Battery module and method of assembling the same, battery pack, vehicle, related carrier and device

Abstract

The present disclosure provides a battery module and its assembling method, a battery pack, a vehicle, a related carrier and device. The present disclosure relates to a battery module (12) comprising: a plurality of battery cells (20); at least one cell carrier (30, 30.1, 30.2, 30.3, 30.4); and a battery management module (21), wherein the at least one cell carrier (30, 30.1, 30.2, 30.3, 30.4) comprises a plurality of cell holders (31), wherein each cell holder (31) is adapted to hold one of the plurality of battery cells (20) in a form-locked manner, wherein the battery management module (21) is arranged within at least two of the plurality of cell holders (31).

Description

Technical Field

[0001] This disclosure relates to battery modules for electric vehicles. It also relates to battery packs including battery modules, electric vehicles including battery packs, battery management module (BMM) carriers, BMM arrangements, and methods for assembling battery modules. Background Technology

[0002] In recent years, vehicles using electricity as a power source for transporting goods and people have been developed. Such electric vehicles are automobiles powered by electric motors using energy stored in rechargeable batteries. Electric vehicles can be powered solely by batteries, or they can be hybrid vehicles powered by, for example, gasoline generators or hydrogen fuel cell power sources. Furthermore, vehicles can include a combination of electric motors and conventional internal combustion engines. Typically, electric vehicle batteries (EVBs), or traction batteries, are batteries used to power the propulsion of battery electric vehicles (BEVs). Electric vehicle batteries differ from starter batteries, lighting batteries, and ignition batteries because they are designed to provide power for a continuous period of time. Rechargeable or secondary batteries differ from primary batteries in that they can be repeatedly charged and discharged, while the latter only provides an irreversible conversion of chemical energy into electrical energy. Low-capacity rechargeable batteries are used as power sources for small electronic devices such as mobile phones, laptops, and cameras, while high-capacity rechargeable batteries are used as power sources for electric vehicles and hybrid vehicles.

[0003] Rechargeable batteries can be used as battery modules formed by connecting multiple unit battery cells in series and / or parallel to provide high energy capacity, particularly for electric motor drives in hybrid vehicles. That is, depending on the required power, battery modules are formed by interconnecting the electrode terminals of multiple unit battery cells to achieve high-power rechargeable batteries.

[0004] Battery modules can be constructed using either a block design or a modular design. In a block design, each battery cell is connected to a common current collector structure and a common battery management system, and its components are arranged within a housing. In a modular design, multiple battery cells are connected to form sub-modules, and several sub-modules are connected to form a battery module. In automotive applications, battery systems typically consist of multiple battery modules connected in series to provide a desired voltage. A battery module may include sub-modules with multiple stacked battery cells, each stack comprising either cells connected in series first and then in parallel (XpYs) or multiple cells connected in parallel first and then in series (XsYp).

[0005] A battery pack is a group of any number (preferably identical) battery modules. They can be configured in series, parallel, or a combination of both to provide a desired voltage, capacity, or power density. The components of a battery pack include the individual battery modules and the interconnections that provide conductivity between them.

[0006] The battery system also includes a battery management system (BMS), which is any electronic system that manages rechargeable batteries, battery modules, and battery packs, such as by protecting batteries from operation outside their safe operating area, monitoring their status, calculating secondary data, reporting that data, controlling their environment, validating them, and / or balancing them. For example, a BMS can monitor the state of a battery, which is represented by: voltage (such as the total voltage of the battery pack or battery module, or the voltage of individual cells), temperature (such as the average temperature of the battery pack or battery module, the coolant inlet temperature, the coolant outlet temperature, or the temperature of individual cells), coolant flow (such as flow rate, coolant pressure), and current. In addition, the BMS can calculate the following values ​​based on the above items, such as minimum and maximum cell voltage, state of charge (SOC) or depth of discharge (DOD) indicating the battery's charge level, state of health (SOH; a measurement of the battery's remaining capacity for various definitions, as a percentage of its original capacity), state of power (SOP; the amount of electricity available within a defined time interval, taking into account current power usage, temperature, and other conditions), state of safety (SOS), maximum charging current as charge current limit (CCL), maximum discharging current as discharge current limit (DCL), and the cell's internal impedance (used to determine the open-circuit voltage).

[0007] A Battery Management System (BMS) can be centralized, where a single controller is connected to the battery cells via multiple wires. A BMS can also be distributed, where the BMS board is installed at each cell, with only one communication cable between the battery and the controller. Alternatively, a BMS can be a modular construction comprising several controllers, each handling a certain number of cells and communicating with each other. Centralized BMSs are the most economical but least scalable and suffer from the inconvenience of multiple wires. Distributed BMSs are the most expensive, simplest to install, and offer the cleanest components. Modular BMSs offer a trade-off between the characteristics and problems of the other two topologies.

[0008] A Battery Management System (BMS) protects the battery pack from operating outside its safe operating area. Overcurrent, overvoltage (during charging), overtemperature, undertemperature, overpressure, and ground fault or leakage current detection may indicate operation outside the safe operating area. The BMS can prevent operation outside the battery's safe operating area by including internal switches (such as relays or solid-state devices that open if the battery is operating outside its safe operating area), requiring devices connected to the battery to reduce or even terminate their use of the battery, and actively controlling the environment (such as through heaters, fans, air conditioning, or liquid cooling).

[0009] The mechanical integration of such a battery system requires appropriate mechanical connections between the various components, such as between the battery cells, BMS, and housing. These connections must remain functional and undamaged throughout the average lifespan of the battery system. Furthermore, installation space and interchangeability requirements must be met, especially in mobile applications.

[0010] Regardless of the modular structure, existing battery systems typically include a battery casing, which serves as an enclosure to seal the battery system relative to the environment and provide structural protection for the components of the battery system. Battery systems with casings are usually installed as a whole into their application environment (e.g., electric vehicles). Therefore, replacing a defective system component (e.g., a defective battery sub-module) requires disassembling the entire battery system and removing its casing. Even defects in small and / or inexpensive system components can further lead to the disassembly and replacement of the entire battery system and its individual repair. This process proves cumbersome due to the high cost, size, and weight of high-capacity battery systems, and makes storing bulky battery systems, for example, difficult in a mechanic's workshop.

[0011] To meet the dynamic power demands of various electrical devices connected to the battery system, static control of battery power output and charging is insufficient. Therefore, stable information exchange between the controllers of the battery system and the electrical devices is necessary. This information includes the battery system's actual state of charge (SoC), potential electrical performance, charging capacity, and internal impedance, as well as the actual or predicted power demand or remaining capacity of the electrical devices. Therefore, a battery system typically includes a Battery Management System (BMS) for acquiring and processing this information at the system level, and multiple Battery Module Managers (also known as Battery Management Modules, BMMs) that are part of the battery modules and acquire and process relevant information at the module level. Specifically, the BMS typically measures system voltage, system current, local temperatures at different locations within the system housing, and insulation resistance between live components and the system housing. Furthermore, the BMM typically measures the individual cell voltage and temperature of the battery cells within the battery module.

[0012] Therefore, the BMS / Battery Management Unit (BMU) provides functions for managing the battery pack, such as protecting the battery from operation outside its safe operating area, monitoring its status, calculating secondary data, reporting that data, controlling its environment, validating it, and / or balancing it.

[0013] In current battery packs with cylindrical cells (which have an axis in the Z direction), the battery management system is placed inside the battery module on top or side, especially when placed on top, resulting in a loss of critical packaging space in the Z direction.

[0014] DE102017011717A1 discloses an energy storage device for a vehicle, having a housing in which a plurality of individual units are arranged, wherein a unit monitoring unit is arranged in another housing located between the individual units in the housing and forming a force-absorbing element. The disclosed energy storage device provides mechanical stability by integrating the unit monitoring unit into the unit block, because the unit monitoring unit can be manipulated like a single unit during assembly. If, for example, the unit monitoring unit and its other housing are arranged centrally relative to the unit block, the unit monitoring unit can be considered a so-called module divider. Therefore, in the event of damage and / or replacement, half of the units, i.e., the individual units arranged to the left or right of the unit monitoring unit, must be removed. Thus, to remove the unit monitoring unit (e.g., for maintenance and / or repair), it is typically necessary to remove a plurality of individual units.

[0015] EP3273500A1 discloses a battery system comprising eight cell monitoring circuits and eighteen battery modules, each battery module comprising two sub-modules. Each sub-module comprises a stack of prismatic battery cells. One cell monitoring circuit is sufficient for two battery modules. Therefore, two battery modules corresponding to a stack of four battery cells are connected to a single cell monitoring circuit. Summary of the Invention

[0016] This invention is defined by the claims. The following description is subject to this limitation. Any disclosure outside the scope of the claims is intended for illustrative and comparative purposes only.

[0017] According to one aspect of this disclosure, a battery module includes: a plurality of battery cells; at least one cell carrier; and a battery management module (BMM), wherein the at least one cell carrier includes a plurality of cell holders, wherein each cell holder is adapted to hold one of the plurality of battery cells in a form-locking manner, and wherein the BMM is disposed within at least two of the plurality of cell holders.

[0018] According to another aspect of this disclosure, a battery pack is provided, the battery pack comprising a plurality of battery modules as described above.

[0019] Another aspect of this disclosure relates to an electric vehicle comprising at least one battery module as described above and / or at least one battery pack as described above.

[0020] Another aspect of this disclosure relates to a BMM carrier adapted to hold a BMM within at least two adjacent cell holders of at least one cell carrier for a battery module.

[0021] Another aspect of this disclosure relates to a BMM device comprising: at least two BMMs; a collector circuit board adapted to electrically connect the at least two BMMs to one or more battery cells; and an adapter mounted to the collector circuit board, wherein the adapter is adapted to be arranged in a form-locking manner within a cell holder of a cell carrier.

[0022] Another aspect of this disclosure relates to a method for assembling a battery module as described above, wherein the method includes the steps of: a) providing a plurality of battery cells, at least one cell carrier, and at least one battery management module (BMM), wherein the at least one cell carrier includes a plurality of cell holders, wherein each cell holder is adapted to hold one of the plurality of battery cells in a shape-locking manner; and b) arranging the at least one BMM within at least two of the plurality of cell holders.

[0023] Further aspects of this disclosure may be learned from the dependent claims or the following description. Attached Figure Description

[0024] Features will become apparent to those skilled in the art from the detailed description of exemplary embodiments with reference to the accompanying drawings, in which:

[0025] Figure 1 A schematic diagram of an electric vehicle according to an embodiment of the present invention is shown.

[0026] Figure 2 A cross-sectional view of a battery module according to an embodiment of the present invention is shown.

[0027] Figure 3 A perspective view of a battery module according to an embodiment of the present invention is shown.

[0028] Figure 4 A top view of a battery module and collector circuit board according to an embodiment of the present invention is shown.

[0029] Figure 5A perspective view and a semi-transparent view of a BMM carrier carrying a battery management module according to an embodiment of the present invention are shown.

[0030] Figure 6 A perspective view of a BMM device according to an embodiment of the present invention is shown.

[0031] Figure 7 A perspective view of a battery pack according to an embodiment of the present invention is shown.

[0032] Figure 8 A perspective view showing the cell carrier and multiple battery cells is shown.

[0033] Figure 9 A perspective view of the unit components is shown.

[0034] Figure 10A and Figure 10B A schematic top view of multiple adjacently arranged unit carriers is shown. Detailed Implementation

[0035] The embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. The effects and features of the exemplary embodiments and their implementation methods will be described with reference to the drawings. In the drawings, the same reference numerals denote the same elements, and redundant descriptions are omitted.

[0036] Overall concept

[0037] According to one aspect of this disclosure, a battery module includes: a plurality of battery cells; at least one cell carrier; and a battery management module (BMM). The at least one cell carrier includes a plurality of cell holders. Each cell holder is adapted to hold one of the plurality of battery cells in a shape-locking manner, for example by providing a cavity therein for holding the battery cell. Therefore, the at least one cell carrier is adapted to hold the plurality of battery cells.

[0038] The Battery Module (BMM) is arranged within at least two of the plurality of cell holders. In other words, the BMM is held by the same cell carrier as the battery cell. Specifically, the BMM is held by two of the cell holders, each of which can also be used to hold one of the plurality of battery cells. Since the holders used to hold the battery cells also house the BMM, it is not necessary to provide separate holders or retainers for securing the BMM within the battery module. Therefore, the BMM is housed in a space-saving manner between the battery cells and within the battery module. The packaged and optimized BMM is placed within the existing cell carrier, thus saving space and also enabling additional cost savings, as the manufacture of such a battery module can be performed more efficiently than in the prior art. Arranging the BMM within at least two of the cell holders means that the BMM is positioned close to the battery cell, which can facilitate the electrical connection between the BMM and the battery cell.

[0039] Optionally, the BMM is arranged in a shape-locking manner within at least two of the plurality of unit retainers to efficiently and reliably install the BMM within at least one unit retainer.

[0040] Optionally, the battery module includes a BMM carrier adapted to hold the BMM within at least two cell holders. The BMM carrier is adapted to be disposed within at least two of the cell holders and to hold the BMM therein. Therefore, the BMM can have any shape suitable for being held by the BMM carrier. For example, the BMM may include a printed circuit board and electrical connectors held within the BMM carrier. Although such printed circuit boards and electrical connectors would be difficult to mount to at least one cell holder, the BMM carrier has a shape that matches the at least two cell holders for shape-locking placement therein. Therefore, the shape matching of the BMM carrier with the at least two cell holders facilitates shape-locking placement of the BMM within the at least one cell holder.

[0041] Optionally, the BMM carrier is arranged in two or more adjacent cell holders. This embodiment enables the BMM to have an extension in one direction greater than the extension of the battery cell (e.g., the diameter of one of the battery cells). For example, the BMM may include a printed circuit board having an extension greater than the diameter of each (optionally) cylindrical battery cell. Adjacent cell holders are connected to each other, allowing the BMM carrier to be arranged within adjacent cell holders. The BMM carrier may carry the printed circuit board, which is thus arranged within the adjacent cell holders. For example, the BMM carrier is arranged in two adjacent cell holders in a form-locking manner as described above.

[0042] Optionally, each battery cell is cylindrical, and each cell holder is at least partially cylindrical and / or includes a cylindrical through-hole. The cylindrical shape allows for efficient and simple arrangement of the cylindrical battery cells within the cell holder, which can provide a cylindrical cavity for receiving the battery cells. The cylindrical through-hole enables efficient mounting of the battery cells by inserting them into the through-hole at one end, wherein the battery cells are connectable at opposite ends of the through-hole, for example, to provide electrical connection. Optionally or additionally, the cell holder may have the shape of a cylindrical segment and / or adjacent cell holders may be connected to each other, particularly adjacent cell holders within a row. Optionally, each cell holder includes an annular protrusion to prevent movement of the battery cells and / or BMM held therein.

[0043] Optionally, the battery module includes a removable bottom cover, and the BMM is removably disposed within the at least two cell holders to enable simple and efficient maintenance and / or replacement of the BMM. After removing the bottom cover, the BMM can be removed, for example, by pulling the BMM out from the at least two holders in which the BMM is disposed.

[0044] Optionally, the battery module includes an adapter and a collector circuit board. The collector circuit board is adapted to electrically connect the BMM to one or more battery cells, wherein the adapter is mounted to the collector circuit board and arranged in a form-locking manner within one of the cell holders. The adapter is mounted to the collector circuit board to fix the position of the collector circuit board relative to the adapter. The adapter is arranged within one of the cell holders to be held therein. Thus, the collector circuit board is held in a fixed position relative to the cell carrier within the battery module. This embodiment can hold the collector circuit board in a space-saving manner because the adapter is held within one of the cell holders. The collector circuit board can be formed from a printed circuit board (i.e., a flat arrangement of electronic components that occupies only a minimal amount of mounting space in the z-direction). Optionally, the adapter is cylindrical, thus being held in a form-locking manner within one of the cell holders.

[0045] Optionally, the battery module includes two or more battery motherboards (BMMs), and a collector circuit board is adapted to electrically connect each battery cell to one of the BMMs. In this embodiment, the two or more BMMs can be held efficiently and space-savingly by a cell carrier, which is particularly useful if cylindrical battery cells are used in the battery module, as the number of electrical connections to one of the BMMs may require two or more BMMs for electrically interconnecting each battery cell to one of the BMMs. To electrically connect each battery cell to one of the BMMs, the collector circuit board may include an electrical connector, and interconnection devices can be connected to the electrical connector, wherein the interconnection devices (e.g., via a current collector structure such as a busbar) electrically interconnect the collector circuit board to each battery cell.

[0046] Optionally, the plurality of cell holders are arranged in a hexagonal pattern and / or in zigzag rows, such that multiple adjacent rows form a hexagonal arrangement of cell holders. A hexagonal pattern can also be referred to as a honeycomb pattern. A hexagonal pattern means that the cell holders consist of six adjacent cell holders of the cell carrier and / or battery module arranged in a regular pattern. The hexagonal arrangement of the cell holders allows for a particularly space-saving construction of the battery module.

[0047] Optionally, the battery module includes multiple cell carriers, each of which is stackable, and the battery module is constructed from the stacked cell carriers. That is, the cell carriers are shaped and / or adapted to be arranged adjacent to each other without leaving any empty main structural space. For example, an effective arrangement of cell holders can mean that adjacent cell carriers can be arranged adjacent to each other in a stacked manner without leaving gaps between the battery cells held within the cell holders. Optionally, the cell carriers include mechanical connecting members adapted to guide adjacent cell carriers during manufacturing, such that adjacent cell carriers are effectively arranged adjacent to each other and adapted to mechanically hold adjacent cell carriers adjacent to each other in the installed state. This enables adjacently arranged cell carriers to be arranged adjacent to each other in a stacked manner to provide a modular construction of the battery module and contribute to the efficient installability of the battery module. The BMM is arranged within at least two of the cell holders of one of the multiple cell carriers and / or within the cell holders of two adjacently arranged cell carriers. That is, the BMM can be held by a cell holder of a single cell carrier, while adjacent cell carriers hold only battery cells, or the BMM can be held by cell holders of adjacent cell carriers. By allowing different possibilities for arranging cell carriers, battery cells, and BMMs for mounting battery modules, this enables highly variable possibilities for mounting battery modules.

[0048] According to another aspect of this disclosure, a battery pack is provided that includes a plurality of battery modules as described above. In other words, the battery pack includes a plurality of battery modules, each battery module including at least one cell carrier having a plurality of cell holders, wherein the battery module (BMM) is held within at least two of the plurality of cell holders. This allows for a space-saving construction of the battery pack. The battery pack and / or the battery modules of the battery pack may include any of the optional features mentioned above to achieve any of the technical effects mentioned above.

[0049] Another aspect of this disclosure relates to an electric vehicle comprising at least one battery module as described above and / or at least one battery pack as described above. In other words, the electric vehicle includes multiple battery modules, each battery module comprising at least one cell carrier having multiple cell holders, wherein the battery module (BMM) is held within at least two of the multiple cell holders. This allows for a space-saving design. The electric vehicle and / or the battery module mounted therein may include any of the optional features mentioned above to achieve any of the technical effects mentioned above.

[0050] Another aspect of this disclosure relates to a BMM carrier adapted to hold a BMM within at least two adjacent cell holders of at least one cell carrier for a battery module. Optionally, the BMM carrier includes a housing made of plastic. Optionally, the housing includes two cylindrical carrier portions, each cylindrical carrier portion adapted to be held in a cell holder. The BMM carrier enables the holders for holding battery cells to be used to accommodate the BMM as described above. Therefore, it is not necessary to provide separate holders or retainers for securing the BMM inside the battery module. Thus, the BMM can be accommodated in a space-saving manner between battery cells and within the battery module. The BMM carrier may include the optional features described above with reference to the BMM carrier to achieve the aforementioned technical effects of the features.

[0051] Another aspect of this disclosure relates to a BMM device comprising: at least two BMMs; a collector circuit board adapted to electrically connect the at least two BMMs to one or more battery cells; and an adapter mounted to the collector circuit board, wherein the adapter is adapted to be arranged in a form-locking manner within a cell holder of a cell carrier. The BMM device is adapted to be mounted in a battery module. The adapter retains the adapter within the battery cell holder, thus the BMM device remains fixed in the battery module. Optionally, the BMM device includes a BMM carrier for each of the at least two BMMs, wherein each BMM carrier is adapted to retain the BMM within at least two adjacent cell holders of the cell carrier. The BMM device and its components may include the optional features described above to achieve the aforementioned technical effects of the features.

[0052] Another aspect of this disclosure relates to a method for assembling a battery module as described above, wherein the method includes the steps of: a) providing a plurality of battery cells, at least one cell carrier, and at least one battery management module (BMM), wherein the at least one cell carrier includes a plurality of cell holders, wherein each cell holder is adapted to hold one of the plurality of battery cells in a shape-locking manner; and b) arranging the at least one BMM within at least two of the plurality of cell holders. This method provides a battery module as described above. The method can be adapted such that the assembled battery module includes the optional features mentioned above. Detailed Implementation

[0054] Figure 1 A schematic diagram of an electric vehicle 300 according to an embodiment of the present invention is shown. The electric vehicle 300 is driven by an electric motor 310 using energy stored in rechargeable batteries arranged in a battery pack 10. The battery pack 10 is a group of any number of battery modules 12. The rechargeable batteries serve as battery modules 12 formed by a plurality of secondary battery cells 20. The components of the battery pack 10 include individual battery modules 12 and interconnections 301 providing conductivity between the battery modules 12. Each battery module 12 includes a battery cell 20.

[0055] Figure 2 A cross-sectional view of a battery module 12 according to an embodiment of the present invention is shown.

[0056] The battery module 12 includes a unit carrier 30, and the unit carrier 30 includes a plurality of unit holders 31. The plurality of unit holders 31 are arranged in a hexagonal pattern, as shown in... Figure 10B Shown and referenced in Figure 10B Specifically, multiple unit holders 31 are arranged in zigzag rows such that multiple adjacent rows form a hexagonal arrangement of unit holders 31. Optionally, the unit carrier 30 is made of a polymer to provide a lightweight unit carrier 30 for efficient manufacturing.

[0057] Each cell holder 31 is adapted to hold one of the battery cells 20 in a shape-locking manner. Each battery cell 20 is cylindrical (without...). Figure 2 (As shown in the diagram), and each cell holder 31 is cylindrical. The shape of the battery cell 20 matches the shape of the cell holder 31 in the sense that the battery cell 20 can be held in a shape-locking manner by the cell holder 31. Each cell holder 31 includes a cylindrical through-hole into which one of the battery cells 20 can be inserted to be held in the cell holder 31. Each cell holder 31 includes a protrusion 34 to prevent movement of the battery cell 20 held therein. The protrusion 34 is annular to effectively reduce the diameter of the through-hole and / or the cell holder 31.

[0058] Battery module 12 includes two battery management modules 21, abbreviated as BMM 21. Each BMM 21 is arranged in one of two cell holders 31. In this specific embodiment, the BMM 21 is arranged in the same zigzag row of the cell carrier 30 and in two pairs 32a, 32b of adjacent cell holders 31 in the same zigzag row. The cell holders 31 between the two pairs 32a, 32b of adjacent cell holders 31 hold an adapter 23, which is referenced to... Figure 6 Further details. The two pairs 32a, 32b of adjacent unit holders 31 are connected pairs of unit holders 31. That is, the unit carrier 30 is shaped such that each of the unit holders 31 in the two pairs 32a, 32b is a cylindrical segment, wherein the circumferential portion of one unit holder 31 in each pair of the two pairs 32a, 32b is open to connect to the other unit holder 31 in each pair.

[0059] The battery module 12 includes two BMM carriers 24 adapted to hold a BMM 21 within a cell holder 31. Specifically, the battery module 12 includes one BMM carrier 24 for each BMM 21. Using the BMM carriers 24, the BMM 21 is arranged in a shape-locked manner within the cell holder 31. Each BMM carrier 24 is adapted to hold a printed circuit board 26 of one of the BMMs 21. The BMM carriers 24 are made of polymer. The printed circuit board 26 of each BMM 21 is arranged in one of two pairs 32a, 32b of the cell holder 31. Optionally, the plastic BMM carriers 24 are held to the cell carrier 30 (not shown) using a plastic clip system. The BMM carriers 24 are related to... Figure 5 Further details.

[0060] A BMM 21, having the same shape as the battery cell 20 along with the BMM carrier 24, can be placed between the cell stacks formed by the battery cells 20. This is similar to a modular battery module 12 (e.g., comprising multiple...). Figure 8 and Figure 9 As shown and referenced Figure 8 and Figure 9 The combination of the battery module 12 with the unit carrier 30 has the advantage that it is not necessary to produce separate components to hold the BMM 21 in the battery module 12.

[0061] Figure 3 A perspective view of a battery module 12 according to an embodiment of the present invention is shown.

[0062] Battery module 12 includes, for example Figure 2 As shown and as referenced Figure 2The unit carrier 30 is described. Two BMMs 21 are shown below the unit carrier 30. The BMMs 21 can be mounted to the unit carrier 30 by inserting the BMMs 21 and the BMM carrier 24 into the unit holder 31 as indicated by the dashed lines.

[0063] Battery module 12 includes a collector circuit board 22 adapted to electrically connect each battery cell 20 to one of the BMMs 21. Battery module 12 includes interconnecting devices 25 and a plurality of busbars 41. The interconnecting devices 25 include flat flexible cables (FFCs), and the collector circuit board 22 includes flexible printed circuits (FPCs). The interconnecting devices 25 are electrically connected to the collector circuit board 22 electrically connected to the BMMs 21, as shown in reference. Figure 6 Explanation: Interconnection device 25 extends through battery module 12 to electrically interconnect collector circuit board 22 with each busbar 41. Busbar 41 is adapted and arranged to electrically interconnect a plurality of battery cells 20 with each other and with collector circuit board 22 via interconnection device 25. Specifically, each busbar 41 electrically interconnects battery cells 20 in a zigzag row with each other. Thus, each of the plurality of battery cells 20 is electrically interconnected with one of BMM 21. BMM 21 is mounted by inserting BMM 21 and BMM carrier 24 into pairs 32a, 32b of adjacent cell holders 31 arranged below collector circuit board 22.

[0064] The battery cell 20 is a cylindrical cell with a diameter of at least 30 mm (optionally at least 32 mm). Optionally, the diameter of the cell holder 31 is at least 30 mm, and optionally at least 32 mm. This allows battery cells 20 of similar diameter to be held in the cell holder 31 and provides sufficient space to arrange the BMM 21 within the cell holder 31.

[0065] Figure 4 A top view of a battery module 12 and a collector circuit board 22 according to an embodiment of the present invention is shown.

[0066] The illustration of the battery module 12 and collector circuit board 22 together with the interconnect device 25 shows the arrangement of pairs 32a, 32b of adjacent cell holders 31 in which the BMM 21 will be arranged. Another cell holder 31 is arranged between the two pairs 32a, 32b of the adjacent cell holders 31. In this cell holder 31 (i.e., the cell holder 31 arranged between the two pairs 32a, 32b of the adjacent cell holders 31), the cell holders 31 will be... Figure 6 As shown and referenced Figure 6 The adapter 23 is used to mount the collector circuit board 22 to the battery module 12.

[0067] In this embodiment, the battery module 12 includes two adjacently arranged unit carriers 30.1 and 30.2. The unit carriers 30.1 and 30.2 are stackable to form a configuration as shown in the reference diagram. Figure 8 and Figure 9 The modular battery module 12, as schematically indicated, includes pairs 32a, 32b of adjacent cell holders 31 where the BMM 21 is arranged, which are included by the cell carrier 30.1. The cell carrier 30.2, which is arranged adjacent to the cell carrier 30.1 (which has pairs 32a, 32b of adjacent cell holders 31 where the BMM 21 is arranged), includes only battery cells 20.

[0068] Figure 5 An embodiment of the invention is shown and as follows Figure 2 and Figure 3 As shown and referenced Figure 2 and Figure 3 Perspective view and semi-transparent view of the BMM carrier 24 that carries the battery management module 21.

[0069] BMM carrier 24 is adapted to hold BMM 21 within two adjacent cell holders 31 of cell carrier 30 for battery module 12. BMM carrier 24 includes a housing made of plastic. The housing includes two cylindrical carrier portions 28a, 28b, each carrier portion adapted to be held in one of the cell holders 31. The carrier portions 28a, 28b have a diameter that matches the diameter of the cell holder 31, in the sense that the carrier portions 28a, 28b can be held in a shape-locking manner within the cell holder 31.

[0070] BMM 21 includes a printed circuit board 26 (indicated by dashed lines) having an electrical connector 27. The printed circuit board 26 is held within the BMM carrier 24 such that the electrical connector 27 is connectable. The printed circuit board 26 extends from one of the carrier portions 28a through the BMM carrier 24 to the other carrier portion 28b.

[0071] Figure 6 A perspective view of a BMM device 33 according to an embodiment of the present invention is shown. The BMM device 33 includes two BMMs 21, a collector circuit board 22 adapted to electrically connect the two BMMs 21 to a plurality of battery cells 20, and an adapter 23 mounted to the collector circuit board 22. Figure 6 The BMM device 33 shown has at least partially been... Figures 1 to 5 Shown or referenced in Figures 1 to 5 illustrate.

[0072] The adapter 23 is adapted to be arranged in a form-locking manner within the cell holder 31 of the cell carrier 30. In this embodiment, the adapter 23 is schematically shown as a cylinder. The adapter 23 has a diameter that matches the diameter of the cell holder 31, in order to be held in a form-locking manner within the cell holder 31. The adapter 23 is mounted to the collector circuit board 22 to ensure that if the adapter 23 is mounted to the cell holder 31, the collector circuit board 22 remains fixed within the battery module 12. The adapter 23 may be hollow to hold electrical components.

[0073] Collector circuit board 22 has a symmetrical shape, with adapter 23 mounted centrally relative to collector circuit board 22. Collector circuit board 22 has two outwardly extending portions at which electrical connectors 27 of BMM 21 can be connected. The outwardly extending portions of collector circuit board 22 are arranged such that printed circuit board 26 can be arranged in two pairs 32a, 32b of adjacent cell holders 31, and thus BMM 21 can be arranged in two pairs 32a, 32b of adjacent cell holders 31.

[0074] Collector circuit board 22 includes interconnect connector 29, which is used for electrical interconnection such as Figure 3 and Figure 4 As shown and referenced Figure 3 and Figure 4 The collector circuit board 22 and interconnection device 25 are described. The collector circuit board 22 is adapted to be connected to two printed circuit boards 26 via electrical connectors 27.

[0075] Optionally, the BMM device 33 includes, as referenced Figure 5 The description refers to the two BMM carriers 24 used to hold each printed circuit board 26.

[0076] Figure 7 A perspective view of a battery pack 10 according to an embodiment of the present invention is shown.

[0077] Battery pack 10 includes multiple components as shown in the reference. Figures 1 to 6 The battery module 12 is described above. The battery pack 10 includes a removable cover that provides a removable bottom cover 42 for the battery module 12. Each BMM 21 is removably arranged in two within the cell holders 31 of the cell carrier 30 of the battery module 12.

[0078] A method for assembling a battery module 12 included in a battery pack 10 includes the following steps: providing a plurality of battery cells 20, a cell carrier 30, and two battery module units (BMMs) 21; and arranging the two BMMs 21 within a cell holder 31 of the cell carrier 30. Electrical interconnection of the components is achieved by attaching (e.g., soldering) interconnecting devices 25 to busbars 41 of the cell stack and connecting the interconnecting devices 25 to a collector circuit board 22. Subsequently, the BMMs 21 within a plastic carrier 24 are connected from the bottom to empty battery slots (i.e., cell holders 31). Electrical connectors 27 of the BMMs 21 are thus attached to corresponding connectors on the collector circuit board 22.

[0079] Figure 8 A perspective view of the unit carrier 30 and multiple battery units 20 is shown. Figure 8 The unit carrier 30 shown can be used to assemble the battery module 12 according to the present invention.

[0080] The unit carrier 30 includes two zigzag ribs 133a and 133b spaced apart from each other. The unit carrier 30 is made of a polymer, therefore the zigzag ribs 133a and 133b are also made of a polymer.

[0081] The cell carrier 30 includes a first plurality of cell holders 31a and a second plurality of cell holders 31b, wherein each of the cell holders 31a and 31b is adapted to hold the battery cell 20 in a shape-locking manner. Each of the first and second plurality of cell holders 31a and 31b includes five cell holders.

[0082] The zigzag ribs 133a and 133b define the cell holders 31a and 31b, meaning that the surfaces of the cell holders 31a and 31b are formed by the zigzag ribs 133a and 133b. The zigzag ribs 133a and 133b provide the cell holders 31a and 31b in the form of cavities for accommodating the battery cell 20.

[0083] The first plurality of unit holders 31a of the unit carrier 30 are arranged between two zigzag ribs 133a and 133b. The two zigzag ribs 133a and 133b are arranged and shaped such that the first plurality of unit holders 31a are zigzagly arranged between the two zigzag ribs 133a and 133b. The first plurality of unit holders 31a are arranged in a first zigzag row.

[0084] Each of the two zigzag ribs 133a and 133b extends substantially within the main extension plane of the respective rib 133a and 133b, wherein the zigzag (i.e., undulating) ribs 133a and 133b extend alternately to either of the two opposite sides relative to the main extension plane. Each of the two zigzag ribs 133a and 133b has a width that varies periodically along the two zigzag ribs 133a and 133b, thereby forming the unit retainers 31a and 31b in a zigzag, undulating manner.

[0085] The second plurality of unit holders 31b is arranged opposite to the first plurality of unit holders 31a and is separated from the first plurality of unit holders 31a by one of at least two bend ribs 133a. That is, the second plurality of unit holders 31b is separated from the first plurality of unit holders 31a by the first bend rib 133a. Therefore, the second plurality of unit holders 31b is arranged in a second bend row separated from the first bend row by the first bend rib 133a.

[0086] Each of the first plurality of unit holders 31a and the second plurality of unit holders 31b is arranged in a zigzag row, such that rows of multiple adjacent arrangements form a reference. Figure 10B The hexagonal arrangement of the unit holders 31a and 31b is described in detail. Therefore, the unit holders 31a and 31b are arranged in a hexagonal pattern.

[0087] Each of the cell holders 31a and 31b is cylindrical and includes a cylindrical through-hole or a portion thereof. Specifically, each of the first plurality of cell holders 31a includes a through-hole, and each of the second plurality of cell holders 31b is formed by a cylindrical segment and includes a corresponding opening in the form of a through-hole. Each of the cell holders 31a and 31b includes a protrusion 34 to prevent movement of the battery cell 20 and / or BMM 21 held therein, particularly along the axis of their cylinder. Each protrusion 34 is annular to effectively reduce the diameter of the corresponding through-hole and / or cell holder 31a, 31b. Specifically, each protrusion 34 of the first plurality of cell holders 31a is O-ring shaped (without an O-ring). Figure 8 (As shown in the figure), each protrusion 34 of the second plurality of unit holders 31b is formed as a segment of a ring.

[0088] The first plurality of unit holders 31a includes a plurality of connected unit holders 31a. That is, the unit carrier 30 is shaped such that each of the first plurality of unit holders 31a is shaped as a cylindrical segment, wherein the circumferential portion of each unit holder 31a is openly connected to the adjacent unit holders 31a of the first plurality of unit holders 31a. Thus, the first plurality of unit holders 31a includes a zigzag row of interconnected unit holders 31a.

[0089] Similarly, the second plurality of unit holders 31b includes a plurality of interconnected unit holders 31b. That is, the unit carrier 30 is shaped such that each of the second plurality of unit holders 31b is shaped as a cylindrical segment, wherein the circumferential portion of each unit holder 31b is openly connected to the adjacent unit holders 31b of the second plurality of unit holders 31b. Thus, the second plurality of unit holders 31b includes a zigzag row of interconnected unit holders 31b.

[0090] The cell carriers 30 are stackable, so that the battery module 12 can be constructed from stacked cell carriers 30.

[0091] The unit carrier 30 includes an even number of unit holders 31a and 31b, that is, the unit carrier 30 includes an odd number of first unit holders 31a and an odd number of second unit holders 31b. The unit carrier includes a total of 10 unit holders 31a and 31b.

[0092] Each battery cell 20 has a cylindrical shape. The shape of the battery cell 20 matches the shape of the unit holders 31a and 31b in the sense that the battery cell 20 can be held and secured within the unit holders 31a and 31b. The battery cells 20 can be mounted to the unit carrier 30 by inserting them along their respective cylindrical axes into the unit holders 31a and 31b. Each of the unit holders 31a and 31b includes a protrusion 34, which is sized to prevent movement of the battery cell 20 through the unit holders 31a and 31b. To improve the securing of the battery cell 20 within the unit holders 31a and 31b, the battery module 12 may include an adhesive. The adhesive may be applied to the surfaces defining the unit holders 31a and 31b and / or to the protrusions 34.

[0093] Figure 9 A perspective view of unit component 36 is shown. (As shown) Figure 9 The unit component 36 shown can be used to assemble the battery module 12 according to the present invention.

[0094] Unit component 36 includes, for example Figure 8 As shown and referenced Figure 8 The unit carrier 30, the plurality of battery units 20 as described above, and the busbar 41.

[0095] The plurality of battery cells 20 are arranged as shown in reference. Figure 8 In the unit holders 31a and 31b of the unit carrier 30.

[0096] The plurality of battery cells 20 are electrically interconnected by busbars 41 welded to the battery cells 20 to electrically interconnect the battery cells 20 with each other.

[0097] The busbar 41 includes a plurality of connecting members 43, each connecting member 43 being adapted and arranged to be electrically connected to a terminal of one of the battery cells 20 held by a first plurality of cell holders 31a. The connecting members 43 are arranged in zigzag rows corresponding to the zigzag rows in which the first plurality of cell holders 31a are arranged.

[0098] The busbar 41 includes a cover portion 44 adapted and arranged to connect to a plurality of battery cell housings (also referred to as housings) of the battery cell 20. The cover portion 44 is arranged in a zigzag manner to correspond to a zigzag row in which a second plurality of cell holders 31b are arranged.

[0099] In this example, a 5p connection is designed as shown, in which 10 battery cells 20 are placed in a plastic cell carrier 30, and a busbar 41 is welded such that its cover portion 44 is at a negative potential on the shoulder of one row (i.e., on the battery cells 20 held by the second plurality of cell holders 31b), and the connecting member 43 is at the positive terminal of another row (i.e., on the battery cells 20 held by the first plurality of cell holders 31a).

[0100] Multiple such as Figure 9 The unit components 36 shown can be stacked together to form, as shown in the figure. Figure 3 As shown and referenced Figure 3 The battery module 12.

[0101] Figure 10A and Figure 10B The basis for showing multiple adjacent arrangements Figure 8 Schematic top views of unit carriers 30, 30.1, 30.2, 30.3, and 30.4 in the embodiment. Unit carriers 30, 30.1, 30.2, 30.3, and 30.4 are as follows: Figure 8 As shown and referenced Figure 8 Those described in detail. Figure 10B The diagram shows a hexagonal arrangement of the first cell holders 31a, 31a.1, 31a.2, 31a.3, 31a.4 and the second cell holders 31b, 31b.1, 31b.2, 31b.3, 31b.4 that hold the battery cells 20.

[0102] For reference, such as Figure 8 The unit holder 30 shown is in Figure 10A The diagram is shown in a schematic top view. For simplicity, the protrusion 34 of the unit carrier 30 is not shown in this diagram.

[0103] Figure 10BFour unit carriers 30.1, 30.2, 30.3, and 30.4 are shown arranged adjacent to each other. For simplicity, the protrusion 34 of unit carrier 30 is not shown in this illustration. For each of unit carriers 30.1, 30.2, 30.3, and 30.4, only one of the first unit holders 31a.1, 31a.2, 31a.3, and 31a.4 and one of the second unit holders 31b.1, 31b.2, 31b.3, and 31b.4 are indicated. To distinguish the adjacent unit carriers 30.1, 30.2, 30.3, and 30.4 from each other, unit carriers 30.1, 30.2, 30.3, and 30.4 are alternately indicated with solid lines or dashed lines.

[0104] For example, regarding unit carrier 30.2, each first unit holder 31a.2 is indicated by a circle with a solid line, and each second unit holder 31b.2 is indicated by a circle with a half-solid line. Still considering unit carrier 30.2, each first unit holder 31a.2 is arranged in a zigzag row, and each second unit holder 31b.2 is arranged in a zigzag row. The first unit holders 31a.2 and second unit holders 31b.2 are separated from each other by zigzag ribs 133a.2. The first unit holders 31a.3 and second unit holders 31b.3 of adjacent unit carrier 30.3, indicated by dashed lines, are separated from each other by zigzag ribs 133a.3. The second unit holders 31b.1 and first unit holders 31a.1 of adjacent unit carrier 30.1, indicated by dashed lines, are separated from each other by zigzag ribs 133a.1. The above considerations can be similarly repeated for any of unit carriers 30.1, 30.2, 30.3, and 30.4.

[0105] For illustrative purposes, boundary B is indicated, which represents a portion of the outer contour of the four unit carriers 30.1, 30.2, 30.3, and 30.4. Unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, and 31b.4, which are not adjacent to the boundary B of the adjacent unit carriers 30.1, 30.2, 30.3, and 30.4, are arranged in a hexagonal pattern, i.e., each of the unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, and 31b.4 has six adjacent unit holders.

[0106] Hexagon H is indicated by a dashed line to show the hexagonal pattern in which unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, and 31b.4 are arranged. Hexagon H does not physically exist, but only indicates the arrangement of unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, and 31b.4. The hexagon H at this specific location indicates the second unit holder 31b.3 of the unit carrier 30.3, which is arranged at the center of the hexagon H and has six adjacent unit holders 31a.2, 31a.3, and 31b.3, namely, the three first unit holders 31a.2 of the adjacent unit carrier 30.2, one first unit holder 31a.3 of the unit holder 30.3, and two second unit holders 31b.3 of the unit holder 30.3. The above considerations can be similarly repeated for any of the unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, and 31b.4 that are not adjacent to the boundary B of the adjacent unit carriers 30.1, 30.2, 30.3, and 30.4.

[0107] Therefore, except for the unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, 31b.4 at the boundary B of the unit carriers 30.1, 30.2, 30.3, 30.4, each of the first plurality of unit holders 31a.1, 31a.2, 31a.3, 31a.4 and the second plurality of unit holders 31b.1, 31b.2, 31b.3, 31b.4 is arranged in a zigzag row, such that the plurality of adjacent rows form a hexagonal arrangement of the unit holders 31a.1, 31a.2, 31a.3, 31a.4, 31b.1, 31b.2, 31b.3, 31b.4.

[0108] Figure Labels

[0109] 10 battery packs

[0110] 12 Battery Modules

[0111] 20 battery cells

[0112] 21 Battery Management Module (BMM)

[0113] 22 Collector Circuit Board

[0114] 23 Adapter

[0115] 24 BMM carrier

[0116] 25 Interconnection devices

[0117] 26 Printed circuit board

[0118] 27 Electrical connector

[0119] 28a, 28b Carrier part

[0120] 29 Interconnecting connector

[0121] 30, 30.1, 30.2, 30.3, 30.4 Unit carrier

[0122] 31, 31a, 31b Unit holder

[0123] 32a, 32b Pair of adjacent unit holders

[0124] 33 BMM device

[0125] 34 Projection

[0126] 36 Unit assembly

[0127] 41 Bus bar[[ID=�2]]

[0128] 42 Bottom cover

[0129] 43 Connecting member

[0130] 44 Cover part

[0131] 31a, 31a.1, 31a.2, 31a.3, 31a.4 First unit holder

[0132] 31b, 31b.1, 31b.2, 31b.3, 31b.4 Second unit holder

[0133] 133a, 133a.1, 133a.2, 133a.3, 133a.4 Zigzag rib

[0134] 133b, 133b.1, 133b.2, 133b.3, 133b4 Zigzag rib

[0135] 300 Vehicle

[0136] 301 Interconnection

[0137] 310 Electric motor

[0138] B Boundary

[0139] H Hexagon

Claims

1. A battery module, comprising: a plurality of battery cells; at least one cell carrier; and a battery management module, wherein the at least one cell carrier comprises a plurality of cell holders, wherein each of the cell holders is adapted to hold one of the plurality of battery cells in a form-locked manner, wherein the battery management module is arranged in a form-locked manner within at least two of the cell holders.

2. The battery module according to claim 1, wherein the battery module comprises a battery management module carrier adapted to hold the battery management module within the at least two cell holders.

3. The battery module according to claim 2, wherein the battery management module carrier is arranged in two or more adjacent cell holders.

4. The battery module according to claim 1, wherein each of the battery cells is cylindrical in shape, and each of the cell holders is at least partially cylindrical in shape and / or comprises a cylindrical through-hole.

5. The battery module according to claim 1, wherein the battery module comprises a removable bottom cover, and the battery management module is removably arranged within the at least two cell holders.

6. The battery module according to claim 1, wherein the battery module comprises an adapter and a collector circuit board adapted to electrically connect the battery management module with one or more of the plurality of battery cells, and the adapter is mounted to the collector circuit board and arranged in a form-locked manner within one of the plurality of cell holders.

7. The battery module according to claim 6, wherein the battery module comprises two or more battery management modules, and the collector circuit board is adapted to electrically connect each of the battery cells with one of the battery management modules.

8. The battery module according to claim 1, wherein the plurality of cell holders is arranged in a hexagonal pattern, and / or the plurality of cell holders is arranged in zigzag rows, such that a plurality of adjacently arranged rows form a hexagonal arrangement of cell holders.

9. The battery module according to claim 1, wherein the battery module comprises a plurality of the cell carriers, each of which is stackable, the battery module is built from stacked cell carriers, and the battery management module is arranged within at least two of the cell holders of one of the plurality of cell carriers and / or within cell holders of two adjacently arranged cell carriers.

10. A battery pack comprising a plurality of battery modules according to any one of the preceding claims.

11. An electric vehicle comprising a battery module according to any one of claims 1 to 9 and / or a battery pack according to claim 10.

12. A battery management module carrier adapted to hold a battery management module in a form-locked manner within at least two adjacent cell holders of at least one cell carrier for a battery module.

13. A battery management module arrangement, comprising: at least two battery management modules; a collector circuit board adapted to electrically connect the at least two battery management modules with one or more battery cells; and a battery management module carrier adapted to hold the at least two battery management modules in a form-locked manner within at least two adjacent cell holders of at least one cell carrier for a battery module. ​ an adapter mounted to the collector circuit board, wherein the adapter is adapted to be arranged in a form-locked manner within a cell holder of a cell carrier, wherein each of the battery management modules is arranged in a form-locked manner within at least two cell holders of the cell carrier.

14. A method for the assembly of a battery module according to claim 1, wherein the method comprises the following steps: a) providing a plurality of battery cells, at least one cell carrier and at least one battery management module, wherein the at least one cell carrier comprises a plurality of cell holders, wherein each of the cell holders is adapted to hold one of the plurality of battery cells in a form-locked manner; and b) arranging the at least one battery management module in a form-locked manner within at least two of the plurality of cell holders.

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