Battery module with battery retainer assembly

Abstract

A battery module (100), a method of assembling the battery module (100), and a battery holder assembly (204) are disclosed. The battery module (100) includes a plurality of batteries (209) positioned between a top cover (102) and a bottom cover (103), and the battery holder assembly (204) includes battery holders (301, 302, 304) for holding the batteries (209). The battery holder assembly (204) includes an inlet manifold (205) and an outlet manifold (206) for flowing coolant through the battery holders (301, 302, 304) for drawing heat generated by the batteries (209). The battery module (100) has the batteries (209) surrounded by the coolant to effectively and efficiently dissipate the heat generated by the batteries (209) and cool the batteries (209) for safe, durable, and convenient and safe during assembly, use, maintenance, and repair of the battery module (100).

Description

TECHNICAL FIELD

[0001] The present subject matter relates to battery modules. More particularly, it pertains to heat dissipation in battery modules. BACKGROUND

[0002] In recent years, rechargeable energy storage devices have been widely used as energy sources for many electronic and electrical devices, hybrid electric vehicles, and electric vehicles. Commonly used rechargeable energy storage devices include, for example, nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, and lithium rechargeable batteries. Lithium rechargeable energy storage devices are widely used in electric vehicles and hybrid electric vehicles because of their rechargeability, compact size, large capacity, high operating voltage, and high energy density per unit weight.

[0003] Existing energy storage devices include one or more energy storage cells, such as lithium ion battery cells enclosed within a housing. Electrochemical reactions with the lithium ion battery cells are responsible for generating voltage and current for the energy storage device. Also, during charging of the energy storage device, electrochemical reactions occur within the lithium ion battery cells. These electrochemical reactions are highly exothermic, and the lithium ion battery cells are prone to heat generation during normal operation. Elevated temperature of the lithium ion battery cells degrades the electrical performance of the energy storage device and can lead to catastrophic failure of the energy storage device.

[0004] Energy storage devices containing lithium ion battery cells are used as energy sources in electric vehicles or hybrid electric vehicles. To sustain the performance and health durability of the lithium ion battery cells, the energy storage devices in electric or hybrid electric vehicles need to be cooled. As the battery cell temperature increases, the vehicle range decreases. There is a possibility of thermal runaway in the energy storage device, which can lead to the propagation of a battery cell explosion wave. Further, due to the temperature increase in the battery module, it can not be possible to charge immediately after riding / driving the vehicle even if a fast charger is used.

[0005] Therefore, to ensure the safety and longevity of the energy storage device, it is necessary to effectively dissipate the generated heat and efficiently cool the lithium ion battery cells of the energy storage device. BRIEF DESCRIPTION OF DRAWINGS

[0006] The detailed description is described with reference to the accompanying drawings. In the drawings, like numbers are used to refer to like features and components.

[0007] Figure 1 An exploded perspective view of the battery module is shown;

[0008] Figure 2 An exploded perspective view of the battery module is shown; Figure 1 An exploded perspective view of the battery module is shown;

[0009] Figure 3An exemplary top perspective view of a battery holder assembly is shown, the battery holder assembly holding batteries as Figure 2 An exemplary battery of a battery module is shown;

[0010] Figure 4 An exemplary partial exploded view of a battery holder assembly is shown, showing a packaging member positioned in each of the battery holders of the battery holder assembly;

[0011] Figure 5 An exemplary battery module is shown Figure 2 An exemplary exploded view of a battery holder assembly of a battery module is shown;

[0012] Figures 6A-6B An exemplary plan view and cross-sectional view of a spacer assembly is shown, showing a flow path of coolant from an inlet manifold to an outlet manifold;

[0013] Figure 7 An exemplary cross-sectional view of a battery module is shown; and

[0014] Figure 8 An exemplary flow chart depicting a method is shown, the method comprising steps for assembling Figure 2 An exemplary battery module is shown. DETAILED DESCRIPTION

[0015] In an embodiment for cooling an energy storage device and, in turn, a lithium ion battery cell, a heat exchange member is used in thermal contact with a housing of the energy storage device. Heat dissipated from the lithium ion battery cell must pass through an air-filled gap between the battery cell and the housing. The efficiency of heat transfer between the battery cell and the housing is not high because air is a poor thermal conductor. To ensure that heat is effectively dissipated from the battery cell, it is necessary to ensure that the heat-generating battery cell is securely fixed in thermal contact with the heat exchange member proximate to the housing. Further, to ensure that heat is effectively transferred to the metal housing, it is also necessary to ensure that there is no air gap between the upper surface of the lithium ion battery cell and the inner surface of the outer housing.

[0016] Currently, one of the embodiments employs liquid cooling for thermal management in an energy storage device. The energy storage device as a whole can be immersed in a liquid coolant. However, the liquid coolant is static and the cooling efficiency of the energy storage device is significantly lower.

[0017] Another embodiment of the energy storage device involves employing a coolant tube for the liquid coolant, which is designed to surround individual battery cells or a group of battery cells in the energy storage device. However, the inbuilt modular coolant tube within the housing of the energy storage device makes the energy storage device bulky and no longer compact for various applications where space is limited. The coolant tube will be made of a thermally conductive material. Further, such an insert with coolant channels needs to be effectively sealed to prevent leakage of the liquid coolant into and outside the energy storage device.

[0018] Therefore, there is a need for an improved design of the energy storage device, which is lightweight and provides efficient and effective heat transfer from the battery cells, which additionally provides ease and safety of the energy storage device during assembly, use, maintenance, and repair, thereby overcoming all the problems disclosed above and other problems of the known art.

[0019] The present subject matter discloses an energy storage device, i.e., a battery module having battery cells surrounded by a coolant to effectively and efficiently dissipate heat generated by the battery cells and cool the battery cells, thereby safe, durable, and easy and safe during assembly, use, maintenance, and repair of the energy storage device. Such a battery module can be used in electrical devices, such as electronic gadgets, laptops, toys, vehicles (e.g., electric vehicles, hybrid electric vehicles, IC engine vehicles, etc.).

[0020] In one embodiment of the present invention, a battery module for an electrical device is disclosed. The battery module includes a housing including a top cover and a bottom cover. A plurality of batteries are positioned between the top cover and the bottom cover. Further, the battery module includes a battery holder assembly including battery holders for holding the plurality of batteries. The battery holder assembly includes an inlet manifold and an outlet manifold for flowing coolant through the battery holders for picking up heat generated by the batteries. Each of the battery holders holds one battery. Each of the battery holders includes an opening for flowing the coolant around the battery in each of the battery holders. The coolant flows from the inlet manifold in the battery holder assembly through the openings in the battery holders in the battery holder assembly in sequence. It picks up heat from the batteries in the battery holders and exits through the outlet manifold in the battery holder assembly.

[0021] In an embodiment, the openings of each of the battery retainers are formed proximate to a bottom location or a top location of the battery retainers. In an embodiment, the contiguous battery retainers in the battery retainer assembly include openings at the bottom location and the top location for the coolant to rise from the bottom to the top in each of the contiguous battery retainers. The openings are formed in the common partition wall between the contiguous battery retainers. In an embodiment, the packaging member is positioned at the collar region proximate to each end of each of the batteries for sealing the coolant at the ends of each of the batteries. In an embodiment, the interconnect tabs contact each end of each of the batteries. In an embodiment, the battery retainer assembly includes a battery retainer locking member having openings positioned at each end of the battery retainers of the battery retainer assembly. In an embodiment, the packaging member is disposed adjacently in the battery locking member. In an embodiment, the packaging member is integrally formed in the battery locking member. In an embodiment, the inlet manifold and the outlet manifold are one of at the same height and at different heights. The outlet manifold extending from the outlet opening of the bottom cover is communicatively connected to the heat sink for effectively cooling the coolant.

[0022] Another embodiment of a method of assembling a battery module is disclosed. The method includes the steps of obtaining a plurality of batteries, positioning the batteries in battery retainers of a battery retainer assembly, sealing each end of each of the batteries in the battery retainers with a packaging member, and positioning a housing having openings for an inlet manifold and an outlet manifold, thereby enclosing the battery retainer assembly to obtain the battery module.

[0023] In one embodiment, positioning the batteries in the battery holders of the battery holder assembly includes the steps of positioning each battery in each battery holder of the battery holder assembly and positioning a battery holder locking member having an opening at each end of each battery. In one embodiment, the packaging member is disposed abutting in the battery locking member. In one embodiment, the method further includes the step of positioning an interconnect sheet in contact with each end of each battery of the plurality of batteries. The battery holder assembly includes an inlet manifold and an outlet manifold for flowing coolant through the battery holders for drawing heat generated by the batteries. In one embodiment, in a battery module assembled by the method, each battery holder of the battery holder assembly of the battery module includes an opening for flowing coolant around a battery in each battery holder. The opening of each battery holder of the battery holders is formed proximate to a bottom location and a top location of each battery holder of the battery holders, consecutive battery holders of the battery holder assembly include openings at the bottom location and the top location for flowing coolant from the bottom to the top in each battery holder of the consecutive battery holders, and the openings are formed in a common dividing wall between the consecutive battery holders.

[0024] In another embodiment, a battery holder assembly for holding a plurality of batteries is disclosed. The battery holder assembly includes a placeholder assembly including a plurality of battery holders that enclose the plurality of batteries; a battery locking member having an opening positioned at each end of the battery holders; and an opening in each battery holder of the battery holders for flowing coolant around one of the plurality of batteries in each battery holder of the battery holders. An inner perimeter of each battery holder of the battery holders is a circular cross-section and an outer perimeter of each battery holder of the battery holders is a geometric shape. The opening of each battery holder of the battery holders is formed proximate to one of a bottom location and a top location of each battery holder of the battery holders. Consecutive battery holders of the battery holder assembly include openings at the bottom location and the top location for flowing coolant from the bottom to the top in each battery holder of the consecutive battery holders, and the openings are formed in a common dividing wall between the consecutive battery holders.

[0025] The packaging member is positioned proximate to each end of each battery of the plurality of batteries for sealing coolant at the end of each battery of the plurality of batteries. In one embodiment, the packaging member is disposed adjacently in the battery holder locking member. In another embodiment, the packaging member is integral with the spacer assembly. The packaging member of the C cross-sectional profile is seated in a groove at the collar region proximate to the end of each battery of the plurality of batteries to form a sealed joint. The battery locking member has a complementary retaining groove profile to enable the battery locking member to be crimped onto the end of the spacer assembly. In one embodiment, the battery locking member is integral with the spacer assembly.

[0026] Figure 1 An example top perspective view of a battery module 100 according to an embodiment of the present application is shown. As shown Figure 1 As shown exemplarily, the battery module 100 includes a housing 101. The housing 101 includes a top cover 102 and a bottom cover 103. The housing 101 encloses a plurality of batteries and other electrical and electronic components, such as a battery management system (BMS) board of the battery module 100. The bottom cover 103 also includes an inlet opening 104 and an outlet opening 105 for liquid coolant to flow around the enclosed batteries. As shown exemplarily, the inlet opening 104 and the outlet opening 105 are at different heights. That is, the inlet opening 104 is disposed at a higher height compared to the outlet opening 105. In an alternative embodiment, the inlet opening 104 and the outlet opening 105 are at the same height. The inlet opening 104 and the outlet opening 105 are openings on the bottom cover 103 through which an inlet manifold and an outlet manifold extend from the battery holder assembly of the battery module 100. The bottom cover 103 is a hollow container in which the batteries are positioned. The top cover 102 serves as a lid to close the bottom cover 103. The top cover 102 and the bottom cover 103 protect the batteries from external factors and environmental influences, such as water and dust ingress. The housing 101 (further to the inlet opening 104 and the outlet opening 105) can include external electrical connections (not shown) of the battery module 100 for charging and discharging of the battery module 100.

[0027] Figure 2 An example top perspective view of a battery module 100 according to an embodiment of the present application is shown. As shown Figure 1An exploded perspective view of the battery module 100 is shown. As exemplarily shown, the battery module 100 includes a top cover 102, a bottom cover 103, a plurality of batteries 209, and a battery holder assembly 204. The batteries 209 are arranged in the battery holder assembly 204. The batteries 209 are exemplarily shown as cylindrical. In one embodiment, the shape of the batteries 209 can be rectangular, hexagonal, etc. The top cover 102 and the bottom cover 103 enclose the batteries 209 in the battery holder assembly 204. The batteries 209 are arranged in a predetermined order in the battery holder assembly 204. The battery holder assembly 204 includes an inlet manifold 205 and an outlet manifold 206. The inlet manifold 205 and the outlet manifold 206 extend from the inlet opening 104 and the outlet opening 105 of the bottom cover 103. The batteries 209 are electrically connected in series and / or parallel configuration using one or more interconnect tabs (such as 201 and 208) to form a battery array. The ends 202a and 202b of each battery 202 are identified as the electrical terminals of the battery 202, which are in contact with the interconnect tabs 201 and 208. The interconnect tabs 201 and 208 connect the batteries 209 in series and / or parallel combination to deliver the required current and voltage of the battery module 100. In one embodiment, this array of batteries 209 is electrically connected with a BMS (not shown) within the battery module 100. The packaging members 203 and 207 are positioned at the ends 202a and 202b of the batteries such that the packaging members are in close proximity to the electrical terminals. In accordance with one aspect of the present disclosure, the packaging members 203 and 207 act as coolant sealants for the battery holder 204 to effectively retain the coolant during use of the battery module 100.

[0028] The coolant flows from the inlet manifold 205 towards the outlet manifold 206 in the battery holder assembly 204. The coolant absorbs the heat generated by the batteries 209 in the battery holder assembly 204. The coolant is a liquid coolant. In one embodiment, the coolant can be a phase change material that changes phase at an elevated temperature and solidifies at a lower temperature. The inlet manifold 205 and the outlet manifold 206 extend from the battery holder assembly 204 through the inlet opening 104 and the outlet opening 105, respectively, outside of the battery module 100. In one further embodiment, the outlet manifold 206 extending from the outlet opening 105 of the bottom cover 103 is connected to a heat sink. At the heat sink, the heated coolant from the outlet manifold 206 is cooled and stored in a reservoir tank for use in the next cycle of heat absorption from the batteries 209. The reservoir tank can be connected to the inlet manifold 205 extending from the inlet opening 104 of the bottom cover 103.

[0029] Figure 3 A top perspective view of the battery holder assembly 204 is exemplarily shown, which holds the batteries 209 as Figure 2The battery 209 of the battery module 100 is shown exemplarily. The battery holder assembly 204 includes battery holders, such as 301, for holding the batteries 209. As disclosed above, the coolant flows through the inlet manifold 205, fills the peripheral space around the batteries 209 in the battery holder 204, and exits from the outlet manifold 206. The coolant flows from the battery holder 301 of a battery, such as 202, to the battery holder of another battery 210, and further sequentially through until the battery 211, and exits from the outlet manifold 206. The packaging members, such as 203, seal the battery holder 301 at the collar portion of each battery, such as 202, of the battery to prevent leakage of the coolant from the collar portions at the top and bottom of the battery holder 301.

[0030] Figure 4 A partial exploded view of the battery holder assembly 204 is shown exemplarily, showing the packaging members 203 and 207 positioned in each of the battery holders, such as 301. The battery holders, such as 301, 302, 304, together form a placeholder assembly 303. As shown exemplarily, the battery holder 301 is a hollow tubular structure (not shown) open at both ends. The open ends allow insertion of the batteries, such as 202, therein. According to one embodiment, the battery holder 301 is hexagonal in outer periphery and circular in inner periphery. In one embodiment, the battery holder 301 can be cylindrical or rectangular in cross-section. The inlet manifold 205 extends from the first battery holder 301, and the outlet manifold 206 extends from the last battery holder 304. The coolant flows from the first battery holder 301 to the last battery holder 304 in the battery holder assembly 204. The packaging members 203 and 207 are positioned proximate to the ends of each of the battery holders, such as 301. The packaging members 203 and 207 are positioned at the collar portions of the ends 202a and 202b. Once the batteries, such as 202, are inserted into the battery holder 301, a pocket or vacant space is formed around the battery 202 in the battery holder 301. The battery 209 is shown exemplarily as a cylindrical battery. The battery 209 can be of any shape, such as rectangular, hexagonal, etc. Figure 2The battery holder 302 is hexagonal, as illustratively shown. The coolant fills the pocket in the battery holder 301. The ends 202a and 202b of the battery 209 protrude from the open ends of the battery holder 301. The collar regions of the battery holder 301 near the ends 202a and 202b of the battery 202 are sealed using the packing members 203 and 207. The packing members 203 and 207 seal the gap between the outer surface of the battery 202 at the collar regions near the ends 202a and 202b and the battery holder 301. The coolant filled in the pocket is sealed by the crimped seal joints formed at the collar regions of the battery so that no leakage occurs at the ends (i.e., 202a and 202b of the battery 209). In one embodiment, the packing members 203 and 207 are elastic washers of C cross-sectional profile that are seated in grooves formed at the collar regions near the ends 202a and 202b of the battery 202. In one embodiment, the packing members 203 and 207 are O-ring washers. The packing members 203 and 207 also prevent the battery 202 from moving in the battery holder 301 due to the flow of the coolant by tightly holding the battery 202 in the battery holder 301.

[0031] Figure 5 As illustratively shown Figure 2An exploded view of the battery holder assembly 204 of the battery module 100 is shown. The battery holder assembly 204 includes a placeholder assembly 303 with battery locking members 501 and 503 at the open ends 303a and 303b of the placeholder assembly 303. The open ends 301a and 301b of the battery holders (e.g., 301) together form the open ends 303a and 303b of the placeholder assembly 303. The inlet manifold 205 and the outlet manifold 206 extend from the first battery holder 301 and the last battery holder 304 of the placeholder assembly 303, respectively. In one embodiment, the battery locking members 501 and 503 can house the packaging members 203 and 207, respectively. In one embodiment, the battery locking members 501 and 503 are secured to the open ends 303a and 303b of the placeholder assembly 303 with screws or snaps. The battery locking members 501 and 503 are plate structures with a predetermined thickness, having openings (e.g., 502 and 504) to accommodate the ends 202a and 202b of the batteries (e.g., 202), respectively. The outer profile of the battery locking members 501 and 503 matches the outer profile of the placeholder assembly 303. According to one aspect of the present application, the battery locking members 501 and 503 have complementary holding groove profiles to enable the battery locking members 501, 503 to press-fit or self-align to the placeholder assembly 303. This hexagonal shape of the placeholder assembly 303 and the battery locking members 501, 503 has advantages such as connection stability, good mechanical performance, and ease of manufacturing. Compared to the circular shape of the battery holders 301, 302, 304, the hexagonal shape of the battery holders 301, 302, 304 provides more space for the coolant at the common spacing distance. The battery holder assembly 204 replicates a honeycomb structure when viewed from the top. In one embodiment, the packaging members 203 and 207 are integral parts of the circular cutouts 502 and 504 in the battery locking members 501 and 503, thus eliminating the need to insert the packaging members 203 and 207 at the ends 202a and 202b of the batteries 202 in the battery holders 301, respectively. In another embodiment, the battery locking members 501, 503 and the packaging members 203, 207 are integral parts of the battery holder assembly 204.

[0032] The coolant fills the first cell holder 301 from the inlet manifold 205, thereby surrounding the cells (e.g., 202) in the first cell holder 301. The first cell holder 301 and the second cell holder 302 are consecutive cell holders. The first cell holder 301 and the second cell holder 302 share a common dividing wall 305. The common dividing wall 305 includes an opening 306 for the coolant to flow from the first cell holder 301 to the second cell holder 302. The coolant now fills the pockets in the second cell holder 302 and further flows through the opening in the common dividing wall of the cell holders into the consecutive cell holders. According to one embodiment, the opening 306 in the common dividing wall 305 is formed near the bottom location or the top location of the cell holder 301. That is, the opening 306 is formed in the common dividing wall 305 at a location near one of the ends 301a and 301b of the cell holder 301. In one embodiment, the opening 306 is formed centrally in the common dividing wall 301. The consecutive cell holders 301 and 302 have the opening 306 at the bottom location or the top location for the coolant to rise from the bottom to the top in the pockets between the cells 202 and the walls of the cell holders 301.

[0033] Figures 6A-6B Exemplary plan and cross-sectional views of the placeholder assembly 303 are shown, illustrating the flow path of the coolant from the inlet manifold 205 to the outlet manifold 206. As shown in Figure 6A Exemplary, the placeholder assembly 303 is divided into even rows, such as six rows of cell holders (e.g., 301, 302, 304). Each row of cell holders witnesses the flow of coolant in one direction. In alternating rows, the direction of flow of the coolant is opposite. The opposite direction of flow of the coolant in alternating rows is due to the design of the opening 306 in the common dividing wall 305 between the cell holders. The flow of coolant in the cell holders is in the direction shown by the arrows in Figure 6A Exemplary, the flow path of the coolant in the first row of cell holders of the placeholder assembly 303. As shown, the coolant flows through the inlet manifold 205 into the cell holder 301 at the top location, fills the pocket of the cell holder 301, and exits the cell holder 301 through the opening 306 in the common dividing wall 305 of the cell holder 301 at the bottom location. In the cell holder 302, the coolant rises from the bottom to the top in the pocket and exits the cell holder 302 from the opening at the bottom location to the subsequent cell holder.

[0034] In Figure 6B Exemplary, the flow path of the coolant in the first row of cell holders of the placeholder assembly 303. As shown, the coolant flows through the inlet manifold 205 into the cell holder 301 at the top location, fills the pocket of the cell holder 301, and exits the cell holder 301 through the opening 306 in the common dividing wall 305 of the cell holder 301 at the bottom location. In the cell holder 302, the coolant rises from the bottom to the top in the pocket and exits the cell holder 302 from the opening at the bottom location to the subsequent cell holder.

[0035] Figure 7 A cross-sectional view of a battery module 100 is illustratively shown. As illustratively shown, the batteries 209 are positioned between the top cover 102 and the bottom cover 103. The batteries 209 are located in the battery holder assembly 204. The wrapping members 203 and 207 are positioned at the collar region 212, which is proximate to the end portions 202a and 202b of the batteries 202 held in the battery holder assembly 204. The collar region 212 of the battery holder 301 holds the wrapping members 203 and 207, which in turn hold the batteries 202 in a tight fit assembly to form a seal. The wrapping members 203 and 207 have a C-shaped cross-sectional profile that abuttingly extends inside and outside of the collar region 212 of the battery holder 301, with the middle portion of the wrapping members 203 and 207 abuttingly holding the outer periphery of each respective battery 202, and the outer periphery of the wrapping members 203 and 207 abutting the inner periphery of the collar region 212 of the battery holder 301. Coolant surrounds each battery 202 in the battery holder assembly 204 in the pockets 213. The wrapping members 203 and 207 seal the coolant from flowing out of the battery holder assembly 204. The coolant passes from one battery (e.g., 202) in the battery holder assembly 204 to another battery, thereby drawing heat from each of the batteries 209, and exits from the outlet manifold 206 in the battery holder assembly 204. The electrical terminals of the batteries 209 contact the interconnects 201 and 208.

[0036] Figure 8 A flowchart 800 is illustratively shown, which depicts a method including steps for assembling a battery module 100 as described above. Figure 2 The steps of the battery module 100 are illustratively shown. The method includes obtaining or organizing a plurality of batteries 209 at step 801. The batteries 209 are positioned in the battery holders (e.g., 301) of the battery holder assembly 204 at step 802. The battery holder assembly 204 includes an inlet manifold 205 and an outlet manifold 206 for flowing coolant through the battery holders (e.g., 301) for drawing heat generated by the batteries. The batteries 209 are sealed at each end portion in the battery holders (e.g., 301) with the wrapping members (e.g., 203 and 207) at step 803. Further, the housing 101 (having openings 104 and 105 for the inlet manifold 205 and the outlet manifold 206) is positioned to enclose the battery holder assembly 204 to obtain the battery module 100 at step 804.

[0037] Different embodiments of a battery module that draws heat from the batteries in the battery holder assembly with the help of a coolant make technical advancements in the field of thermal management of battery modules. The battery module uses a battery holder for containing the coolant and further flowing it towards the outlet manifold. The external infrastructure of coolant channels around the batteries is avoided, thus making the battery module lighter in weight, easy to assemble, maintain and replace. Also, the difference in the height of the inlet manifold and the outlet manifold in the battery holder assembly ensures that the coolant is further pushed in the battery holders arranged in sequence, thus avoiding the external pumping force to push the coolant. The coolant is in direct contact with the batteries in the battery holder, thus drawing heat steadily through convection. The work of packaging the battery module assembly to ensure efficient cooling by the coolant outside the housing, such as immersion cooling, is avoided. Heat is drawn from each of the batteries, thus maintaining the battery temperature at the desired temperature for the life of the battery module.

[0038] The packaging member across the battery prevents the flow of coolant outside the battery holder. The packaging member contracts or expands to efficiently pack the gap between the battery and the wall of the battery holder. The packaging member prevents the coolant from coming in contact with the terminals of the battery. Also, the coolant is preferably thermally conductive and electrically insulating in nature. The coolant can be a free-flowing liquid or a phase change material that does not chemically react with the battery holder, thus extending the life of the battery module.

[0039] This assembly of the battery module ensures efficient heat transfer between the battery and the coolant. The efficient dissipation of heat ensures thermal stability and durability of the battery module. The complete and tight packing of the batteries in the battery holder assembly makes the battery module mechanically stable, shock resistant and vibration proof. The elastic nature of the packaging member acts as a shock absorber for the batteries of the battery module.

[0040] Improvements and modifications can be incorporated herein without deviating from the scope of the application.

Claims

1. A battery module (100) for use in an electrical device, the battery module (100) comprising: a housing (101) comprising a top cover (102) and a bottom cover (103); a plurality of batteries (209) positioned between the top cover (102) and the bottom cover (103); and a battery holder assembly (204) comprising battery holders (301, 302, 304) for holding the plurality of batteries (209), wherein the plurality of batteries (209) are arranged in a predetermined order in the battery holder assembly (204), wherein the battery holder assembly (204) comprises an inlet manifold (205) and an outlet manifold (206) for flowing a coolant through the battery holders (301, 302, 304) for extracting heat generated by the plurality of batteries (209), wherein the coolant flows from the inlet manifold (205) and sequentially through the battery holders (301, 302, 304), wherein the coolant passes through the plurality of batteries (209) in the predetermined order, wherein the coolant extracts heat from the plurality of batteries (209) in the battery holders (301) and the coolant exits through the outlet manifold (206) in the battery holder assembly (204).

2. The battery module (100) of claim 1, wherein, Each battery holder of the battery holders (301) holds one battery of the plurality of batteries (209).

3. The battery module (100) of claim 1, wherein, Each battery holder of the battery holders (301) comprises an opening (306) for flowing the coolant around one battery of the plurality of batteries (209) in the each battery holder of the battery holders (301).

4. The battery module (100) of claim 3, wherein, The opening (306) of each battery holder of the battery holders (301) is formed proximate to one of a bottom location and a top location of the each battery holder of the battery holders (301).

5. The battery module (100) of claim 4, wherein, Consecutive battery holders (301, 302) of the battery holder assembly (204) comprise the opening (306) at the bottom location and the top location for the coolant to rise from the bottom to the top in each battery holder of the consecutive battery holders (301, 302).

6. The battery module (100) of claim 3, wherein, The opening (306) is formed in a common dividing wall (305) between consecutive battery holders (301, 302).

7. The battery module (100) of claim 1, wherein, The coolant flows from the inlet manifold (205) in the battery holder assembly (204) through the openings (306) in the battery holders (301, 302) sequentially in the battery holder assembly (204), extracts heat from the plurality of batteries (209) in the battery holders (301), and exits through the outlet manifold (206) in the battery holder assembly (204).

8. The battery module (100) of claim 1, wherein, The battery holder assembly (204) includes battery locking members (501, 503) having openings (502, 504) positioned at each end (301a and 301b) of the battery holder (301) of the battery holder assembly (204).

9. The battery module (100) as claimed in claim 8, further comprising packing members (203 and 207) positioned at collar regions (212) proximate to each end (202a and 202b) of each cell of the plurality of cells (209) for sealing the coolant at the ends (202a and 202b) of each cell of the plurality of cells (209).

10. The battery module (100) of claim 9, wherein, The packing members (203 and 207) are adjacently disposed in the battery locking members (501, 503).

11. The battery module of claim 9, wherein, The packing members (203 and 207) are integrally formed in the battery locking members (501, 503).

12. The battery module (100) as claimed in claim 1, further comprising interconnecting sheets (201, 208) in contact with each end (202a, 202b) of each cell of the plurality of cells (209).

13. The battery module (100) of claim 1, wherein, The inlet manifold (205) and the outlet manifold (206) are one of at same height and at different heights.

14. The battery module (100) of claim 1, wherein, The outlet manifold (206) extending from the outlet opening (105) of the bottom cover (103) is communicatively connected to a heat sink for effectively cooling the coolant.

15. A method of assembling a battery module (100) comprising the steps of: obtaining (step 801) a plurality of cells (209); positioning (step 802) the plurality of batteries (209) in a predetermined order in the battery holders (301) of the battery holder assembly (204), wherein, The battery holder assembly (204) includes an inlet manifold (205) and an outlet manifold (206) for flowing a coolant through the battery holder (301) to draw heat generated by the plurality of cells (209), wherein the coolant flows from the inlet manifold (205) and sequentially through the battery holders (301, 302, 304), wherein the coolant passes through the plurality of cells (209) in a predetermined order, wherein the coolant draws heat from the plurality of cells (209) in the battery holder (301) and the coolant exits through the outlet manifold (206) in the battery holder assembly (204); sealing (step 803) collar regions (212) proximate to each end (202a, 202b) of each cell of the plurality of cells (209) in the battery holder (301) by means of packing members (203, 207); and positioning (step 804) a housing (101) having openings (306) for the inlet manifold (205) and the outlet manifold (206) to enclose the battery holder assembly (204) to obtain the battery module (100).

16. The method of claim 15, wherein, positioning the plurality of batteries (209) in the battery holders (301) of the battery holder assembly (204) comprises the step of: positioning each battery of the plurality of batteries (209) in each battery holder (301) of the battery holder assembly (204), and positioning a battery locking member (501, 503) having an opening (502, 504) at each end (202a, 202b) of the each battery of the plurality of batteries (209), wherein the packaging member (203, 207) is adjacently arranged in the battery locking member (501, 503).

17. The method of claim 15, further comprising positioning an interconnect sheet (201, 208) in contact with each end (202a, 202b) of the each battery of the plurality of batteries (209).

18. The method of claim 15, wherein each battery holder (301) of the battery holder assembly (204) of the battery module (100) comprises an opening (306) for flowing the coolant around one battery of the plurality of batteries (209) in the each battery holder (301), wherein the opening (306) of each battery holder (301) is formed proximate to one of a bottom location and a top location of the each battery holder (301), wherein consecutive battery holders (301, 302) of the battery holder assembly (204) comprise the opening (306) at the bottom location and the top location for the coolant to rise from the bottom to the top in each battery holder of the consecutive battery holders (301, 302), and wherein the opening (306) is formed in a common partition wall (305) between the consecutive battery holders (301, 302).

19. A battery holder assembly (204) for holding a plurality of batteries (209), the battery holder assembly (204) comprising: a placeholder assembly (303) comprising a plurality of battery holders (301, 302) enclosing the plurality of batteries (209); a battery locking member (501, 503) having an opening (502, 504) positioned at each end (301a and 301b) of the battery holder (301); and an opening (306) in each of the battery holders (301) for flowing a coolant around one of the plurality of batteries (209) in the each of the battery holders (301), wherein the coolant flows from an inlet manifold (205) of the battery holder assembly (204) sequentially through the plurality of battery holders (301, 302) enclosing the plurality of batteries (209), wherein the coolant passes through the plurality of batteries (209) in a predetermined order, wherein the coolant extracts heat from the plurality of batteries (209) in the battery holder (301) and the coolant exits through an outlet manifold (206) in the battery holder assembly (204).

20. The battery holder assembly (204) of claim 19, wherein, An inner periphery of the each of the battery holders (301) has a circular cross-section and an outer periphery of the each of the battery holders (301) has a geometric shape.

21. The battery holder assembly (204) of claim 19, wherein The opening (306) of each of the battery holders (301) is formed proximate to one of a bottom location and a top location of the each of the battery holders (301), wherein the consecutive battery holders (301, 302) of the battery holder assembly (204) include the opening (306) at the bottom location and the top location for the coolant to rise from the bottom to the top in each of the consecutive battery holders (301, 302), and wherein the opening (306) is formed in a common partition wall (305) between the consecutive battery holders (301, 302).

22. The battery holder assembly (204) of claim 19, wherein, A packaging member (203 and 207) is positioned proximate to each end (202a and 202b) of each of the plurality of batteries (209) for sealing the coolant at the end (202a and 202b) of each of the plurality of batteries (209).

23. The battery holder assembly (204) of claim 22, wherein, The packaging member (203 and 207) is adjacently arranged in the battery locking member (501, 503).

24. The battery holder assembly (204) of claim 22, wherein, The packaging member (203 and 207) is integral with the spacer assembly (303).

25. The battery holder assembly (204) of claim 22, wherein, The packaging member (203 and 207) having a C-shaped cross-sectional profile is located in a groove at a collar region (212) proximate to the end (202a and 202b) of each of the plurality of batteries (209) to form a sealed joint.

26. The battery holder assembly (204) of claim 19, wherein, The battery locking member (501, 503) has a complementary holding groove profile to enable the battery locking member (501, 503) to be crimped onto an end of the spacer assembly (303).

27. The battery holder assembly (204) of claim 19, wherein, The battery locking member (501, 503) is integral with the spacer assembly (303).

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