Battery assembly with temperature control device

Abstract

A battery module of the present invention is adaptable to be utilized in various configurations including and not limited to an overlapping battery cell packaging configuration and a vertical stack battery cell packaging configuration used in an automotive and non-automotive applications. The battery module has a plurality of battery 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.

Claims

1. A battery assembly comprising: a plurality of prismatic cells, each having a central portion; a plurality of frames including first, second, and third frames holding the plurality of prismatic cells such that the central portions of plurality of prismatic cells are spaced apart from each other, each of the first, second, and third frames having an open central portion, the plurality of frames interlocked to be removably coupled together; and a plurality of compliant devices positioned between the plurality of prismatic cells and adjacent the central portions of the plurality of prismatic cells, wherein a first compliant device of the plurality of compliant devices is received in an open central portion of the first frame of the plurality of frames, a first prismatic cell of the plurality of prismatic cells is held relative to the first frame by the second frame, a second prismatic cell of the plurality of prismatic cells is held relative to the first frame by the third frame, and the first compliant member is positioned between a central portion of the first prismatic cell and a central portion of the second prismatic cell.

2. A battery assembly as set forth in claim 1 wherein each of the plurality of prismatic cells includes a raised portion extending to a peripheral lip portion, a negative terminal and a positive terminal, the raised portion including the central portion.

3. A battery assembly as set forth in claim 2 wherein the first compliant member includes a layer of expandable material sized to substantially cover the raised portion of the first prismatic cell.

4. A battery assembly as set forth in claim 1 wherein a second compliant device of the plurality of compliant devices is received in an open central portion of a fourth frame of the plurality of frames, a third prismatic cell of the plurality of prismatic cells is held relative to the fourth frame by a fifth frame, a fourth prismatic cell of the plurality of prismatic cells is held relative to the fourth frame by a sixth frame, and the second compliant member is positioned between a central portion of the third prismatic cell and a central portion of the fourth prismatic cell.

5. The battery assembly as set forth in claim 1, wherein the plurality of frames are interlocked at a snap interface.

6. A battery assembly comprising: a plurality of prismatic cells, each having a central portion; a plurality of frames holding the plurality of prismatic cells such that the central portions of plurality of prismatic cells are spaced apart from each other, each of the frames having an open central portion, the plurality of frames being removably coupled together; a plurality of compliant devices positioned between the plurality of prismatic cells and adjacent the central portions of the plurality of prismatic cells, wherein a first compliant device of the plurality of compliant devices is received in an open central portion of a first frame of the plurality of frames, a first prismatic cell of the plurality of prismatic cells is held relative to the first frame by a second frame, a second prismatic cell of the plurality of prismatic cells is held relative to the first frame by a third frame, and the first compliant member is positioned between a central portion of the first prismatic cell and a central portion of the second prismatic cell; a second compliant device of the plurality of compliant devices is received in an open central portion of a fourth frame of the plurality of frames, a third prismatic cell of the plurality of prismatic cells is held relative to the fourth frame by a fifth frame, a fourth prismatic cell of the plurality of prismatic cells is held relative to the fourth frame by a sixth frame, and the second compliant member is positioned between a central portion of the third prismatic cell and a central portion of the fourth prismatic cell; and a heat sink positioned between the first prismatic cell and the third prismatic cell, the heat sink contacting the first prismatic cell through an open center of the second frame, and the heat sink contacting the third prismatic cell through an open center of the fifth frame.

7. A battery assembly as set forth in claim 6 wherein the heat sink includes a first surface in contact with the raised portion of the first prismatic cell and a second surface in contact with the raised portion of the third prismatic cell.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIG. 1 illustrates a battery case having a pair of battery packs of the present invention;

(3) FIG. 2 illustrates a heat sink sandwiched between a pair of inner frames;

(4) FIG. 3 illustrates a fragmental perspective view of the heat sink sandwiched between the inner frames as shown in FIG. 2;

(5) FIG. 4 illustrates an exploded view of FIG. 2;

(6) FIG. 5 illustrates a perspective view of a cell retaining element having the heat sink sandwiched between the inner frames, a pair of prismatic cells positioned on opposite sides of the heat sink with each prismatic cell extending over the respective inner frames and a pair of outer frames each extending over the respective prismatic cell;

(7) FIG. 6 illustrates an exploded view of the cell retaining element shown in FIG. 5; and

(8) FIG. 7 illustrates a perspective and exploded view of one of the battery module including a plurality of the cell retaining elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(9) Referring to the Figures, wherein like numerals indicate like or corresponding parts, a battery assembly of the present invention is generally indicated at 10 in FIG. 1 having a pair of battery packs, generally indicated at 12, disposed in a housing 14. The battery pack 12 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 or non-automotive applications. Each battery pack 12 includes a plurality of cells 16. Preferably, each cell 16 is a lithium ion cell having a prismatic configuration 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 16 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 the first and second electrodes with electrolyte therebetween. A plurality of first electrodes and second electrodes are stacked and packaged into an electrical insulating envelope to form a cell.

(10) Alluding to the above, each cell 16 presents side edges 18 and 20. A first terminal or first bend 22 presents a positive terminal and extends from one of the edges 18. A second terminal or bend 24 presents a negative terminal extending from the other edge 20. Each bend 22 and 24 defines an angle of at least ninety degrees. The angle may vary at its degree and may be configured to be up to ninety degrees without limiting the scope of the present invention. Alternatively, the first and second terminals may present a planar configuration. Each bend 22 and 24 presents a pair of semicircular openings 26. Alternatively, each bend may present other openings (not shown) having different configurations without limiting the scope of the present invention.

(11) Referring now to FIGS. 2 through 6, each battery pack includes a plurality of cell retaining elements, generally shown at 30, removeably connected with one another to form the battery pack 12. FIG. 7 illustrates an exploded view of the battery pack 12 to appreciate the inventive concept. The cell retaining element 30 includes a heatsink, generally indicated at 32. The heatsink 32 presents a plate 34 formed from a thermally conductive material such as aluminum, copper, and the like, without limiting the scope of the present invention. Each heatsink 32 terminates to oppositely spaced from one another fin portions, generally indicated at 36 and 38 in FIG. 4. The fin portion 38 presents a rectangular or tubular cross section 40. The other fin portion 36 presents a flat surface 42. The fin portions 36 and 38 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. Those skilled in the art will appreciate that numerous other shapes of the fin portions 36 and 38 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 36 and 38 of each thermally conductive plate, sheet, or foil to either cool or to heat the cells 16. The fin portions 36 and 38 may be cold formed and are designed to transfer heat either to or from the cells depending on application. The plate 34 defines a plurality of slots 43 and semicircular configuration 44 at the sides 46 of the plate 34 to receive a plurality of rods 48 extending therethrough to interconnect the cell retaining elements 30 with one another to form the battery pack 12.

(12) As best illustrated in FIGS. 4 through 7, a frame assembly of the cell retaining element 30 is disclosed. The frame assembly includes a first set of inner frames 50 and 52 securing the plate 34, sandwiched between the inner frames 50 and 52, and a second set of outer frames 54 and 56 for securing the cells 16. One of the cells 16 is secured between one of the inner frames 50 and one of the outer frames 54. The other inner and outer frames 52 and 56 secure another of the cells 16 retained therebetween.

(13) As best shown in FIG. 4, one of the inner frames 50 presents a peripheral edge 58 and side walls 60 and 62. One of the side walls 62 includes a pair of pins 64 and 66 to electro-mechanically engage the bends 22 or 24 of the cells 16. A plurality of holes or female connectors 68 are defined in the inner frame 50. A plurality of male connectors or hooks 70 are formed and integrally extend from and about the peripheral edge 58 of the inner frame 50. The hooks 70 extend in the opposite direction and away from the plate 34. A plurality of studs 72 extend from the inner frame 50 in the direction opposite from the hooks 70 to mechanically engage another inner frame 52 and the plate 34 sandwiched therebetween.

(14) As best illustrated in FIG. 6, another inner frame 52 presents a configuration similar to the configuration of inner frame 52. The inner frame 52 includes a peripheral edge 80 and side walls 82 and 84. One of the side walls 82 may also includes a pair of pins (not shown) to electro-mechanically engage the bends 22 or 24 of the cells 16. A plurality of holes or female connectors 86 are defined in the frame 52. A plurality of male connectors or hooks 88 are formed and integrally extend from and about the peripheral edge 58 of the frame 50. The hooks 88 extend in the opposite direction and away from the plate 34. A plurality of studs 89 extend from the inner frame 52 in the direction opposite from the hooks 88 to mechanically engage the inner frame 50 and the plate 34 sandwiched therebetween. The frames 50 and 52 are molded from a polymeric material. Those skilled in the art will appreciate that various polymeric materials may be used to form the frames 50 and 52 without limiting the scope of the present invention. The frames 50 and 52 may be partially formed from the polymeric material and have the hooks and studs disposed therein during the molding stage, wherein the hooks and studs may be formed from a non-polymeric material. The molding may be injection molding or cast molding. The materials and methods of formation of the lower frames 50 and 52 are used for exemplary purposes and are not intended to limit the scope of the present invention.

(15) As best shown in FIG. 6, one of the outer frames 54 presents a peripheral edge 90 and side walls 92 and 94 each presenting cut out portions 96 and 98 dimensionally configured to engage the bends 22 and/or 24. A plurality of holes or female connectors 100 are defined in the frame 54. A plurality of female connectors 102 are formed in the peripheral edge 90 to engage the hooks 70 extending from the inner frame 50 in a snap interface to secure one of the prismatic cells 16 therebetween. The outer frame 54 and the inner frame 50 define an opening to surround the raised portions 104 of the cell 16 and sandwiched a peripheral lip portion 106 of the cell 16 therebetween. One of the raised portions 104 of each cell 16 frictionally engaged the plate 34 while the other raised portion 104 frictionally engages the raised portion 104 of another cell 16 retained by adjacent cell retaining element, as best shown in FIG. 7.

(16) Alternatively, as best shown in FIG. 7, a device or a layer of material 110, such as foam or any other non-rigid polymeric materials, is sandwiched between the raised portions 104 of the prismatic cells 16. The device 110 substantially covers the raised portions 104 of the prismatic cell 16. Alternatively, the device 110 is sandwiched between the peripheral lip portion 106 of the cell 16 and the upper frame 54 to mechanically retain the device 110 with the cell retaining element 30. As the cell retaining elements 30 are assembled with one another to form the battery pack 12, the cell 16 of one cell retaining element 30 is placed adjacent the cell 16 of adjacent cell retaining element 30 wherein the device 110 is sandwiched between the prismatic cells 16. As the cell retaining elements 30 are combined to form the battery pack 12, the device 110 allows expansion and contraction of the prismatic cells 16 during typical charge and discharge states therefore causing the cell 16 to maintain intimate contact with the heat sink 34 for efficient thermal transfer inside the battery pack 12 and/or battery assembly 10.

(17) Similarly, the other outer frame 56 presents a peripheral edge 112 and side walls 114 and 116 each presenting cut out portions 118 and 120 dimensionally configured to engage the bends 22 and/or 24. A plurality of holes or female connectors 122 are defined in the frame 56. A plurality of female connectors 124 are formed in the peripheral edge 112 to engage the hooks 88 extending from the inner frame 52 to secure one of the prismatic cells 16 in a snap interface therebetween. The outer frame 56 and the inner frame 52 define an opening to surround the raised portions 104 of another prismatic cell 16 and sandwiched a peripheral lip portion 106 of the prismatic cell 16 therebetween.

(18) One of the raised portions 104 of the prismatic cell 16 frictionally engaged the plate 34 while the other raised portion 104 frictionally engages the raised portion 104 of another cell 16 retained by adjacent cell retaining element, as best shown in FIG. 7. The outer frames 54 and 56 are molded from a polymeric material. Those skilled in the art will appreciate that various polymeric materials may be used to form the frames 54 and 56 without limiting the scope of the present invention. The frames 54 and 56 may be partially formed from the polymeric material and have the hooks and studs disposed therein during the molding stage, wherein the hooks and studs may be formed from a non-polymeric material. The molding may be injection molding or cast molding. The materials and methods of formation of the inner frames 54 and 56 are used for exemplary purposes and are not intended to limit the scope of the present invention.

(19) While the invention has been described as an example embodiment, 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. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.