U.S. patent application number 17/478893 was filed with the patent office on 2022-06-09 for scalable battery module.
The applicant listed for this patent is EnerDel, Inc.. Invention is credited to Derrick Buck, Bruce Silk.
Application Number | 20220181746 17/478893 |
Document ID | / |
Family ID | 1000006168210 |
Filed Date | 2022-06-09 |
United States Patent
Application |
20220181746 |
Kind Code |
A1 |
Buck; Derrick ; et
al. |
June 9, 2022 |
SCALABLE BATTERY MODULE
Abstract
A scalable battery module (10, 210) includes a plurality of
similarly configured cell groupings (1251, 1851), a plurality of
framed heatsink assemblies (50, 250), and a plurality of jumper
tabs (32, 232). Each cell grouping (1251, 1751) includes a
plurality of cell packs (52, 1752) electrically coupled in parallel
including a negative terminal (70, 270) and a positive terminal
(64, 264). Each plurality of framed heatsink assemblies (50, 250)
is disposed between one cell pack (52, 1752) of the plurality of
cell packs of each cell groupings (1251, 1751) and an adjacent cell
pack (52, 1752) of the plurality of cell packs of each cell
grouping (1251, 1751) and includes a thermally conductive sheet
portion. Each of the plurality of jumper tabs (32, 232)
electrically couples a negative terminal (70, 270) of one of the
plurality of cell groupings (1251, 1851) to a positive terminal
(64, 264) of an adjacent cell grouping (1251, 1851).
Inventors: |
Buck; Derrick; (Pendleton,
IN) ; Silk; Bruce; (Boca Raton, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EnerDel, Inc. |
Indianapolis |
IN |
US |
|
|
Family ID: |
1000006168210 |
Appl. No.: |
17/478893 |
Filed: |
September 18, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13508770 |
May 9, 2012 |
11152669 |
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PCT/US2010/055985 |
Nov 9, 2010 |
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17478893 |
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61259412 |
Nov 9, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M 10/615 20150401;
H01M 50/209 20210101; H01M 10/0525 20130101; H01M 10/647 20150401;
H01M 10/613 20150401; H01M 50/258 20210101; H01M 50/502 20210101;
H01M 10/625 20150401; H01M 10/6555 20150401 |
International
Class: |
H01M 50/502 20060101
H01M050/502; H01M 10/647 20060101 H01M010/647; H01M 10/613 20060101
H01M010/613; H01M 10/615 20060101 H01M010/615; H01M 10/6555
20060101 H01M010/6555; H01M 10/625 20060101 H01M010/625; H01M
50/258 20060101 H01M050/258; H01M 50/209 20060101 H01M050/209 |
Claims
1. A scalable battery module, comprising: a plurality of similarly
configured cell groupings comprising a plurality of cell packs
electrically coupled in parallel, each cell grouping of the
plurality of cell groupings including a negative terminal and a
positive terminal; a plurality of framed heatsink assemblies each
having a thermally conductive sheet portion each of the plurality
of framed heat sink assemblies being disposed between one cell pack
of the plurality of cell packs of each cell groupings and an
adjacent cell pack of the plurality of cell packs of each cell
grouping; and a plurality of jumper tabs each of the plurality of
jumper tabs electrically coupling a negative terminal of one of the
plurality of cell groupings to a positive terminal of an adjacent
cell grouping.
2. The scalable battery module of claim 1 wherein each cell pack of
the plurality of cell packs in each cell grouping are prismatic
cell packs.
3. (canceled)
4. The scalable battery module of claim 1 wherein each cell pack of
the plurality of cell packs include oppositely facing large area
surfaces.
5. The scalable battery module of claim 4 wherein the negative and
positive terminals of each cell grouping of the plurality of cell
groupings each include a coupling surface of a corresponding
terminal of each cell pack of the plurality of cell packs forming
the cell grouping wherein the coupling surface extends laterally
with respect to the oppositely facing large area surfaces.
6. The scalable battery module of claim 5 wherein the positive
terminal of each cell pack positioned along a first edge of the
cell pack and the negative terminal of each cell pack is positioned
along a second edge opposite the first edge of the cell pack with
the oppositely facing large area surfaces disposed between the
positive terminal and negative terminal.
7. The scalable battery module of claim 6 wherein the coupling
surfaces of the positive and negative terminals of each cell pack
extend in the same direction laterally relative to the large area
surfaces.
8. The scalable battery module of claim 7 wherein each coupling
surface is formed to include openings along a distal edge.
9. (canceled)
10. The scalable battery module of claim 8 wherein the each
heatsink assembly of the plurality of heatsink assemblies is a
framed heatsink assembly including a heatsink portion and a frame
portion with the thermally conductive sheet portion being framed by
the frame portion.
11. The scalable battery module of claim 10 wherein the frame
portion of each heatsink assembly of the plurality of heatsink
assemblies is formed to include jumper tab capture features and
coupling surface capture features.
12. The scalable battery module of claim 11 wherein the jumper tab
capture features and coupling surface capture features comprise at
least one threaded stud.
13. The scalable battery module of claim 12 wherein the jumper tabs
include a plurality of stud-receiving holes for receiving the
threaded stud therein.
14. The scalable battery module of claim 13 wherein the orientation
of the cell groupings determines whether they are coupled in
parallel or in series to an adjacent cell pack.
15. (canceled)
16. The scalable battery module of claim 1 wherein each cell
grouping of the plurality of cell groupings has at least one large
area surface in thermal conduction communication with the sheet
portion of at least one heatsink assembly of the plurality of
heatsink assemblies.
17. The scalable battery module of claim 1 wherein the each
heatsink assembly of the plurality of heat sink assemblies includes
thermal edges extending beyond a frame member.
18. (canceled)
19. (canceled)
20. A scalable battery module, comprising; a plurality of similarly
configured cell groupings comprising a plurality of lithium ion
prismatic cell packs electrically coupled in parallel, each lithium
ion prismatic cell pack including oppositely facing large area
surfaces having oppositely facing first and second edges with a
positive terminal extending beyond the first edge of the oppositely
facing large area surfaces and a negative terminal extending beyond
the second edge of the oppositely facing large area surfaces
wherein the positive terminal includes a positive coupling surface
extending laterally from the oppositely facing large area surfaces
and having at least one opening formed in a distal edge of the
coupling surface and the negative terminal includes a negative
coupling surface extending laterally from the oppositely facing
large area surfaces and having at least one opening formed in a
distal edge of the coupling surface; a plurality of framed heatsink
assemblies each having a thermally conductive sheet portion framed
by a frame portion formed to include jumper tab capture features
and coupling surface capture features including at least one
threaded stud formed on opposite sides of the frame portion, each
of the plurality of framed heat sink assemblies being disposed
between one cell pack of the plurality of cell packs of each cell
groupings and an adjacent cell pack of the plurality of cell packs
of each cell grouping with the opening formed in the distal edge of
the negative coupling surface of the one cell pack and the opening
formed in the distal edge of the negative coupling surface of the
adjacent cell pack combining to surround portions of the at least
one threaded stud on one side of the frame portion and with the
opening formed in the distal edge of the positive coupling surface
of the one cell pack and the opening formed in the distal edge of
the positive coupling surface of the adjacent cell pack combining
to surround portions of the at least one threaded stud on the
opposite side of the frame portion; and a plurality of jumper tabs
each of the plurality of jumper tabs formed to include a plurality
of stud-receiving holes each receiving a threaded stud therein at
least one of the stud-receiving holes receiving a threaded stud
with portions surrounded by cooperating openings in the distal
edges of coupling surfaces and each of the plurality of jumper tabs
electrically coupling a negative terminal of one of the plurality
of cell groupings to a positive terminal of an adjacent cell
grouping.
21. The scalable battery module of claim 20 further comprising a
plurality of nuts each received on threaded stud to maintain the
jumper tab in engagement with a positive or negative terminal of a
cell grouping.
22. The scalable battery module of claim 21 wherein at least one of
the plurality of nuts is received on a threaded stud with portions
surrounded by cooperating openings in the distal edges of coupling
surfaces to maintain the jumper tab in engagement with the coupling
surfaces.
23. The scalable battery module of claim 20 wherein each of the
plurality of framed heatsink assemblies includes at least two pairs
of threaded studs, each pair of threaded studs being formed on
opposite sides of the frame portion and being spaced apart by a
displacement and each distal edge of each coupling surface being
formed to include a pair of openings spaced apart from each other
by a displacement substantially equal to the displacement of one of
the pairs of studs formed on each framed heatsink assembly.
24. The scalable battery module of claim 23 wherein each cell
grouping includes an odd number of cell packs electrically coupled
in parallel.
25. The scalable battery module of claim 24 wherein the pair of
threaded studs on one side of each framed heat sink assembly are
spaced apart by a first displacement and the pair of threaded studs
on the opposite side of each framed heat sink assembly are spaced
apart by a second displacement different from the first
displacement, the openings formed in the distal edge of each
negative coupling surface are spaced apart by a displacement
substantially equal to the first displacement and the openings
formed in the distal edge of each positive coupling surface are
spaced apart by a displacement substantially equal to the second
displacement and each of the plurality of jumper tabs is formed to
include at least a first pair of stud-receiving holes spaced apart
by a displacement substantially equal to the first displacement
each of the first pair of stud-receiving holes receiving a threaded
stud from one side of a first framed heatsink assembly therein and
at least a second pair of stud-receiving holes spaced apart by a
displacement substantially equal to the second displacement each of
the second pair of stud-receiving holes receiving a threaded stud
from the other side of a second framed heatsink assembly adjacent
to the first heat sink assembly therein.
26. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This International Application claims the benefit of and
incorporates by reference herein the disclosure of U.S. Provisional
Application Ser. No. 61/259,412, filed Nov. 9, 2009.
BACKGROUND AND SUMMARY
[0002] The subject invention relates to scalable battery modules
having cells and more particularly, to a battery module pack for
electric/hybrid vehicles having a cooling system or a heating
system for cooling the cells within the battery pack.
[0003] Motor vehicles, such as, for example, hybrid vehicles
("HEV") use multiple propulsion systems to provide motive power.
This most commonly refers to gasoline-electric hybrid vehicles,
which use gasoline (petrol) to power internal-combustion engines
(ICEs), and electric batteries to power electric motors. These
hybrid vehicles recharge their batteries by capturing kinetic
energy via regenerative braking. When cruising or idling, some of
the output of the combustion engine is fed to a generator (merely
the electric motor(s) running in generator mode), which produces
electricity to charge the batteries. This contrasts with
all-electric cars ("EV") which use batteries charged by an external
source such as the grid, or a range extending trailer. Nearly all
hybrid vehicles still require gasoline as their sole fuel source
though diesel and other fuels such as ethanol or plant based oils
have also seen occasional use.
[0004] Batteries and cells are important energy storage devices
well known in the art. The batteries and cells typically comprise
electrodes and an ion conducting electrolyte positioned
therebetween. For purposes of simplicity, the term "cells" is used
herein to mean unicells, bicells, or any other basic battery cell
construction. Battery packs that contain lithium ion batteries are
increasingly popular with automotive applications and various
commercial electronic devices because they are rechargeable and
have no memory effect. Storing and operating the lithium ion
battery at an optimal operating temperature is very important to
allow the battery to maintain a charge for an extended period of
time.
[0005] EV and HEV manufacturers have different requirements for the
battery packs that they utilize in their vehicles. Among the
requirements that may differ are the overall voltage produced by
the battery pack and the overall capacity of the battery pack.
Battery packs are formed from individual battery cells that utilize
different internal configurations but which include a first
electrode, a second electrode and an electrolyte disposed between
the first and second electrodes. Cells also typically include other
components such as separator layers and current collectors. Based
upon the size, configuration and chemical makeup of the first and
second electrodes and the chemical makeup of the electrolyte, cells
produce a specified voltage and exhibit a specified capacity.
Similarly configured cells exhibit similar voltages and similar
capacities.
[0006] Cells and batteries may be connected in series, in parallel,
or in combinations of both. Each specific battery or cell exhibits
a voltage and a capacity. Cells or batteries connected in series
have the positive terminal of one cell or battery connected to the
negative terminal of the other cell or battery. When cells or
batteries having like voltages and capacities are connected in
series, the overall voltage is increased (voltages of each cell or
battery are essentially added together to determine the overall
voltage when connected in series) but maintain the same overall
capacity. Batteries or cells connected in parallel have their like
terminals connected together (positive terminal is connected to
positive terminal and negative terminal is connected to negative
terminal). When cells or batteries having similar voltages and
capacities are connected in parallel, the overall voltage of the
combination remains the same while the overall capacity of the
combination is greater than the capacity of the individual
cells.
[0007] Cells or batteries may also be connected in series/parallel
combinations. Utilizing the series/parallel combination, a battery
pack may be developed having the desired overall voltage and
overall capacity desired for the application with which the battery
pack is to be utilized. There are an infinite number of ways to
combine batteries and cells in series/parallel combinations.
However, since it is typically preferred to combine only batteries
and cells having similar voltages and capacities, only two methods
of combining cells or batteries in a series/parallel combination
will be described. Cells or batteries may be combined in parallel
to form parallel subunits having the desired overall capacity and
then various parallel subunits may be combined in series to obtain
the desired overall voltage. Alternatively, cells or batteries may
be combined in series to form series subunits exhibiting the
desired overall voltage and then various series subunits may be
connected in parallel to obtain the desired overall capacity.
[0008] Most battery system vendors and manufacturers assembling
prismatic cells currently ultrasonically weld cell terminals of the
individual prismatic cells together to create the desired
electrical configuration of cells to generate a battery having the
desired requirements. The number of cells to be welded together in
parallel is limited by the length of the cell terminal. If the
number of cells to be ultrasonically welded together exceeds the
number of cells that can have their terminals ultrasonically welded
together, power buss jumpers are ultrasonically welded, fastened,
or wired together to series connect the paralleled cells into a
module or pack. Traditional joining methods such as welding or
soldering are avoided in these prior manufacturing and assembly
methods because those methods generate heat that is transferred
into the cell which could potentially damage the electrodes and
packaging seals of the prismatic cells. These methods of
manufacturing are time and labor intensive and are not
manufacturing friendly, Additionally, it is difficult to maintain
quality control utilizing these prior methods of manufacturing.
[0009] Since the performance of a battery or cell is adversely
affected by temperature differences, battery packs are often
manufactured with temperature regulating devices associated
therewith. For example, battery packs may include heatsinks
disposed between one or more of the cells or battery subunits of
the battery pack. Examples of battery packs constructed with
heatsinks disposed between various cells or battery subunits are
described in U.S. Pat. No. 7,531,270 and U.S. patent application
Ser. No. 12/103,830 and International Application Nos.
PCT/US2008/013451 and PCT/US2008/012545. U.S. Pat. No. 7,531,270
and U.S. patent application Ser. No. 12/103,830 and International
Application Nos, PCT/US2008/013451 and PCT/US2008/012545 are owned
by the assignee of the present application. The disclosures of U.S.
Pat. No. 7,531,270 and U.S. patent application Ser. No. 12/103,830
and International Application Nos, PCT/US2008/013451 and
PCT/US2008/012545 are incorporated herein.
[0010] Due to the characteristics of the lithium ion batteries, the
battery pack operates within an ambient temperature range of
-20.degree. C. to 60.degree. C. However, even when operating within
this temperature range, the battery pack may begin to lose its
capacity or ability to charge or discharge should the ambient
temperature fall below 0.degree. C. Depending on the ambient
temperature, the life cycle capacity or charge/discharge capability
of the battery may be greatly reduced as the temperature strays
from 0.degree. C. Nonetheless, it may be unavoidable that the
lithium ion battery be used where the ambient temperature falls
outside the temperature range.
[0011] Alluding to the above, significant temperature variances can
occur from one cell to the next, which is detrimental to
performance of the battery pack. To promote long life of the entire
battery pack, the cells must be below a desired threshold
temperature. To promote pack performance, the differential
temperature between the cells in the battery pack should be
minimized. However, depending on the thermal path to ambient,
different cells will reach different temperatures. Further, for the
same reasons, different cells reach different temperatures during
the charging process. Accordingly, if one cell is at an increased
temperature with respect to the other cells, its charge or
discharge efficiency will be different, and, therefore, it may
charge or discharge faster than the other cells. This will lead to
decline in the performance and life of the entire pack.
[0012] The art is replete with various designs of the battery packs
with cooling systems, including U.S. Pat. No. 5,071,652 to Jones et
al., U.S. Pat. No. 5,354,630 to Earl et al., U.S. Pat. No.
6,117,584 to Hoffman et al., U.S. Pat. No. 6,709,783 to Ogata et
al., U.S. Pat. No. 6,821,671 to Hinton et al., and Japanese
publication No. JP2001-229897.
[0013] Therefore, there remains an opportunity to improve upon the
packs of lithium batteries of the prior art to increase the ambient
temperature range at which the lithium battery operates and to
provide a new scalable battery pack with improved packaging
characteristics.
[0014] Also, there remains an opportunity to maintain the scalable
battery pack at the optimal operating temperature to ensure the
longest possible life cycle, rated capacity, and nominal charge and
discharge rates.
[0015] The disclosed scalable battery module is a battery cell
interconnect system to provide scalable electrical configurations
in the assembly of multiple electrochemical cells within a battery
module or battery pack. This electrical configurability allows a
plurality of battery cells to be assembled into an electrical
series string, or an electrical parallel string, or any multiples
there between. The disclosed battery module or pack is adaptable to
be utilized in various electrical configurations including and not
limited to the overlapping of positive terminals and negative
terminals of prismatic electrochemical battery cells. Electrical
conductive power bussing straps or jumper tabs are mechanically
assembled onto the overlapping cell terminals to create the
appropriate series/parallel configuration. The battery module has a
plurality of battery cells and heatsink assemblies with the cells
disposed therebetween. A plurality of rods extend through the
heatsink assemblies to secure the heatsink assemblies and the cells
together with one another to form the battery module or battery
pack.
[0016] According to one aspect of the disclosure, a scalable
battery module includes a plurality of similarly configured cell
groupings, a plurality of framed heatsink assemblies, and a
plurality of jumper tabs. Each cell grouping includes a plurality
of cell packs electrically coupled in parallel including a negative
terminal and a positive terminal. Each plurality of framed heatsink
assemblies is disposed between one cell pack of the plurality of
cell packs of each cell groupings and an adjacent cell pack of the
plurality of cell packs of each cell grouping and includes a
thermally conductive sheet portion. Each of the plurality of jumper
tabs electrically couples a negative terminal of one of the
plurality of cell groupings to a positive terminal of an adjacent
cell grouping.
[0017] According to another aspect of the disclosure, a scalable
battery module includes a plurality of similarly configured cell
groupings, a plurality of framed heatsink assemblies and a
plurality of jumper tabs. Each of the plurality of similarly
configured cell groupings includes a plurality of lithium ion
prismatic cell packs electrically coupled in parallel. Each lithium
ion prismatic cell pack includes oppositely facing large area
surfaces having oppositely facing first and second edges with a
positive terminal extending beyond the first edge of the oppositely
facing large area surfaces and a negative terminal extending beyond
the second edge of the oppositely facing large area surfaces. The
positive terminal includes a positive coupling surface extending
laterally from the oppositely facing large area surfaces and has at
least one opening formed in a distal edge of the coupling surface
and the negative terminal includes a negative coupling surface
extending laterally from the oppositely facing large area surfaces
and has at least one opening formed in a distal edge of the
coupling surface. The plurality of framed heatsink assemblies each
have a thermally conductive sheet portion framed by a frame portion
formed to include jumper tab capture features and coupling surface
capture features including at least one threaded stud formed on
opposite sides of the frame portion. Each of the plurality of
framed heat sink assemblies is disposed between one cell pack of
the plurality of cell packs of each cell groupings and an adjacent
cell pack of the plurality of cell packs of each cell grouping with
the opening formed in the distal edge of the negative coupling
surface of the one cell pack and the opening formed in the distal
edge of the negative coupling surface of the adjacent cell pack
combining to surround portions of the at least one threaded stud on
one side of the frame portion and with the opening formed in the
distal edge of the positive coupling surface of the one cell pack
and the opening formed in the distal edge of the positive coupling
surface of the adjacent cell pack combining to surround portions of
the at least one threaded stud on the opposite side of the frame
portion. Each of the plurality of jumper tabs is formed to include
a plurality of stud-receiving holes each receiving a threaded stud
therein with at least one of the stud-receiving holes receiving a
threaded stud with portions surrounded by cooperating openings in
the distal edges of coupling surfaces. Each of the plurality of
jumper tabs electrically couple a negative terminal of one of the
plurality of cell groupings to a positive terminal of an adjacent
cell grouping.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Other advantages of the present invention will be readily
appreciated as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0019] FIGS. 1 through 18 illustrate various embodiments of the
disclosed scalable battery module;
[0020] FIGS. 1 through 12 illustrate an even parallel (even P)
battery module configuration and FIGS. 13 through 18 an odd
parallel (odd P) battery module configuration;
[0021] FIG. 1 is a partially exploded perspective view of an even
parallel (even P) battery module configuration of a scalable
battery module showing side shields and an interim dual row clip
exploded away from a battery sub-assembly module, FIG. 1 may also
be viewed as illustrating steps in the method of forming a scalable
battery module;
[0022] FIG. 2 is a partially exploded perspective view from a
similar perspective to FIG. 1 of the battery-sub assembly module
showing washer nuts, positive cell tab compression bars, negative
cell tab compression bars, a non-terminal side assembly flex
circuit and jumper tabs exploded away from the non-terminal side of
the battery sub assembly module, FIG. 2 may also be viewed as
illustrating steps preceding the steps shown in FIG. 1 in the
method of forming a scalable battery module;
[0023] FIG. 3 is a partially exploded perspective view from an
opposite perspective to FIGS. 1 and 2 of the battery-sub assembly
module showing washer nuts, positive cell tab compression bars,
negative cell tab compression bars, a terminal side assembly flex
circuit and jumper tabs exploded away from the terminal side of a
battery sub assembly, FIG. 3 may also be viewed as illustrating
steps preceding the steps shown in FIG. 2 in the method of forming
a scalable battery module;
[0024] FIG. 4 is a partially exploded view of the battery sub
assembly of FIG. 3 showing a plurality of framed heatsink protected
parallel cells assemblies, a positive terminal endplate, a negative
terminal endplate, foam elements, tie rods and nuts, FIG. 4 may
also be viewed as illustrating steps preceding the steps shown in
FIG. 3 in the method of forming a scalable battery module;
[0025] FIG. 5 is a partially exploded view of one of the plurality
of framed heatsink protected parallel cells assemblies of FIG. 4
showing a framed heatsink assembly 50, two cell packs, a first cell
frame, and a second cell frame, FIG. 5 may also be viewed as
illustrating steps preceding the steps shown in FIG. 4 in the
method of forming a scalable battery module that are repeated as
many times as necessary to form the required number of framed
heatsink protected parallel cells assemblies to be utilized in the
scalable battery module;
[0026] FIG. 6 is a perspective view of the assembled framed
heatsink protected parallel cells assembly of FIG. 5;
[0027] FIG. 7 is a view of the portion of the assembled framed
heatsink protected parallel cells assembly shown in circle 7 of
FIG. 6;
[0028] FIG. 8 is a perspective view of a partially assembled even
parallel (even P) battery module configuration of a scalable
battery module showing tape holding jumper tabs received on the
positive and negative studs of the various framed heatsink
protected parallel cells assemblies securely in position on the
terminal side of the battery sub-assembly module, FIG. 8 may also
be viewed as illustrating interim steps performed in performing the
steps shown in FIG. 3;
[0029] FIG. 9 is a perspective view of a partially assembled even
parallel (even P) battery module configuration of a scalable
battery module following the performance of the steps illustrated
in FIGS. 3 and 8;
[0030] FIG. 10 is a perspective view of a partially assembled even
parallel (even P) battery module configuration of a scalable
battery module showing tape holding jumper tabs received on the
positive and negative studs of the various framed heatsink
protected parallel cells assemblies securely in position on the
non-terminal side of the battery sub-assembly module, FIG. 10 may
also be viewed as illustrating interim steps performed in
performing the steps shown in FIG. 2;
[0031] FIG. 11 is a perspective view of an assembled even parallel
(even P) battery module configuration of a scalable battery;
[0032] FIG. 12 is a diagrammatic view of the series/parallel
connection between framed heatsink protected parallel cells
assemblies of the even parallel (even P) battery module
configuration of a scalable battery module showing jumper tabs
coupling the positive and negative studs and terminals of the
various framed heatsink protected parallel cells assemblies on both
sides of the even parallel (even P) battery module
configuration;
[0033] FIG. 13 is a partially exploded view of an odd parallel (odd
P) battery module configuration of a scalable battery module
showing a side shield, a plurality of nuts, a plurality of
compression bars, a first side long flex circuit, first side short
flex circuit exploded away from a battery sub-assembly having a
plurality of jumper tabs attached thereto, FIG. 13 may also be
viewed as illustrating steps in the method of forming a scalable
battery module;
[0034] FIG. 14 is a partially exploded view of the opposite side of
the odd P battery module configuration of a scalable battery module
of FIG. 13 showing a side shield, a plurality of nuts, a plurality
of compression bars, a second side long flex circuit, a second side
short flex circuit exploded away from a battery sub-assembly having
a plurality of jumper tabs and two end jumper tabs attached
thereto, FIG. 14 may also be viewed as illustrating steps preceding
the steps shown in FIG. 13 in the method of forming a scalable
battery module;
[0035] FIG. 15 is a partially exploded view of an odd parallel (odd
P) battery module configuration of a scalable battery module
showing a side shield, a plurality of nuts, a plurality of
compression bars, a first side long flex circuit, first side short
flex circuit and jumper tabs exploded away from a battery
sub-assembly, FIG. 15 may also be viewed as illustrating steps in
the method of forming a scalable battery module including a step
not shown as being performed in FIG. 13;
[0036] FIG. 16 is a partially exploded view of the opposite side of
the odd P battery module configuration of a scalable battery module
of FIG. 14 showing a side shield, a plurality of nuts, a plurality
of compression bars, a second side long flex circuit, a second side
short flex circuit, a plurality of jumper tabs and two end module
jumper tabs exploded away from a battery sub-assembly, FIG. 16 may
also be viewed as illustrating steps in the method of forming a
scalable battery module including steps not shown as being
performed in FIG. 14;
[0037] FIG. 17 is a partially exploded view of the battery sub
assembly of FIGS. 13-16 showing a plurality of framed heatsink
assemblies, a plurality of cell packs, a positive endplate, a
negative endplate, foam elements, tie rods and nuts, FIG. 17 may
also be viewed as illustrating steps preceding the steps shown in
FIG. 16 in the method of forming a scalable battery module;
and,
[0038] FIG. 18 is a diagrammatic view of the series/parallel
connection between cell packs sandwiching framed heatsink
assemblies therebetween of the odd parallel (odd P) battery module
configuration of a scalable battery module showing jumper tabs
coupling the positive and negative terminals of the various cell
packs.
DETAILED DESCRIPTION
[0039] Referring to the Figures, wherein like numerals indicate
like or corresponding parts, a battery unit or pack of the present
invention is adaptable to be utilized in various configurations
including and not limited to a horizontally or vertically stacked
battery cell packaging configuration used in an automotive vehicle
applications.
[0040] Referring to FIGS. 1-12, an even P embodiment of a battery
module 10 of a battery pack is illustrated. Those of ordinary skill
in the art will recognize that a battery pack can be formed by
electrically coupling multiple battery modules 10 in series,
parallel or series/parallel combinations. The battery module 10
includes two side shields 12, tape filament 14, a battery
sub-assembly module 16 and an interim dual row 2.54 clip 18. As
shown, for example, in FIGS. 1-3, the battery sub-assembly module
16 includes battery sub-assembly 20, a plurality of washer nuts 22,
a plurality of positive stud cell tab compression bars 24, a
plurality of negative cell tab compression bars 26, a non-terminal
side assembly flex circuit 28, a terminal side assembly flex
circuit 30, and a plurality of jumper tabs 32.
[0041] The tape filament 14 is wrapped around the battery
sub-assembly module 16 with portions covering portions of the
plurality of positive stud cell tab compression bars 24, the
plurality of negative cell tab compression bars 26, the
non-terminal side assembly flex circuit 28, the terminal side
assembly flex circuit 30, and the plurality of jumper tabs 32 of
the battery sub-assembly module 16, as shown, for example, in FIG.
1. The two side shields 12 are positioned on opposite sides of the
battery sub-assembly module 16. The two side shields 12 are
received in the molded relief features 116 of the plurality of
framed heatsink protected parallel cells assemblies 34 to cover the
plurality of positive cell tab compression bars 24, the plurality
of negative cell tab compression bars 26, portions of the
non-terminal side flexible circuit 28, portions of the terminal
side flexible circuit 30, the plurality of jumper tabs 32 of the
battery sub-assembly module 16 and portions of the tape filament 14
is wrapped around the battery sub-assembly module 16, as shown, for
example, in FIG. 1.
[0042] As shown, for example, in FIGS. 1-3, the plurality of
positive cell tab compression bars 24 having a crowned or bowed
configuration are connected to the frames to apply uniform pressure
across the positive terminal coupling surfaces 68 of the parallel
coupled cell packs 52 interconnected with one another and to the
jumper tabs 32 and to secure the flexible circuits 28 and 30 which
are attached about both sides of the module 10. The plurality of
negative cell tab compression bars 26 having a crowned or bowed
configuration are connected to the frames to apply uniform pressure
across the negative terminal coupling surfaces 74 of parallel
coupled cell packs 52 interconnected with one another and to the
jumper tabs 32 and to secure the flexible circuits 28 and 30 which
are attached about both sides of the module 10. This attachment is
accomplished by screwing nuts 22 onto threaded studs 90 and 100 of
each framed heatsink protected parallel cells assembly 34,
described below.
[0043] As best illustrated in FIG. 4, battery sub-assembly 20
includes a plurality of framed heatsink protected parallel cells
assembly 34, a positive terminal endplate 36, a negative terminal
endplate 38, a plurality of foam elements 40, four tie rods 42 and
four nuts 44. In the illustrated embodiment, a foam element 40 is
sandwiched between each framed heatsink protected parallel cells
assembly 34 and between each end framed heatsink protected parallel
cells assembly 34 and the positive terminal endplate 36 and the
negative terminal endplate 38, respectively. The four tie rods 42
are each passed through tie rod-receiving holes 46 formed in each
of the plurality of frames 54, 58 and frame members 82, 84 of each
framed heatsink protected parallel cells assembly 34 and endplates
36, 38 and a nut 44 is placed on the threaded end of each of the
tie rods 42 to secure the components of the battery sub assembly
together, as shown, for example, in FIG. 4.
[0044] As shown, for example, in FIGS. 5-7, each framed heatsink
protected parallel cells assembly 34 includes a framed heatsink
assembly 50, first and second typical lithium battery cell packs
52, a first cell frame 54 and a second cell frame 58. Preferably,
each cell pack 52 is a prismatic lithium ion cell without limiting
the scope of the present invention. Those skilled in the battery
art will appreciate that other cells can be utilized with the
present invention. Each cell pack 52 includes a plurality of
battery components (not shown) co-acting between one another with
electrolyte therebetween as known to those skilled in the lithium
battery art. A first electrode is adjacent a first current
collector and a second electrode of charge opposite from the first
electrode is adjacent a second current collector. A separator layer
is positioned between the first and second electrodes with
electrolyte disposed between the first and second electrodes to
provide ion communication between the electrodes. A plurality of
first electrodes and second electrodes are stacked and packaged
into an electrical insulating envelope 56 to form a cell pack
52.
[0045] Referring to FIG. 5, two cell packs are shown each generally
designated 52. FIG. 5 shows that the lithium battery cell pack
includes an anode or negative terminal 70, a cathode or positive
terminal 64, a packaging envelope 56, side seal edges 60, 62, first
end seal edge 61, and second end seal edge 63. In the illustrated
embodiment, the packaging envelope is made from two or more
separate pieces of polymer coated aluminum foil and subsequently
sealed on all four edges 60, 61, 62, 63. In an alternative
embodiment, packaging envelope 56 is made from a single piece of
polymer coated aluminum foil and is folded around the lithium
battery cell at one edge 61, 63 the cell, and subsequently sealed
to itself on side seal edges 60, 62 and the other edge 63, 61.
[0046] Alluding to the above, the cell pack 52 presents side edges
60 and 62. A positive terminal 64 extends from inside to beyond the
side edge 60 of the envelope 56 of the cell pack 52. The positive
terminal 64 is formed to include a bend 66 so that a positive
terminal coupling surface 68 extends laterally to the plane of the
envelope 56 beyond the edge 60 of the cell pack 52. In one
embodiment, bend 66 defines an angle of approximately ninety
degrees between the coupling surface 68 and the plane of the
envelope 56 of the cell pack 52. A negative terminal 70 extends
from inside to beyond the side edge 62 of the envelope 56 of the
cell pack 52. The negative terminal 70 is formed to include a bend
72 so that a negative terminal coupling surface 74 extends
laterally to the plane of the envelope 56 beyond the edge 62. In
one embodiment, bend 72 defines an angle of approximately ninety
degrees between the coupling surface 74 and the plane of the
envelope 56 of the cell pack 52.
[0047] The distal edge of positive terminal coupling surface 68
presents a pair of semicircular openings 76 displaced on centers
from one another by a first displacement 78. The distal edge of
negative terminal coupling surface 74 presents a pair of
semicircular openings (not clearly illustrated) displaced on
centers from one another by a second displacement (not clearly
shown). Second displacement differs from first displacement 78 to
aid in proper assembly of the framed heatsink protected cells
assembly 34. In the illustrated embodiment, first displacement is
greater than second displacement, although those skilled in the art
will recognize that second displacement may be greater than first
displacement 78 within the scope of the disclosure. Alternatively,
coupling surface 68, 74 may present other openings (not shown).
[0048] As best shown in FIGS. 4 and 5, the openings in the coupling
surfaces 68, 74 of each of the positive and negative terminals 64,
70 are positioned symmetrically about the lateral centerline 80 of
the cell pack 52. This symmetrical positioning of the openings
allows the cell pack 52 to be rotated about the lateral centerline
80 to facilitate coupling the two cell pack 52 in a parallel
electrical configuration to the framed heatsink assembly 50, By way
of illustration, the upper and lower cell packs 52 shown in FIG. 5
are identically configured cell packs with the upper cell pack in a
first orientation and the lower cell pack in a second orientation
rotated 180 degrees about the lateral centerline 80 from the first
orientation.
[0049] The first and second cell frames 54, 58 clamp the packaging
envelopes 56 of the cell packs 52 around the perimeter to opposing
sides of the framed heatsink assembly 50 to form the framed
heatsink protected parallel cells assembly 34. If the packaging
envelope 56 is of the folded type, the frames 54, 58 can clamp on
the three seal edges of the packaging envelopes 56 and provide a
concave feature on the fourth or bottom edge to cradle and protect
the packaging envelope bottom edge. If the packaging envelope 56 is
manufactured from two separate pieces and therefore sealed on all
four edges 60, 61, 62, 63, the cell frames 54, 58 may be designed
to clamp on all four seal edges 60, 16, 62, 63.
[0050] Each of the frame members 82, 84 has a positive side rail 88
formed to include a threaded stud 90 extending laterally therefrom.
When frame members 82, 84 are joined together with heatsink 86
sandwiched therebetween, studs 90 are displaced on center from each
other by a third displacement 92. Third displacement 92 is
approximately equal to first displacement 78 so that studs 90 can
act as a jumper tab/terminal coupling surfaces capture feature.
When the top and bottom cell packs 52 are coupled to framed
heatsink assembly 50, the studs 90 are received in the openings 76
of the positive terminal coupling surfaces 68 of the top and bottom
cell packs 52 with the two positive terminal coupling surfaces
overlapping so that the openings 76 formed in the distal edge of
the positive terminal coupling surfaces of the top and bottom cell
packs cooperating to surround a portion of the studs 90. Studs 90
are also received in positive stud receiving holes 94 of the jumper
tabs 32. Stud receiving holes 94 are displaced from each other by a
fifth displacement 96 (see FIG. 2) approximately equal to first
displacement 78 and third displacement 92. Studs 90 hold a jumper
tab 32 securely in place to facilitate mechanically and
electrically connecting all of the terminals of two adjacent framed
heatsink protected parallel cells assemblies 34 in series, in a
configuration shown in more detail in FIG. 12. Each of the heat
sink protected parallel cell assemblies 34 include a cell grouping
1251 (shown individually as 1251 a-l) and a framed heat sink
assembly 50.
[0051] Each of the frame members 82, 84 has a negative side rail 98
formed to include a threaded stud 100 extending laterally
therefrom. When frame members 82, 84 are joined together with
heatsink 86 sandwiched therebetween, studs 100 are displaced on
center from each other by a fourth displacement 102 (see FIG. 3).
Fourth displacement 102 is approximately equal to second
displacement so that studs 100 can act as a jumper tab/terminal
coupling surfaces capture feature. When the top and bottom cell
packs 52 are coupled to framed heatsink assembly 50, the studs 100
are received in the openings of the negative terminal coupling
surfaces 74 of the top and bottom cell packs 52 with the two
negative terminal coupling surfaces overlapping so that the
openings formed in the distal edge of the negative terminal
coupling surfaces of the top and bottom cell packs cooperating to
surround a portion of the studs 100. Studs 100 are also received in
negative stud-receiving holes 104 of the jumper tabs 32.
Stud-receiving holes 104 are displaced from each other by a sixth
displacement 106 approximately equal to second displacement and
fourth displacement 102. Studs 100 hold a jumper tab 32 securely in
place to facilitate mechanically and electrically connecting all of
the terminals of two adjacent framed heatsink protected parallel
cells assemblies 34 in series.
[0052] The studs 90, 100 molded into and extending from the frame
members 82, 84 on a positive and a negative side of the framed
heatsink assembly 50, respectively, act as terminal/jumper tab bar
capture devices. Each side of the frame 82, 84 also has a molded
relief feature 116 to provide positioning for a thermal sensor
which may be included in the flexible circuits 28, 30.
[0053] The heatsink 86 includes top thermal transfer edge 108 and
bottom thermal transfer edge 110. The top and bottom thermal
transfer edges 108, 110 may include a plurality of fins integral
with and extending from the heatsink 86. The fins may be cold
formed and are designed to transfer heat either to or from the
cells depending on application. The frame members 82, 84 are
mechanically attached on each side of the heatsink 86.
[0054] The positive terminals 64 of both cell packs 52 are folded
over so that the openings 76 of the overlapping positive terminal
coupling surfaces 68 cooperate to surround the positive studs 90
formed in the positive side rail 88 of the framed heatsink 50 (as
shown, for example, in FIG. 7) and the negative terminals 70 of
both cell packs 52 are folded over so that the openings of the
overlapping negative terminal coupling surfaces 74 cooperate to
surround the negative studs 100 formed in the negative side rail 98
of the framed heatsink 50 so that the two cell packs in each framed
heatsink protected parallel cells assembly 34 are coupled in an
electrical parallel configuration, During assembly jumper tabs 32
are positioned and secured onto the studs 90, 100 of two adjacent
framed heatsink protected parallel cells assemblies 34 with stud 90
being received in positive stud-receiving holes 94 and negative
studs 100 being received in negative stud-receiving holes 104 to
couple the parallel coupled cell packs 52 of the adjacent framed
heatsink protected parallel cells assemblies 34 in series. As
shown, for example, in FIGS. 2, 3, 8 and 10, the centerlines
between positive stud-receiving holes 94 and negative
stud-receiving holes 104 is approximately equal to the thickness of
each framed heatsink protected parallel cells assemblies 34 so that
the holes 94, 104 are appropriately positioned to receive
appropriate studs 90, 100. The overall length of jumper tab 32 is
greater than the displacement 92 between positive studs, but less
than the width of the molded relief features 116 of the frame
member 82, 84 of the framed heatsink protected parallel cells
assemblies 34, The overall width of each jumper tab, in the
illustrated embodiment, is less than twice the thickness of a
heatsink protected parallel cells assembly 34. Jumper tabs are
formed of appropriate conductive material to form an electrical
connection between the various terminals of the cell packs 52 of
the framed heatsink protected parallel cells assemblies 34 to which
they are attached. In one embodiment of the disclosed scalable
battery module and method of assembling the same, the positive and
negative terminals of each cell pack assembly and the jumper tabs
are plated in a common plating process to reduce the potential seen
in different metals to decrease impedance due to galvanic corrosion
over long periods of time.
[0055] As shown in FIGS. 1-4 and 8-12, the process of positioning
and securing jumper tabs 32 onto the studs 90, 100 of two adjacent
framed heatsink protected parallel cells assemblies 34 to couple
the parallel coupled cell packs 52 of the adjacent framed heatsink
protected parallel cells assemblies 34 in series is continued until
a battery sub-assembly module 16 having the desired overall voltage
and capacity is formed. As shown, for example, in FIGS. 8 and 10,
tape 118 may be utilized to hold the jumper tabs 32 on the battery
sub-assembly 20 until other components and nuts 22 are attached to
the studs 90, 100.
[0056] Frames 54, 58 and frame members 82, 84 are preferably
plastic frames, such as from readily moldable plastics. An
exemplary readily moldable plastic that is relatively inexpensive
and structurally sufficient is valox but not limited to elyte
resistant. If there is a requirement for a fire resistant plastic,
a plastic having intumescent properties is preferably used, such as
the elastomeric intumescent material disclosed in U.S. Pat. No.
6,809,129 to Abu-Isa. In another aspect of the present invention,
the two frame members 82, 84 may be identical, thereby being
manufacturable from a single mold cavity. In another aspect of the
present invention, the two frames 54, 58 may be identical, thereby
being manufacturable from a single mold cavity.
[0057] As shown for example, in FIGS. 5-7, in the one embodiment of
the disclosed scalable battery module, the cell frames 54, 58 have
a pin and socket configuration on the side facing away from the
clamping surfaces in order to mate and align with one or more
framed heatsink protected parallel cells assemblies 34.
[0058] FIGS. 5-7 provide a detailed explanation of the mechanical
connection defined between the framed heatsink assembly 50, the
first cell frame 54 and the second cell frame 58 for securing the
cell packs 52 sandwiching framed heatsink assembly 50 therebetween
and between the first and second frame members 82, 84 sandwiching
the heatsink 86 therebetween. The frames 54, 58 and frame members
82, 84 present a mechanical connection therebetween presented in
the shape of snap towers, hooks and other mechanical devices
without limiting the scope of the present invention. Mechanical
connection between the cell packs 52 and the framed heatsink
assembly 50 is generally shown in FIGS. 5 and 7. Additional
descriptions of mechanisms and structures formed on cell frames and
framed heatsink assembly frame members are described in co-owned
International Application Nos. PCT/US2008/013451 and
PCT/US2008/012545 the disclosures of which are incorporated herein
by this reference.
[0059] As the illustrated even P battery module 10 is being
assembled, the framed heatsink protected parallel cells assemblies
34 are oriented in such a fashion wherein the adjacent framed
heatsink protected parallel cells assemblies 34 are oriented in
alternating fashion, as shown for example, particularly in FIGS. 4
and 12 and generally in FIGS. 1-3 and 8-11. In one embodiment, the
orientation achieved in FIGS. 1-12 is accomplished by providing a
plurality of identically configured framed heatsink protected
parallel cells assemblies 34 and rotating every other framed
heatsink protected parallel cells assembly 34 180 degrees about its
longitudinal access so that adjacent framed heatsink protected
parallel cells assemblies 34 have oppositely charged terminals on
the same side of the battery module 10.
[0060] The disclosed Even P battery module 10 is adaptable to
provide scalable electrical configurations, battery module 10 is
configured to permit multiple even P battery modules to be coupled
together to form a battery pack including one or more battery
modules each presenting a multitude of prismatic cell packs each
having at least one large area surface in contact with a heatsink
formed from thermally conductive materials such as, for example,
flat stock aluminum alloy foils and the like, without limiting the
scope of the present invention. This facilitates regulating the
temperature of each cell pack fairly evenly across the entire
battery module.
[0061] As best shown in FIGS. 1 and 5, the disclosed even P battery
module 10 includes a plurality of heatsinks, generally shown at 86
in FIG. 5. Each heatsink 86 is formed from a thermally conductive
material such as aluminum, copper, and the like, without limiting
the scope of the present invention. Each heatsink 86 terminates to
opposite fin portions or thermal edges, generally indicated at 108,
110 in FIG. 5. The fin portion 108,110 may include a gate shape,
may be pleated, planar, may present a plurality of slots or holes,
may be formed as a bend to provide a thermal interface plane for an
external heating or cooling device including but not limited to
heater blankets and/or cooling jackets.
[0062] Those skilled in the art will appreciate that numerous other
shapes of the fin portions 108, 110 can be utilized to provide
better surface area for cooling or heating media, such as liquids,
solids, or gasses, and the like, are introduced to the fin portions
108, 110 of each thermally conductive plate, sheet, or foil to
either cool or to heat the cell packs 52.
[0063] Positive terminal endplate 36 and negative terminal endplate
38 act as a pair of compression plates sandwiching the framed
heatsink protected parallel cells assemblies 34 and foam elements
40 therebetween. The positive terminal endplate 36 is formed to
include a top positive terminal 120 electrically coupled to a
positive jumper 122 having a flange 124 extending perpendicular to
the plane of the endplate 36 having semicircular openings 126
present in the distal end for partially encompassing the positive
studs 90 of the framed heatsink protected parallel cells assembly
34 that is adjacent to the positive terminal endplate 36. The
semicircular openings 126 in the flange 124 are displaced on center
from each other by a seventh displacement 128 approximately equal
to the third displacement 92 to facilitate capturing studs 90
within the openings 126. The negative terminal endplate 38 is
formed to include a top negative terminal 130 electrically coupled
to a negative jumper 132 having a flange 134 extending
perpendicular to the plane of the endplate having semicircular
openings 136 present in the distal end for partially encompassing
the negative studs 100 of the framed heatsink protected parallel
cells assembly 34 that is adjacent to the negative terminal
endplate 38. The semicircular openings 136 in the flange 134 are
displaced on center from each other by an eighth displacement 138
approximately equal to the fourth displacement 102 to facilitate
capturing studs 100 within the openings 136. Cables may be coupled
to the top positive terminals 120 and top negative terminals 130 of
multiple scalable battery modules 10 in series, parallel or series
parallel electrical configurations to create a battery pack.
[0064] The positive terminal endplate 36 and negative terminal
endplate 38 are fastened together to provide additional compressive
force to the framed heatsink protected parallel cells assemblies
34. In one embodiment, the tape filament acts as a compression
strap. The compression strap wraps around the framed heatsink
protected parallel cells assemblies 34 to apply compressive
stress.
[0065] While only an even P battery module 10 having adjacent
framed heatsink protected parallel cells assemblies 34 coupled in
series by a jumper tab 32 having two positive stud-receiving holes
94 and two negative stud-receiving holes 104 is illustrated, it is
within the contemplated scope of the disclosure for cell packs of
two or more adjacent heatsink protected parallel cells assemblies
34 to be coupled in parallel to each other and in series to two or
more heatsink protected parallel cells assemblies 34 utilizing an
appropriately configured jumper tab and proper orientation of
heatsink protected parallel cells assemblies 34 to form other
configurations of even P battery modules 10.
[0066] Referring to FIGS. 13-18, an odd parallel (odd P) embodiment
of a battery module 210 of a battery pack is illustrated. Those of
ordinary skill in the art will recognize that a battery pack can be
formed by electrically coupling multiple battery modules 210 in
series, parallel or series/parallel combinations. The battery
module 210 utilizes many components so similar to those used in the
even P battery module 10 that some identical reference numerals
will be utilized for slightly differing components with the
differences being pointed out but with the remainder of the
description not being repeated. Similar, but differing, components
will be identified with reference numerals exactly 200 higher than
those utilized in describing the even P embodiment.
[0067] Referring to FIGS. 13-16, the battery module 210 includes
two side shields 212, a battery sub-assembly 220, a plurality of
washer nuts 22, a plurality compression bars 224, a first side long
flex circuit 228, a first side short flex circuit 229, a second
side long flex circuit 230, a second side short flex circuit 231, a
plurality of jumper tabs 232 and a pair of end module jumper tabs
233.
[0068] The two side shields 212 are positioned on opposite sides of
the battery module 220. The two side shields 212 are received in
the recess features 316 of the plurality of framed heatsink
assemblies 250 to cover the plurality of tab compression bars 224,
flexible circuit 228-231, the plurality of jumper tabs 232 and end
module jumper tabs 233 of the battery sub-assembly 220, as shown,
for example, in FIGS. 13 and 14.
[0069] As shown, for example, in FIGS. 13-16, the plurality of
compression bars 224 having a crowned or bowed configuration are
connected to the frames to apply uniform pressure across any
underlying terminal coupling surfaces 268 of coupled cell packs 52
interconnected with one another and to the jumper tabs 232, 233 and
to secure the flexible circuits 228-231 which are attached about
both sides of the module 210. This attachment is accomplished by
screwing nuts 22 onto threaded studs 290 of each framed heatsink
assembly 250, described below.
[0070] As best illustrated in FIG. 17, battery sub-assembly 220
includes a plurality of framed heatsink assembly 250, a plurality
of cell packs 52, a positive endplate 236, a negative endplate 238,
a plurality of foam elements 40 and four tie rods 242. In the
illustrated embodiment, a foam element 40 is sandwiched between
each framed heatsink assembly 250 and between each cell pack and an
adjacent end framed heatsink assembly 250 or the negative terminal
endplate 238, respectively. The four tie rods 242 are each passed
through tie rod-receiving holes 246 formed in each of the plurality
of frame members 282, 284 of each framed heatsink assembly 250 and
positive endplate 236 and threaded into one of four threaded holes
247 in the negative endplate 238 to secure the components of the
battery sub-assembly 220 together, as shown, for example, in FIG.
17.
[0071] Cell packs 52 of odd P battery module 210 are substantially
similar to those described with regard to even P battery module 10
except that the semicircular openings 276 formed in the distal ends
of the positive terminal coupling surface 268 and negative terminal
coupling surface 274 are both displaced from each other by the same
opening displacement 278.
[0072] The first frame member 282 of one framed heatsink assembly
250 and second frame member 284 of an adjacent framed heatsink
assembly 250 clamp the packaging envelope 56 of the cell pack 52
sandwiched therebetween around the perimeter. If the packaging
envelope 56 is of the folded type, the frame members 282, 284 can
clamp on the three seal edges of the packaging envelopes 56 and
provide a concave feature on the fourth or bottom edge to cradle
and protect the packaging envelope bottom edge. If the packaging
envelope 56 is manufactured from two separate pieces and therefore
sealed on all four edges 60, 61, 62, 63, the frame members 282, 284
may be designed to clamp on all four seal edges 60, 61, 62, 63.
[0073] Each of the frame members 282, 284 has a first and second
side rail 288, 298 formed to include a threaded stud 290 extending
laterally therefrom. When frame members 282, 284 are joined
together with heatsink 286 sandwiched therebetween, studs 290 are
displaced on center from each other by a stud displacement 292.
Stud displacement 292 is approximately equal to opening
displacement 278 so that studs 290 can act as a jumper tab/terminal
coupling surfaces capture feature. When the cell packs 52 are
coupled between adjacent framed heatsink assemblies 250, the studs
290 are received in the openings 276 of the positive terminal
coupling surfaces 268 or negative terminal coupling surfaces 274 of
one or two adjacent cell packs 52, as shown, for example, in FIG.
17. Studs 290 are also received in stud-receiving holes 294 of the
jumper tabs 232, 233. Stud-receiving holes 294 are displaced from
each other by a hole displacement 296 (see FIG. 15) approximately
equal to opening displacement 278 and stud displacement 292. Studs
290 hold a jumper tab 232, 233 securely in place to facilitate
mechanically and electrically connecting all of the terminals in
the desired series, parallel or series/parallel configuration.
[0074] The studs 290 molded into and extending from the frame
members 282, 284 on a positive and a negative side of the framed
heatsink assembly 250, respectively, act as terminal/jumper tab bar
capture devices. Each side of the frame 282, 284 also has a molded
relief feature 316 to provide positioning for a thermal sensor
which may be included in the flexible circuits 228-231.
[0075] The heatsink 286 includes top thermal transfer edge 308 and
bottom thermal transfer edge 310. The top and bottom thermal
transfer edges 308, 310 may include a plurality of fins integral
with and extending from the heatsink 286. The fins may be cold
formed and are designed to transfer heat either to or from the
cells depending on application. The frame members 282, 284 are
mechanically attached on each side of the heatsink 286.
[0076] Frame members 282, 284 are preferably plastic frames, such
as from readily moldable plastics. An exemplary readily moldable
plastic that is relatively inexpensive and structurally sufficient
is valox but not limited to elyte resistant. If there is a
requirement for a fire resistant plastic, a plastic having
intumescent properties is preferably used, such as the elastomeric
intumescent material disclosed in U.S. Pat. No. 6,809,129 to
Abu-Isa. In another aspect of the disclosed scalable battery module
210, the two frame members 282, 284 may be identical, thereby being
manufacturable from a single mold cavity.
[0077] As shown for example, in FIG. 17, in the one embodiment of
the disclosed scalable battery module 210, the frame members 282,
284 have a pin and socket configuration on the side facing away
from the heat sink clamping surfaces in order to mate and align
with one or more adjacent framed heatsink assemblies 250.
[0078] FIG. 17 provides a detailed explanation of the mechanical
connection defined between the first and second frame members 282,
284 sandwiching the heatsink 286 therebetween. The frame members
282, 284 present a mechanical connection therebetween presented in
the shape of snap towers, hooks and other mechanical devices
without limiting the scope of the present invention. Additional
descriptions of mechanisms and structures formed on frame members
are described in co-owned International Application Nos.
PCT/US2008/013451 and PCT/US2008/012545 the disclosures of which
are incorporated herein by this reference.
[0079] As the illustrated odd P battery module 210 is being
assembled, the cell packs 52 are oriented to have the negative
terminal couplings surfaces 274 and positive terminal coupling
surfaces 268 oriented as shown in FIGS. 17 and 18.
[0080] As shown, for example, in FIGS. 13-16 and 18, during
assembly jumper tabs 232 are positioned and secured onto the studs
290 of three sequentially ordered framed heatsink assemblies 250
with studs 290 being received in stud-receiving holes 294 to couple
the three sequentially ordered parallel coupled cell packs 52
adjacent the framed heatsink assemblies 250 in series with the next
three parallel coupled cell packs 52. As shown, for example, in
FIGS. 14, 16 and 18, during assembly jumper tabs 233 are positioned
and secured onto the studs 290 of the nearest famed heat sink
assembly of three sequentially ordered framed heatsink assemblies
250 to an endplate with studs 325, 345 on the adjacent endplate
236, 238. The studs 290, 325, 345 are received in stud-receiving
holes 294 to couple the three sequentially ordered parallel coupled
cell packs 52 adjacent the framed heatsink assemblies 250 in series
with the endplate 236, 238.
[0081] As shown, for example, in FIGS. 15 and 16, the centerlines
between each pair of cooperating stud-receiving holes 294 and
adjacent pairs of cooperating stud-receiving holes 294 is
approximately equal to the thickness of each framed heatsink
assembly 250 so that the holes 294 are appropriately positioned to
receive appropriate studs 290. The overall length of jumper tab 232
is greater than the displacement 292 between studs 290, but less
than the width of the molded relief features 316 of the frame
member 282, 284 of the framed heatsink assemblies 250. The overall
width of each jumper tab 232, in the illustrated embodiment, is
less than three time the thickness of a heatsink assembly 250.
Jumper tabs 232, 233 are formed of appropriate conductive material
to form an electrical connection between the various terminals of
the cell packs 52 sandwiched between the framed heatsink assemblies
250 to which they are attached.
[0082] The disclosed odd P battery module 210 is adaptable to
provide scalable electrical configurations. Odd P battery module
210 is configured to permit multiple odd P battery modules to be
coupled together to form a battery pack including one or more
battery modules 210 each presenting a multitude of prismatic cell
packs 52 each having at least one large area surface in contact
with a heatsink 286 formed from thermally conductive materials such
as, for example, flat stock aluminum alloy foils and the like,
without limiting the scope of the present invention. In the
illustrated embodiment, one large area surface of each cell pack 52
is in direct contiguous contact with a heatsink 286 and the other
large area surface is in thermal conductive contact via a foam
element with a heatsink 286 or the negative endplate 238. This
facilitates regulating the temperature of each cell pack 52 fairly
evenly across the entire battery module 210.
[0083] As best shown in FIGS. 13-17, the disclosed odd P battery
module 210 includes a plurality of heatsinks 286 formed from a
thermally conductive material such as aluminum, copper, and the
like, without limiting the scope of the present invention. Each
heatsink 286 terminates to opposite fin portions or thermal edges
308, 310. The fin portion 308, 310 may include a gate shape, may be
pleated, planar, may present a plurality of slots or holes, may be
formed as a bend to provide a thermal interface plane for an
external heating or cooling device including but not limited to
heater blankets and/or cooling jackets.
[0084] Those skilled in the art will appreciate that numerous other
shapes of the fin portions 308, 310 can be utilized to provide
better surface area for cooling or heating media, such as liquids,
solids, or gasses, and the like, are introduced to the fin portions
308, 110 of each thermally conductive plate, sheet, or foil to
either cool or to heat the cell packs 52.
[0085] Positive endplate 236 and negative endplate 238 act as a
pair of compression plates sandwiching the framed heatsink
assemblies 250, cell packs 52 and foam elements 40 therebetween.
The positive endplate 236 is formed to include a pair of studs 325
displaced by a stud displacement 327 approximately equal to the
opening displacement 278. Studs 325 are configured to receive the
openings 276 on the distal edge of the positive terminal coupling
surface 268 of the cell pack 52 adjacent the positive endplate 236
thereabout. The negative endplate 238 is formed to include is
formed to include a pair of studs 345 displaced by a stud
displacement 347 approximately equal to the opening displacement
278. Studs 345 are configured to receive the openings 276 on the
distal edge of the negative terminal coupling surface 274 of the
cell pack 52 adjacent the negative endplate 238 thereabout.
[0086] The positive endplate 236 and negative endplate 238 are
fastened together to provide additional compressive force to the
cell packs 52 and framed heatsink assemblies 250.
[0087] While only an odd P battery module 210 having three
sequential cell packs terminals coupled in parallel which are
coupled in series to the adjacent sequential cell packs 52 coupled
in parallel a jumper tab 232 having three pairs of cooperating
stud-receiving holes 294 is illustrated, it is within the
contemplated scope of the disclosure for terminals of more than
three sequential cell packs 52 sandwiching framed heat sink
assemblies therebetween to be coupled in parallel to form a
parallel cell group that is coupled in series with a like number of
cell packs sandwiching heat sink assemblies therebetween coupled in
parallel to form an adjacent parallel cell group utilizing
appropriately configured jumper tabs and end jumper tabs and proper
orientation of cell packs to form other configurations of odd P
battery modules 210.
[0088] A scalable battery module 10, 210 of the present disclosure
is adaptable to provide scalable electrical configurations. A large
battery pack may be formed by coupling one or a plurality of
scalable battery modules 10, 210 comprising a multitude of cells
each sandwiched by respective heatsinks formed from thermally
conductive materials such as, for example, flat stock aluminum
alloy foils and the like, without limiting the scope of the present
disclosure.
[0089] The basis for the electrical configuration in the disclosed
scalable battery modules is the overlapping of the positive
terminal of one parallel cell grouping and the negative terminal of
an adjacent prismatic electrochemical cells to facilitate
connecting parallel cell groupings in series. When the cell
terminals are connected in this manner, a single parallel string
(1P) is formed. Alternatively; the adjacent electrochemical cell
pairs may be configured with their respective positive terminals
overlapping each other and their respective negative terminals
overlapping each other thus forming a parallel cell configuration
(2P). To construct a string of parallel cells, the first grouping
of two adjacent cells positive terminals are electrically connected
to the adjacent cells negative terminals by use of an electrically
conductive jumper tab. An alternating stack of cell pairs, positive
terminals to negative terminals, can be strung together to achieve
the desired electrical characteristics. To those skilled in the
art, it is apparent that the series and parallel combinations
present an infinite number of electrical configuration
combinations.
[0090] This disclosed odd P scalable battery module 210 permits the
configuration of an odd number of cells in parallel. For example,
as shown in FIGS. 17-18, in assembling a 3P (three parallel)
configuration, cell pack orientation alternates every three cell
grouping i.e. the first three cells have their positive terminals
to the left and their negative terminals to the right, the next
three cell grouping have their negative terminals to the left and
their positive terminals to the right. In detail, the first three
cell grouping (cell numbers 1-3) have their positive terminals to
one side; the next three cell grouping (cell numbers 4-6) have
their positive terminals to the opposite side.
[0091] Assuming the orientation of the first cell pack 1752a of the
first three cell grouping 1751a shown to the left of the drawing in
FIG. 17 exhibits a base orientation, the configuration described
above can be accomplished by rotating subsequent cells about their
lateral and or longitudinal axis relative to the base orientation.
In the illustrated embodiment, the second cell pack 1752b of the
first cell grouping 1751a is rotated 180 degrees end over end about
its lateral axis from the base orientation so that its negative
terminal still faces forward in the drawing. Continuing, in the
illustrated embodiment, the third cell pack 1752c of the first cell
grouping 1751a, is placed in the base orientation with its negative
terminal facing forward in the drawing. Continuing further, in the
illustrated embodiment, the fourth cell pack 1752d which is the
first cell pack of the second cell grouping 1751b is rotated 180
degrees side to side about its longitudinal axis from the base
orientation so that its negative terminal faces rearward in the
drawing and its positive terminal faces forward in the drawing.
Continuing, in the illustrated embodiment, the fifth cell pack
1752e which is the second cell pack of the second cell grouping
1751b is rotated 180 degrees side to side about its longitudinal
axis and 180 degrees end over end about its lateral axis from the
base orientation so that its negative terminal faces rearward in
the drawing and its positive terminal faces forward in the drawing.
Continuing, further, in the illustrated embodiment, the sixth cell
pack 1752f which is the third cell pack of the second cell grouping
1751b is rotated 180 degrees side to side about its longitudinal
axis from the base orientation so that its negative terminal faces
rearward in the drawing and its positive terminal faces forward in
the drawing.
[0092] Continuing, the third set of three cell grouping (cell
numbers 7-9) will return to having their positive terminals on the
same side as the first three cell grouping (cells 1-3). This
alternating pattern of positive terminals and negative terminals
continues until the appropriate number of cell grouping are
assembled to provide the desired electrical characteristics. For
further clarification, by placing the first electrochemical cell
grouping with its positive terminal overlapping the second cell
grouping positive terminal and its negative terminal overlapping
the second cell grouping negative terminal you create a 2P
configuration. By adding a third electrochemical cell grouping with
its positive cell terminal positioned on the same plane as the
positive terminals of the previous two cell groupings and its
negative terminal positioned on the same plane as the negative
terminal of the previous two cell groupings, three positive
terminals are presented on a common plane and three negative
terminals are presented on an opposite common plane. The first
three cell groupings negative terminals (cells 1-3) would be joined
using an electrically conductive jumper tab and would form the
negative end of a battery module. The first three cell groupings
(cells 1-3) positive terminals would be joined with the next three
cell groupings (cells 4-6) negative terminals with an electrically
conductive jumper tab to place the first three cell groupings
(cells 1-3) and the next three cell groupings (cells 4-6) in a
series connection. The next three cell groupings (cells 4-6)
positive terminals are joined to the negative terminals of the
third set of three cell groupings (cells 7-9). This alternating
connection method continues until the desired number of three
parallel cell groupings (3P) in series is reached.
[0093] The disclosed scalable battery module is a battery cell
interconnect system to provide scalable electrical configurations
in the assembly of multiple electrochemical cells within a battery
module. This electrical configurability will allow a plurality of
battery cells to be assembled into an electrical series string, or
an electrical parallel string, or any multiples there between. The
disclosed scalable battery module is adaptable to be utilized in
various electrical configurations including and not limited to the
overlapping of positive terminals and negative terminals of
prismatic electrochemical battery cells. Electrical conductive
power bussing straps or jumper tabs are mechanically assembled onto
the overlapping cell terminals to create the appropriate
series/parallel configuration. The battery module has a plurality
of battery cells, heatsink assemblies with the cells disposed
therebetween. A plurality of rods extend through the each heatsink
assemblies to secure the heatsink assemblies and the cell with one
another to form the battery module or battery pack. A plurality of
bands may also be used around the outline of module as a method to
secure all components of the battery module or battery pack
assembly, as described in co-owned U.S. Pat. No. 7,531,270, U.S.
application Ser. Nos. 12/103,830, 12/463,548 the disclosures of
which are incorporated herein by this reference.
[0094] While the disclosed scalable battery module has been
described with reference to electric and hybrid electric vehicles,
the disclosed scalable battery module may find applicability within
the automotive, grid storage, military, and numerous consumer
application markets within the scope of the disclosure. In
particular, this invention promotes a scalable battery capacity and
voltage solution to meet the varying requirements of the market's
battery system needs.
[0095] The disclosed scalable battery module provides scalable
capacity and voltage solutions for module or battery assemblies.
The disclosed scalable battery module promotes the use of common
product components to manufacture numerous end-product variations.
This vastly reduces all development and manufacturing contributors
that affect cost and time to market.
[0096] An advantage recognized by the disclosed scalable battery
module is to provide a battery module with a very high energy
density characteristic, wherein the high energy density is
accomplished by assembling cells, power and data bussing devices,
controllers, cooling, and retention architecture in the small
volume of space thereby improving packaging characteristics and
providing a compact product.
[0097] Another advantage recognized by the disclosed scalable
battery module is to provide a battery module having excellent
retention that surrounds and secures the cells.
[0098] Still another advantage recognized by the disclosed scalable
battery module is to provide a battery module having excellent
retention that surrounds and secures the electrode stack within the
cell envelope from shifting.
[0099] Still another advantage recognized by the disclosed scalable
battery module is to provide a scalable battery pack that reduces
manufacturing costs due to simplified assembly methods.
[0100] Still another advantage recognized by the disclosed scalable
battery module is to provide a scalable battery pack having a
balanced thermal management system wherein each cell of the battery
pack receives a similar temperature and flow of thermal management
media to assist in the removing or adding heat.
[0101] Still another advantage recognized by the disclosed scalable
battery module is to provide a cooling system which allows the
battery pack to deliver and receive high rates of current, i.e. the
C-rate by efficiently removing undesired heat during the rapid
charge or discharge pulse that may negatively impact the
performance and life span of the battery pack.
[0102] Still another advantage recognized by the disclosed scalable
battery module is to provide heatsinks that may interface with a
heating system to allow the battery pack to operate when exposed to
temperatures below the optimal operating range of the cell
chemistry.
[0103] Still another advantage recognized by the disclosed scalable
battery module is to provide a pack that is simple in design and
has a reduced mass.
[0104] The disclosed scalable battery module provides several
advantages over the battery packs of the prior art by increasing an
ambient temperature range at which the battery pack can operate.
Also, the disclosed scalable battery module subject invention helps
maintain the battery pack at an optimal operating temperature to
extend the life cycle of the battery pack, and to increase battery
pack safety.
[0105] While the invention has been described as example
embodiments, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention.
In addition, many modifications may be made to adapt a particular
situation or material to the teachings of the invention without
departing from the essential scope thereof. It is to be understood
that the presently preferred embodiment of the present invention
disclosed is representative of the subject matter which is broadly
contemplated by the present invention, that the scope of the
present invention fully encompasses other embodiments which may
become obvious to those skilled in the art. All structural and
functional equivalents to the elements of the above-described
preferred embodiment that are known or later come to be known to
those of ordinary skill in the art are expressly incorporated
herein by reference and are intended to be encompassed by the
present disclosure. Moreover, it is not necessary for a device or
method to address each and every problem sought to be solved by the
disclosed scalable battery module and method of making the same.
Furthermore, no element, component, or method step in the present
disclosure is intended to be dedicated to the public.
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