it is desirable for a
non-traditional battery system 12 (e.g., a lithium ion car battery)
to be largely compatible with traditional vehicle designs. In this
respect, present embodiments include various types of battery
modules for xEVs and systems that include xEVs. Accordingly, the
battery system 12 may be placed in a location in the vehicle 10
that would have housed a traditional battery system. For example,
as illustrated, the vehicle 10 may include the battery system 12
positioned similarly to a lead-acid battery of a typical
combustion-engine vehicle (e.g., under the hood of the vehicle 10).
Furthermore, as will be described in more detail below, the battery
system 12 may be positioned to facilitate managing temperature of
the battery system 12. For example, in some embodiments,
positioning a battery system 12 under the hood of the vehicle 10
may enable an air duct to channel airflow over the battery system
12 and cool the battery system 12.
[0032] A more detailed view of the battery system 12 is described
in FIG. 2. As depicted, the battery system 12 includes an energy
storage component 14 coupled to an ignition system 16, an
alternator 18, a vehicle console 20, and optionally to an electric
motor 22. Generally, the energy storage component 14 may
capture/store electrical energy generated in the vehicle 10 and
output electrical energy to power electrical devices in the vehicle
10.
[0033] In other words, the battery system 12 may supply power to
components of the vehicle's electrical system, which may include
radiator cooling fans, climate control systems, electric power
steering systems, active suspension systems, auto park systems,
electric oil pumps, electric super/turbochargers, electric water
pumps, heated windscreen/defrosters, window lift motors, vanity
lights, tire pressure monitoring systems, sunroof motor controls,
power seats, alarm systems, infotainment systems, navigation
features, lane departure warning systems, electric parking brakes,
external lights, or any combination thereof. Illustratively, in the
depicted embodiment, the energy storage component 14 supplies power
to the vehicle console 20 and the ignition system 16, which may be
used to start (e.g., crank) the internal combustion engine 24.
[0034] Additionally, the energy storage component 14 may capture
electrical energy generated by the alternator 18 and/or the
electric motor 22. In some embodiments, the alternator 18 may
generate electrical energy while the internal combustion engine 24
is running. More specifically, the alternator 18 may convert the
mechanical energy produced by the rotation of the internal
combustion engine 24 into electrical energy. Additionally or
alternatively, when the vehicle 10 includes an electric motor 22,
the electric motor 22 may generate electrical energy by converting
mechanical energy produced by the movement of the vehicle 10 (e.g.,
rotation of the wheels) into electrical energy. Thus, in some
embodiments, the energy storage component 14 may capture electrical
energy generated by the alternator 18 and/or the electric motor 22
during regenerative braking. As such, the alternator and/or the
electric motor 22 are generally referred to herein as a
regenerative braking system.
[0035] To facilitate capturing and supplying electric energy, the
energy storage component 14 may be electrically coupled to the
vehicle's electric system via a bus 26. For example, the bus 26 may
enable the energy storage component 14 to receive electrical energy
generated by the alternator 18 and/or the electric motor 22.
Additionally, the bus may enable the energy storage component 14 to
output electrical energy to the ignition system 16 and/or the
vehicle console 20. Accordingly, when a 12 volt battery system 12
is used, the bus 26 may carry electrical power typically between
8-18 volts.
[0036] Additionally, as depicted, the energy storage component 14
may include multiple battery modules. For example, in the depicted
embodiment, the energy storage component 14 includes a lithium ion
(e.g., a first) battery module 28 and a lead-acid (e.g., a second)
battery module 30, which each includes one or more battery cells.
In other embodiments, the energy storage component 14 may include
any number of battery modules. Additionally, although the lithium
ion battery module 28 and lead-acid battery module 30 are depicted
adjacent to one another, they may be positioned in different areas
around the vehicle. For example, the lead-acid battery module may
be positioned in or about the interior of the vehicle 10 while the
lithium ion battery module 28 may be positioned under the hood of
the vehicle 10.
[0037] In some embodiments, the energy storage component 14 may
include multiple battery modules to utilize multiple different
battery chemistries. For example, when the lithium ion battery
module 28 is used, performance of the battery system 12 may be
improved since the lithium ion battery chemistry generally has a
higher coulombic efficiency and/or a higher power charge acceptance
rate (e.g., higher maximum charge current or charge voltage) than
the lead-acid battery chemistry. As such, the capture, storage,
and/or distribution efficiency of the battery system 12 may be
improved.
[0038] To facilitate controlling the capturing and storing of
electrical energy, the battery system 12 may additionally include a
control module 32. More specifically, the control module 32 may
control operations of components in the battery system 12, such as
relays (e.g., switches) within energy storage component 14, the
alternator 18, and/or the electric motor 22. For example, the
control module 32 may regulate amount of electrical energy
captured/supplied by each battery module 28 or 30 (e.g., to de-rate
and re-rate the battery system 12), perform load balancing between
the battery modules 28 and 30, determine a state of charge of each
battery module 28 or 30, determine temperature of each battery
module 28 or 30, control voltage output by the alternator 18 and/or
the electric motor 22, and the like.
[0039] Accordingly, the control unit 32 may include one or
processor 34 and one or more memory 36. More specifically, the one
or more processor 34 may include one or more application specific
integrated circuits (ASICs), one or more field programmable gate
arrays (FPGAs), one or more general purpose processors, or any
combination thereof. Additionally, the one or more memory 36 may
include volatile memory, such as random access memory (RAM), and/or
non-volatile memory, such as read-only memory (ROM), optical
drives, hard disc drives, or solid-state drives. In some
embodiments, the control unit 32 may include portions of a vehicle
control unit (VCU) and/or a separate battery control module.
Furthermore, as depicted, the lithium ion battery module 28 and the
lead-acid battery module 30 are connected in parallel across their
terminals. In other words, the lithium ion battery module 28 and
the lead-acid module 30 may be coupled in parallel to the vehicle's
electrical system via the bus 26.
[0040] It should be noted that presently disclosed embodiments may
be applicable to any battery module having the same or different
configurations and/or orientations described above and in detail
below. One of ordinary skill in the art would recognize that the
components and examples used to describe battery modules in
accordance with the present disclosure should not be construed to
limit the present disclosure to those components and examples
alone. Rather, the disclosed examples are merely intended to serve
as non-limiting examples to facilitate discussion of the present
disclosure.
[0041] As set forth above, in accordance with the present
disclosure, different types of the lithium ion battery module 28
(e.g., a lithium ion battery module product portfolio including
different lithium ion battery module products) may utilize
components of the same type and may have similar geometrical
features (e.g., layout, overall architecture). An example
embodiment of the layout of the lithium ion battery module 28 is
illustrated in FIG. 3. Specifically, the illustrated embodiment of
the lithium ion battery module 28 includes a housing 40, which is
intended to represent a one-piece housing or a multi-piece housing
(e.g., two-piece, three-piece, or more). To facilitate discussion,
different sections of the housing 40 (which may or may not
correspond to sections of the overall lithium ion battery module
28) may be defined as follows: a base 42, which may also be
referred to as a bottom portion and generally defines the footprint
of the lithium ion battery module 28 when placed in operation
(e.g., in the xEV 10), sides including a left side 44 and a right
side 46, and a top region or top portion 48. The top portion 48 is
generally opposite the base 42, with the sides generally extending
between the two. The left side 44 and right side 46 are determined,
in the illustrated embodiment, with reference to a cell receptacle
region 50, which may be considered to correspond to a front end 52
of the lithium ion battery module 28. As described in further
detail below, the cell receptacle region 50 is configured to
receive a plurality of battery cells (e.g., prismatic
electrochemical cells) in a particular orientation. A back end 54
of the lithium ion battery module 28 may be considered to
correspond to an end opposite the cell receptacle region 50 (and,
accordingly, opposite the front end 52). In accordance with present
embodiments, these different sections of the lithium ion battery
module 28 may have substantially the same layout and/or
configuration across multiple versions, meaning that similar
components (e.g., components from the same source), referred to as
components of the same type, may be located in these regions. It
should be noted that the battery module 28 of FIG. 3 is intended to
represent multiple versions (e.g., individual products of a product
portfolio), also referred to as embodiments or types, of lithium
ion battery modules having the same regions located in the same
(e.g., corresponding from a location standpoint) portion of the
battery module relative to all other features of the battery
module. For example, a region of the lithium ion battery module 28
of FIG. 3 is intended to represent first, second, third, fourth,
and so on, regions of the housing 40 corresponding to first,
second, third, fourth, and so on, respective embodiments of the
battery module 28.
[0042] In accordance with the present disclosure, the phrase
"common component" or "shared component" is intended to denote a
component that can be interchangeably coupled for use in a set of
different types of the lithium ion battery module 28, where the
component is provided from a common source. For instance, a source
of a particular one component such as a particular relay, a
particular bus bar, a particular battery cell, and so forth, may be
interchangeably used in the different types of lithium ion battery
modules 28 set forth herein. That is, common or shared components
are interchangeable, and have dimensions to within manufacturing
tolerances of their common source.
[0043] In accordance with an aspect of the present disclosure, one
common layout for the different versions of the lithium ion battery
module 28 may include an electrical layout 56 of the top region 48.
For example, the electrical layout 56, as illustrated, may include
first and second terminal regions 58, 60, corresponding to
respective locations of a first terminal and second terminal (e.g.,
pairs of terminals, which are shown in FIG. 4) of the lithium ion
battery module 28, the terminals being configured to provide an
electrical output of the respective lithium ion battery modules 28.
The illustrated electrical layout 56 also includes a control board
region 62 corresponding to a location of a control board (where
examples of the control board are shown in FIGS. 9 and 10), and a
relay region 64 corresponding to a location of a relay. Examples of
the relay are shown in FIGS. 9 and 10. It should be noted that the
regions 58, 60, 62, 64 are not only locations corresponding to
these components, but also may include certain features (e.g.,
receptacle areas, connectors, pegs, electrical traces) that enable
that particular region to interface with these components, and, in
certain embodiments enable them to interface and house the
components in a particular way.
[0044] The sides of the lithium ion battery module 28 (e.g., the
housing 40) may also be configured in this manner. For example, the
left and/or right sides 44, 46 (located laterally with respect to
the cell receptacle region 50) may include a vent region 66,
corresponding to a location where gases may be vented out of the
module 14. The vent region 66 may include one or more features
configured to interface with, for example, vent plugs, vent
adapters for hose connections of a vehicle, and the like. It should
be noted that the disclosed embodiments are not limited to these
regions and the particular components set forth above. Rather,
there may be other features, including but not limited to those
described in further detail below. For example, the lithium ion
battery modules 28 configured in accordance with present
embodiments may also include regions specifically configured to
couple with other components, such as fans, fan filters, fan
covers, thermal management features, and the like.
[0045] As set forth above, the base 42 of the lithium ion battery
module 28 generally defines its footprint. With regard to vehicle
integration, this can be an important design concern in that
certain sizes for the base 42 may be desired for integration into a
particular vehicle due to, for example, spatial constraints.
Indeed, in embodiments where the xEV 10 of FIGS. 1 and 2 is a
micro-hybrid, it may be desirable for the base 42 to be a size that
enables the lithium ion battery module 28 to be located relatively
close to a lead acid battery, close to an alternator, etc. Thus,
the lithium ion battery module 28 may be a size that enables
vehicle integration, as an example, under a hood of the xEV 10, or
within a cage located toward a front of the xEV 10.
[0046] With this in mind, one aspect of the present disclosure
provides embodiments in which first, second, and third types of the
lithium ion battery module 28 may have substantially the same base
configuration (e.g., substantially the same footprint). This aspect
may be further appreciated with reference to FIGS. 4, 5, and 6,
which respectively depict a first embodiment of the lithium ion
battery module 28A, a second embodiment of the lithium ion battery
module 28B, and a third embodiment of the lithium ion battery
module 28C. Again, the base 42 may be represented by the dimensions
of the portion of the battery module housing 40 that is ultimately
mounted to or rests on a surface of the xEV 10 (e.g., closest to
the ground/floor). In accordance with an embodiment, the respective
housings 40 have bases 42 each having the same dimensions.
[0047] The base 42 may generally correspond to a length (L) and a
width (W) of the lithium ion battery module 28, and the length and
width of the respective bases of the first, second, and third
embodiments of the lithium ion battery modules 28 may be the same,
which is intended to account for manufacturing tolerances. Further,
although the lithium ion battery modules 28 are intended to
represent advanced battery modules having lithium ion
electrochemical cells, the base 42 may correspond to any one of the
many group representations (e.g., Battery Council International
(BCI) group numbers, Deutsche Industrie Normen (DIN codes),
European Norm (EN) codes) established for traditional lead acid
batteries (e.g., lead acid battery module 30). Each group (e.g.,
group number) from these established set of standards has a
standard length and width for the base of the particular battery
corresponding to the particular group designation. The secondary
lithium ion battery modules described herein may or may not have
dimensions that substantially match or comply with the standard
dimension requirements of at least a base of a known lead acid
battery standard (e.g., a BCI group, DIN code, or EN code).
[0048] As one example, the first, second, and third embodiments of
the lithium ion battery modules 28 of FIGS. 4-6 may be sized to
have an H5 (DIN code) base, which is 242 mm in length by 175 mm in
width. The H5 base is also commonly referred to as an LN2 base.
However, the base 42 of the lithium ion battery modules 28 may have
any length and width suitable to substantially match a particular
base of a lead acid battery. Although standardized for lead acid
batteries, it can be difficult to conform to such standards using
lithium ion electrochemical cell technologies, especially when
considering that lithium ion battery modules, such as those
described herein, may be associated with equipment not found in
traditional lead acid batteries such as intelligent control
features, thermal management features, advanced venting features,
and so forth. However, the present disclosure is not limited to the
bases 42 of the lithium ion battery modules 28 being the same size
as a lead acid standard. Rather, the lithium ion battery modules 28
may have any size for their respective bases 42, which in certain
embodiments may be the same for the different lithium ion battery
modules 28. As a non-limiting example, the length L may be a value
between 150 mm and 450 mm, and the width W may be a value between
100 mm and 200 mm, where the values match for all the modular
lithium ion battery modules 28.
[0049] While the lithium ion battery modules 28 of FIGS. 4-6 have
aspects or features with the same configuration or layout (e.g.,
substantially the same base 42 or the same lateral arrangement of
terminals), it should be noted that their respective heights (e.g.,
vertical profiles opposing respective bases of the housings) may
differ, depending, for example, on their power components. For
example, in FIG. 4, the lithium ion battery module 28 may have a
first output voltage (e.g., 12 V) and a first capacity (e.g., 10
amp hours (Ah)). In FIG. 5, the lithium ion battery module 28 may
have a second output voltage that is the same as the first output
voltage while having a second capacity greater than the first
capacity (e.g., 20 Ah). From a power component standpoint, the
lithium ion battery module 28 of FIG. 5 differs from the first
lithium ion battery module 28 of FIG. 4 by the number of total
electrochemical cells in their respective housings 40. In one
embodiment, the first embodiment of the lithium ion battery module
28A of FIG. 4 may include a first number (e.g., 6) of
electrochemical cells electrically coupled in a serial arrangement,
while the second embodiment of the lithium ion battery module 28B
of FIG. 5, which has a larger capacity (e.g., twice the capacity),
has a second number (e.g., 12) of the same type of electrochemical
cells coupled using a combination of serial and parallel electrical
connections. The arrangement of the electrochemical cells within
the housings 40, which is described in further detail below, is the
primary factor that causes a respective vertical profile, or height
H1 of the lithium ion battery module 28 of FIG. 4 and a vertical
profile, or respective height H2 of the lithium ion battery module
28 of FIG. 5 to differ. For the lithium ion battery module 28 in
FIG. 4, its cell receptacle region 50 and, therefore, its housing
40, is configured to (e.g., sized to) receive (e.g., fit) a first
number of prismatic electrochemical cells conforming to a set of
manufacturing specifications, while the lithium ion battery module
28 of FIG. 5 has an embodiment of the housing 40 configured to
(e.g., sized to) receive (e.g., fit) a second number of the
prismatic electrochemical cells, the second number being greater
than the first.
[0050] The third embodiment of the lithium ion battery module 28C
of FIG. 6 has a significantly larger vertical profile or height H3,
compared to the lithium ion battery modules 28 of FIGS. 4 and 5.
This is due, at least in part, to the additional number of
electrochemical cells required for the lithium ion battery module
28 to reach a higher voltage (e.g., 48 V using a third number, such
as 20, of the same type of electrochemical cells connected in
series). That is, the housing 40 of the third embodiment of the
lithium ion battery module 28C may be configured to (e.g., sized
to) receive (e.g., fit) the third number of prismatic
electrochemical cells). It should be noted that the different
lithium ion battery modules 28 of FIGS. 4-6 all utilize lithium ion
electrochemical cells having standardized dimensions, which are
dimensions that are intended to be produced for a particular
electrochemical cell type, and is intended to allow for
manufacturing tolerances. For instance, the electrochemical cells
in some embodiments may be prismatic electrochemical cells that
have standardized dimensions associated with a particular
tolerance.
[0051] As will be appreciated from the present disclosure, the
lithium ion battery modules 28 described herein may be modular not
only from the standpoint of their electrochemical cells and their
footprint (e.g., base 42), but also from the standpoint of their
architecture and common components. For instance, the base 42 of
each lithium ion battery module 28 is located at an end that is
substantially opposite a location of a set of terminals of the
lithium ion battery module 28, illustrated as a first terminal 70
(e.g., a positive terminal) and a second terminal 72 (e.g., a
negative terminal), which are positioned in the first and second
terminal regions 58, 60, respectively. The terminals 70, 72 may
include a single component or a set of components that are common
to (e.g., of the same type and configured to be interchangeably
coupled to) the different lithium ion battery modules 28. Further,
in accordance with certain embodiments, the first and second
terminal regions 58, 60 are specifically configured to position
terminal posts 74, 76 (e.g., an end of the terminal posts) of the
first and second terminals 70, 72 at substantially the same level
as a top cover 78 of the first lithium ion battery module 28 of
FIG. 4, a top cover 80 of the second embodiment of the lithium ion
battery module 28B of FIG. 5 (which may be the same as the top
cover 78), and a top cover 82 of the third embodiment of the
lithium ion battery module 28C of FIG. 6. In this regard, the
terminal posts 74, 76 may not protrude beyond an outer surface of
the lithium ion battery modules 28, which may reduce the likelihood
that the terminals 74, 76 will be subjected to tangential forces,
short circuits, and so forth, that could potentially damage the
lithium ion battery modules 28. The terminal regions 58, 60 may, in
some embodiments, be the same size for the different lithium ion
battery modules 28, in terms of volume or any one of a length,
width, height, or any combination thereof, to within manufacturing
tolerances. In certain embodiments, a top cover (e.g., top cover
78) may be configured to interchangeably cover the top portions of
the lithium ion battery modules 28A and 28B of FIGS. 4 and 5.
[0052] In the illustrated embodiments of FIGS. 4-6, immediately
adjacent to the first terminal region 58 is the venting region 66
including a vent plug 84, which is a common component for the
different lithium ion battery modules 28. The vent plug 84 may be
configured to open a vent of the lithium ion battery module 28
after an internal portion of the housing 40 reaches a pressure
threshold (e.g., as a result of a battery cell rupture).
[0053] The first and second embodiments of the lithium ion battery
modules 28 in FIGS. 4 and 5, respectively, may include additional
shared components. For example, the first and second embodiments of
the lithium ion battery modules 28 of FIGS. 4 and 5, respectively,
may include a common fan assembly 86, which may include a filter
portion 88 including a fan filter, and a fan portion 90 including a
fan. The common fan assembly 86 of the first and second embodiment
of the lithium ion battery modules 28 of FIGS. 4 and 5 may also
include a cover that is specifically configured (e.g., shaped and
sized and having specific connection features) to couple with the
respective top portions 48 of the first and second lithium ion
battery modules 28 of FIGS. 4 and 5.
[0054] It is now recognized that the ability to utilize
interchangeable and modular components across the different
embodiments (i.e., types, versions) of the lithium ion battery
modules 28 may result in the ability to manufacture the lithium ion
battery modules 28 according to more efficient processes, such as
performed by the embodiment of a manufacturing system 100 shown in
FIG. 7. Such a process may be more efficient than a traditional
manufacturing process in that different types of lithium ion
battery modules may be formed using shared assembly regions, shared
component sources, and so forth, which may reduce capital costs and
increase the speed of manufacturing. The shared assembly regions
and shared component sources may include common components of the
same type, size, and overall configuration, to within manufacturing
tolerances, that can be used in any one or a combination of
different types of the lithium ion battery modules (e.g., lithium
ion battery modules 28 having different output voltages, different
capacities, and so forth).
[0055] As depicted, the manufacturing system 100 may include the
use of an initial set of shared source components 102, which may
include, for example, components that can be integrated into the
respective housings 40 of the different lithium ion battery modules
28. For example, overmolded components such as terminals,
structural support components, and the like, shared by the
different lithium ion battery modules 28 may be incorporated into
this particular portion of the system 100.
[0056] The initial shared source components 102 may be distributed
among different areas of the manufacturing system 100 where the
housings 40 may be produced. For example, the initial shared source
components 102 (e.g., common heat sinks for in-molding with
housings) may be distributed to a first housing mold region 104
where the housing 40 of the first embodiment of the lithium ion
battery module 28A may be molded, to a second housing mold region
106 where the housing 40 of the second embodiment of the lithium
ion battery module 28B may be molded, and/or to a third housing
mold region 108 where the housing 40 of the third embodiment of the
lithium ion battery module 28C may be molded. From these regions,
the different module housings 40 may be provided to various module
component integration regions 110, where different portions of the
modules are provided to the housings 40 for module completion.
[0057] The module component integration regions 110 may include, as
shown, a battery cell (electrochemical cell) shared source 112,
which provides the same type of battery cell (e.g., prismatic
lithium ion electrochemical cells having the same manufacturing
specifications) to the different module housings 40 in their
respective cell receptacle regions 50. Other shared source
components 114 may be similarly provided, including fans, fan
covers, fan filters, printed control boards, bus bars, vent plugs,
and the like. Non-shared source components 116 provided at the
regions 114 may include size-specific components, such as
integrated bus bar and voltage sense carrier assemblies, certain
types of relays, front covers, thermal gap pads, and the like. As a
result of the integration of these various components into the
three different housings 40, the first, second, and third
embodiments of the lithium ion battery module 28, for example
corresponding to the modules 28A-28C, respectively, are
produced.
[0058] An example embodiment of the component integration region
110 is depicted in FIG. 8. As shown, the region 110 includes a
first path 124 that conveys intermediates for the first embodiment
of the battery module 28A, a second path 126 that conveys
intermediates for the second embodiment of the battery module 28B,
and a third path 128 that conveys intermediates for the third
embodiment of the battery module 28C, wherein the term
"intermediates" refers to incomplete versions of the battery
modules (e.g., the battery module housings 40 will some, but not
all, of their respective components). As an example, the paths 124,
126, 128 may correspond to one or more conveyance paths, such as
conveyor belts or the like, that traverse all or a portion of the
region 110.
[0059] The illustrated embodiment includes a first version of the
battery module housing 130 introduced along the first path 124, a
second version of the battery module housing 132 introduced along
the second path 126, and a third version of the battery module
housing 134 introduced along the third path 128. The first, second,
and third versions of the battery module housing 130, 132, 134 may
correspond, for example, to as-formed versions of the battery
module housing 40 shown in FIGS. 4, 5, and 6, respectively. The
as-formed versions may be provided, for example, after molding the
housings in the first, second, and third housing molding regions
104, 106, 108 of FIG. 7.
[0060] In the component integration region 110 of the system 100,
the paths 124, 126, 128 may converge in regions where a common
component is introduced to the different modules, while they
diverge in regions where size-specific or other non-shared
components are introduced to the modules 28. For example, as shown,
the paths 124, 126, 128 convey the housings 40 to a battery cell
positioning region 136 that uses the battery cell source 112. The
battery cell positioning region 136, in certain embodiments,
includes an automated system that positions battery cells in the
housings 130, 132, 134 in a particular manner, for example in a
specific orientation and in a specific number for the different
embodiments of the battery module 28.
[0061] The paths 124, 126, 128 may then diverge from one another to
separate respective sections of a first component integration
region, depicted as region 138A for path 124, region 138B for path
126, and region 138C for path 128. The regions 138A-138C utilize
different sources of a component not shared by the different
lithium ion battery modules 28, including a first version of a
first non-shared component 140A for region 138A, a second version
of the first non-shared component 140B for region 138B, and a third
version of the first non-shared component 140C. As an example, the
different versions of the first non-shared component may include
size-specific components, such as structural supports (carriers)
for integrated bus bar and voltage sense assemblies for each
lithium ion battery module 28, a front cover for each lithium ion
battery module 28, and the like. It should be noted that conveyance
of different partial battery module assemblies on an area for
shared components may be avoided in accordance with present
embodiments by distributing the shared components from a common
source (i.e., a source of a set of the same type of component
having the same dimensions and configuration, to within
manufacturing tolerances).
[0062] The illustrated component integration region 110 may also
include additional regions where common (i.e., interchangeably
couplable) components are provided to the different types of the
lithium ion battery module 28. Such embodiments are intended to be
represented by a second component integration region 146 that
utilizes a second shared component 148 (and/or source thereof),
where the different types of the lithium ion battery module 28 may
be fitted with common components, such as the same fan assemblies,
the same bus bars, the same electrical connectors, and so forth. It
should be noted that such modularity of the different versions of
the lithium ion battery module 28 may be a result of all the
lithium ion battery modules 28 having a corresponding region (e.g.,
a recess having a particular shape) for these different common
components, including connectors, receptacles, spaces, or the like,
that are specifically configured to receive the shared components.
Further, the component integration region 110 may include more
regions where additional components, from shared or non-shared
sources of these components, may be used to integrate the
components with the lithium ion battery modules 28.
[0063] The modular aspect of the lithium ion battery modules 28
described herein may be further appreciated with respect to FIGS. 9
and 10, which depict exploded perspective views of the first,
second, and third embodiments of the lithium ion battery module
28A, 28B, and 28C, respectively. Specifically, as shown in FIG. 9,
a comparison between the first and second lithium ion battery
modules 28A, 28B demonstrates that the two modules 28 have a
similar architecture, and have a number of shared components.
[0064] Starting from their respective housings 40A and 40B, it can
be seen that while the respective heights H1, H2 (FIGS. 4 and 5) of
the two are different, they actually have a very similar
configuration. For example, the housing 40A of the first embodiment
of the lithium ion battery module 28A and the housing 40B of the
second embodiment of the lithium ion battery module 28B each have a
layout including a plurality of regions (e.g., the terminal
regions, the relay regions, and so forth). Each region of the
plurality of regions has a particular location on the respective
housings 40A, 40B, and is configured to mechanically couple to a
particular component, such as control boards, relays, plugs, and so
on. The particular locations and particular components of the
plurality of regions of the first and second embodiments of the
lithium ion battery modules 28A, 28B match (e.g., have the same
corresponding location and the same type of component).
[0065] For instance, the illustrated lithium ion battery modules
28A, 28B include a common electrochemical cell 160, meaning that
the electrochemical cells 160 used in the different embodiments of
the lithium ion battery modules 28 have the same manufacturing
specifications, including the same chemistry (e.g., cathode and
anode electrode active materials, electrolyte, additives) and the
same size manufacturing specifications, to within a specified
tolerance. In accordance with an aspect of the present disclosure,
it is now recognized that certain types of electrochemical cells
may benefit such approaches more than others. For example, in one
embodiment, the electrochemical cells 160 may have a particular
combination of anode active materials (e.g., including
Li.sub.4Ti.sub.5O.sub.12, which is lithium titanate (LTO)) and
cathode active materials (e.g., including
LiNi.sub.1/3Co.sub.1/3Mn.sub.1/3O.sub.2, which is nickel cobalt
manganese oxide (NMC)) that prevent them from swelling beyond a
predetermined threshold. For example, in the illustrated
embodiments, the electrochemical cells 160 have a prismatic casing
162. The prismatic casings 162 are subject to, and may conform to,
a set of manufacturing specifications, including their size in all
dimensions.
[0066] The prismatic casings 162 include a top casing portion 164
where a set of cell terminals 166, 168 (e.g., positive and negative
cell terminals) are located. One or more cell vents 170 may also be
located on the top casing portion 164. The set of cell terminals
166, 168 for each of the electrochemical cells 160 enables the
cells to be electrically connected to various electrical
components, including each other, to the terminals 70, 72 of the
lithium ion battery module 28, and a load to which the lithium ion
battery module 28 may be coupled. The cell vents 170 are configured
to enable venting of gases under certain conditions.
[0067] The prismatic cell casings 162 also include a bottom casing
portion 172 positioned opposite the top casing portion 164, first
and second rounded sides 174, 176 that extend between the bottom
and top casing portions 172, 164 proximate the cell terminals 166,
168, and first and second faces 178, 180 that couple the first and
second rounded sides 174, 176 at opposing ends of each cell 160.
The presently disclosed configurations may be, in some embodiments,
facilitated by the presently illustrated orientation of the
electrochemical cells 160 within the housings 40. Specifically, the
electrochemical cells 160, which are prismatic in FIGS. 9 and 10,
are situated in the housings 40 with their respective sets of
terminals 166, 168 pointed outward from the cell receptacle regions
50. Further, the electrochemical cells 160 rest on one of their two
faces 178, 180 within the lithium ion battery modules 28, and the
electrochemical cells are in a stacked arrangement in which the
faces 178, 180 are oriented substantially parallel with respect to
one another in a particular column 182 having a plurality (i.e.,
more than one) electrochemical cells 160. In the embodiments
illustrated in FIGS. 9 and 10, the electrochemical cells 160 are
arranged in two such columns 182, with the number of rows depending
on the number of total electrochemical cells 160.
[0068] Such an arrangement may be desirable, for example, to
maintain standard dimensions for the base 42 across the different
embodiments of the lithium ion battery modules 28. Indeed, it is
now recognized that a combination of the cell chemistry (e.g.,
NMC/LTO electrochemical cells), cell shape (e.g., prismatic), and
cell size may provide advantages that have not traditionally been
used to achieve the technical effects set forth herein. For
example, it is now recognized that NMC/LTO electrochemical cells
may enable a total cell volume to be defined for the housing, and
the remaining layout of the battery modules 28 to be defined
relative to this volume.
[0069] As noted above, the terminals 70, 72 of the lithium ion
battery modules 28 are all the same across the different
embodiments described above with respect to FIGS. 4-6. In addition,
their illustrated vent configurations are also the same--where the
battery modules 28 may use the same type of closure, securement,
and venting features, such as a common set of threads and screws, a
common side plug 190, and a common vent opening 192 into which a
common barbed fitting 194 of a corresponding size may be used to
enable the vent opening 192 to be coupled to a vent hose of the xEV
10 (where the xEV is shown in FIG. 2). As an example, the first and
second embodiments of the lithium ion battery module 28A, 28B, may
each include a respective set of common components, and the common
components may represent between 60% and 95% of a total part count
of the first and second embodiments of the lithium ion battery
modules 28A, 28B. For example, the common components may represent
between 60% and 90% of the total part count, between 65% and 85% of
the total part count, or between 70% and 80% of the total part
count of the lithium ion battery modules 28A, 28B.
[0070] Further, it should be noted that the respective layouts of
the different lithium ion battery modules 28 described herein are
substantially the same. For example, the relative location of the
components of the different embodiments of the lithium ion battery
modules 28 is the same (i.e., matching) for each module 28. This
includes, for example, the regions described above with respect to
FIG. 3.
[0071] With respect to their electrical components, the first and
second embodiments of the lithium ion battery modules 28 include a
common relay 200 configured to electrically couple and de-couple
one of the terminals (e.g., the first terminal 70) to an electrical
load, and a common set of electronics 202. The electronics 202 may
include the same shape and size of circuit board, as well as the
same electrical architecture (e.g., components, location, and
connections) and layout. For instance, a single source of the
electronics 202 is intended to be appropriately used in either the
first embodiment or the second embodiment of the lithium ion
battery module 28. The electronics 202 may include a control board,
as shown, as well as various short circuit protection circuitry, a
battery control module including control circuitry configured to
control operational parameters of the battery modules 28, and so
forth.
[0072] The modularity of the present approaches is reflected in the
different regions of the housings 40, as well. For instance, the
top portions 48 of the housings 40 also include the control board
region 62 and the relay region 64, which are all the same layout
and configuration for the first and second embodiments of the
lithium ion battery module 28. That is, the control board region 62
for both the first and second embodiments of the lithium ion
battery module 28 includes the same arrangement of prongs,
connectors, and so forth, that enable the top portion 48 to
mechanically couple to and secure the set of electronics 202. In
addition, the relay region 64 for both the first and second
embodiments of the lithium ion battery module 28 includes the same
arrangement of prongs, connectors, and so forth, that enable the
top portion 48 to mechanically couple to and secure the relay 200
(i.e., the same type and configuration of relay). It should be
noted that such common configurations may enhance manufacturing
capability, even for different housing molds. For example, the top
portion 48 of the different lithium ion battery modules 28 may be
the same, meaning that if the housing 40, or the portion of the
housings illustrated, are formed from different pieces, the top
portion 48 may be produced at a common source. Further, in
embodiments where the housings 40 are one-piece molded units, then
the mold tools used to mold the housings 40 may utilize the same
types of equipment, for example the same portion of the mold tool
used to form the top portion 48.
[0073] Other illustrated and common electrical components include
shunt bridges 204 and relay bus bars 206. Indeed, various other
connectors and features may also be common to two or more of the
lithium ion battery modules 28. For example, the first and second
embodiments of the lithium ion battery modules 28 may include a
common low voltage connector 208 that may be used to electrically
couple the relay 200 to certain components, for example to couple
the lithium ion battery module 28 to the xEV 10, and/or to
electrically couple a common fan 210 to the lithium ion battery
module 28 to power the fan 210.
[0074] The top cover 78, over which the fan 210 is disposed, is
also common for the first and second embodiments of the lithium ion
battery modules 28. Further, as noted above, the fan assembly 86 is
also common between the two, including a fan filter 212. The manner
in which a back cover 214 of the fan assembly 86 interfaces with
the first and second embodiments of the lithium ion battery modules
28 may also be the same.
[0075] The third embodiment of the lithium ion battery module 28C,
as shown in FIG. 10, also includes common components as set forth
above. Indeed, in addition to having the same general layout as set
forth above for the first and second embodiments of the lithium ion
battery module 28A, 28B, the third embodiment of the lithium ion
battery module 28C also uses the same shunt bridge 204, relay bus
bar 206, terminals 70, 72, side plugs 190, and barbed fittings 194,
among others. As noted above, the modular aspect of the lithium ion
battery modules 28 also includes the use of the common
electrochemical cell 160.
[0076] Furthermore, while a respective relay 220 and a respective
set of electronics 222 may be different for the third embodiment of
the lithium ion battery module 28C compared to others, the relative
layout and placement of these features on its respective top
portion 48 of the housing 40 is substantially the same (i.e.,
matches the first and second embodiments of the lithium ion battery
modules 28A-28C). Furthermore, because these components are
different, the electronics region 62 and the relay region 64 of the
third embodiment of the lithium ion battery module 28C may be
different compared to the others illustrated. For example, its
layout of connectors, prongs, and so forth, may be different but
generally located in a matching position as set forth for modules
28A and 28B.
[0077] One or more of the disclosed embodiments, alone or on
combination, may provide one or more technical effects including
the use of a number of shared components across different battery
modules having different electrical characteristics. For example,
two or more battery modules, each having a different number of
electrochemical cells, may include a number of components that are
provided by a common source. The use of such common components
facilitates manufacturing and reduces associated costs by enabling
faster manufacture and greater compatibility between battery
modules. The technical effects and technical problems in the
specification are exemplary and are not limiting. It should be
noted that the embodiments described in the specification may have
other technical effects and can solve other technical problems.
[0078] While only certain features and embodiments have been
illustrated and described, many modifications and changes may occur
to those skilled in the art (e.g., variations in sizes, dimensions,
structures, shapes and proportions of the various elements, values
of parameters (e.g., temperatures, pressures, etc.), mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
disclosed subject matter. The order or sequence of any process or
method steps may be varied or re-sequenced according to alternative
embodiments. It is, therefore, to be understood that the appended
claims are intended to cover all such modifications and changes as
fall within the true spirit of the invention. Furthermore, in an
effort to provide a concise description of the exemplary
embodiments, all features of an actual implementation may not have
been described. It should be appreciated that in the development of
any such actual implementation, as in any engineering or design
project, numerous implementation specific decisions may be made.
Such a development effort might be complex and time consuming, but
would nevertheless be a routine undertaking of design, fabrication,
and manufacture for those of ordinary skill having the benefit of
this disclosure, without undue experimentation.
* * * * *