Inverted battery pack assembly

Abstract

A rechargeable energy storage system for a vehicle includes: a bottom shear plate; and a side wall member having a bottom end connected to the bottom shear plate. A top shear plate is connected to a top end of the side enclosure, and a plurality of battery cells are suspended from a bottom of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate.

Description

Technical Field

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. The work of the presently named inventors, to the extent it is described in this section and in all aspects of the description that may not otherwise be considered prior art at the time of filing, is neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0003] The present disclosure relates to an inverted battery pack assembly for an electric vehicle. Background Art

[0004] The rechargeable energy storage system of an electric vehicle contains hundreds of battery cells, which weigh from 1,000 pounds for electric vehicles to nearly 3,000 pounds for electric trucks / SUVs. Although the entire battery pack is mounted to the vehicle floor structure, the huge weight and corresponding load of these battery cells are carried by load-bearing components in the rechargeable energy storage system structure. Typical engineering solutions to withstand such loads include hanging batteries or modules from rigid beams and / or bolting modules down to bottom shear plates. Both methods impose size or structural limitations that inhibit design optimization. Each battery module contains multiple battery cells. Summary of the invention

[0005] The present disclosure provides a novel inverted battery pack design and assembly sequence to connect the bottom of the battery cell to the top shear plate. This design largely engages the top rechargeable energy storage system structure to evenly distribute the battery cell weight, thereby opening up design space for the cross beam and bottom shear plate and improving the serviceability of the rechargeable energy storage system.

[0006] According to aspects of the present disclosure, a rechargeable energy storage system for a vehicle includes: a bottom shear plate; and a side enclosure having a bottom end connected to the bottom shear plate. A top shear plate is connected to a top end of the side enclosure, and a plurality of battery cells are suspended from the bottom of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate.

[0007] According to a further aspect, the top shear panel is a vehicle floor panel.

[0008] According to a further aspect, the corresponding mating features include a threaded protrusion on one of the plurality of battery cells and the shear plate, and a threaded aperture on the other of the plurality of battery cells and the shear plate.

[0009] According to a further aspect, the corresponding mating features include a protrusion on the plurality of battery cells and an aperture on the shear plate, wherein one of the protrusion and the aperture includes a resilient retention feature.

[0010] According to a further aspect, the resilient retention feature includes a pair of rails that engage recesses in the protruding portion.

[0011] According to a further aspect, the corresponding mating features include flanges on the plurality of battery cells and grooves on the shear plate for receiving the flanges of the plurality of battery cells.

[0012] According to a further aspect, the plurality of battery cells have electrode terminals and venting facing the bottom shear plate.

[0013] According to another aspect of the present disclosure, an electric vehicle includes: a vehicle body supported by a plurality of wheels; and a rechargeable energy storage system located below the vehicle body. The rechargeable energy storage system includes a bottom shear plate. The side enclosure includes a bottom end connected to the bottom shear plate. A top shear plate is connected to a top end of the side enclosure. A plurality of battery cells are suspended from the bottom of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate.

[0014] According to another aspect of the present disclosure, a method of assembling a rechargeable energy storage system into a vehicle includes connecting a side enclosure member to a first shear plate. Connecting mating features of a plurality of battery cells to corresponding mating features of the first shear plate, and connecting a second shear plate to the side enclosure member to form an enclosed housing. Inverting the enclosed housing so that the second shear plate is located on a bottom of the battery housing and the plurality of battery cells are suspended from the bottom of the first shear plate. The battery housing is then assembled into a vehicle body.

[0015] The present invention at least includes the following technical solutions:

[0016] Solution 1. A rechargeable energy storage system for a vehicle, the rechargeable energy storage system comprising:

[0017] Bottom shear plate;

[0018] a side wrapping member having a bottom end connected to the bottom shear panel;

[0019] a top shear panel connected to a top end of the side wrapping member; and

[0020] A plurality of battery cells are suspended from a bottom portion of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate.

[0021] Option 2. A rechargeable energy storage system according to Option 1, wherein the top shear plate is a vehicle floor.

[0022] Option 3. A rechargeable energy storage system according to Option 1, wherein the corresponding mating features include threaded protrusions on one of the plurality of battery cells and the shear plate, and threaded openings on the other of the plurality of battery cells and the shear plate.

[0023] Option 4. A rechargeable energy storage system according to Option 1, wherein the corresponding mating features include protrusions on the plurality of battery cells and holes on the shear plate, wherein one of the protrusions and the holes includes an elastic retention feature.

[0024] Option 5. A rechargeable energy storage system according to Option 4, wherein the resilient retention feature includes a pair of ledges that engage recesses in the protrusion.

[0025] Option 6. A rechargeable energy storage system according to Option 1, wherein the corresponding mating features include flanges on the plurality of battery cells and grooves on the shear plate for receiving the flanges of the plurality of battery cells.

[0026] Option 7. A rechargeable energy storage system according to Option 1, wherein the plurality of battery cells have electrode terminals facing the bottom shear plate.

[0027] Solution 8. An electric vehicle, comprising:

[0028] a vehicle body, the vehicle body being supported by a plurality of wheels,

[0029] A rechargeable energy storage system supported by the vehicle body and comprising:

[0030] Bottom shear plate;

[0031] a side wrapping member having a bottom end connected to the bottom shear panel;

[0032] a top shear plate connected to a top end of the side enclosure member;

[0033] a plurality of battery cells suspended from a bottom of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate; and

[0034] One of a mesh panel or a continuous panel is located directly below the plurality of battery cells and connected to the side enclosure members.

[0035] Option 9. An electric vehicle according to Option 8, wherein the top shear plate is a vehicle floor.

[0036] Option 10. An electric vehicle according to Option 8, wherein the corresponding mating features include threaded protrusions on one of the plurality of battery cells and the shear plate, and threaded holes on the other of the plurality of battery cells and the shear plate.

[0037] Option 11. An electric vehicle according to Option 8, wherein the corresponding mating features include protrusions on the plurality of battery cells and holes on the shear plate, wherein one of the protrusions and the holes includes an elastic retention feature.

[0038] Embodiment 12. The electric vehicle of embodiment 11, wherein the resilient retention feature comprises a pair of ledges that engage recesses in the protruding portion.

[0039] Option 13. An electric vehicle according to Option 8, wherein the corresponding mating features include flanges on the plurality of battery cells and grooves on the shear plate for receiving the flanges of the plurality of battery cells.

[0040] Option 14. The electric vehicle according to Option 8, wherein the plurality of battery cells have electrode terminals and vents facing the bottom shear plate.

[0041] Embodiment 15. A method of assembling a rechargeable energy storage system into a vehicle, the method comprising:

[0042] connecting the side enclosure members to the first shear panel;

[0043] connecting mating features of a plurality of battery cells to corresponding mating features of the first shear plate;

[0044] connecting a second shear panel to the side wrapping members to form an enclosed shell;

[0045] inverting the enclosed housing so that the second shear plate is located on a bottom of the battery housing and the plurality of battery cells are suspended from a bottom of the first shear plate; and

[0046] The battery housing is assembled into a vehicle body.

[0047] Option 16. A method of assembling a rechargeable energy storage system according to Option 15, wherein the first shear plate is a floor of the vehicle.

[0048] Option 17. A method for assembling a rechargeable energy storage system according to Option 15, wherein the corresponding mating features include threaded protrusions on one of the plurality of battery cells and the shear plate, and threaded openings on the other of the plurality of battery cells and the shear plate.

[0049] Option 18. A method for assembling a rechargeable energy storage system according to Option 15, wherein the corresponding mating features include protrusions on the plurality of battery cells and holes on the shear plate, wherein one of the protrusions and the holes includes an elastic retention feature.

[0050] Option 19. A method for assembling a rechargeable energy storage system according to Option 15, wherein the corresponding mating features include flanges on the plurality of battery cells and grooves on the shear plate for receiving the flanges of the plurality of battery cells.

[0051] Option 20. A method for assembling a rechargeable energy storage system according to Option 15, wherein the plurality of battery cells have electrode terminals facing the second shear plate.

[0052] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The present disclosure will become more fully understood from the detailed description and accompanying drawings, in which:

[0054] Figure 1A illustrates the assembly of side enclosure members to the top shear panels of a rechargeable energy storage system according to the principles of the present disclosure;

[0055] Figure 1B illustrates the assembly of a battery cell to a top shear plate of an energy storage system according to the principles of the present disclosure;

[0056] Figure 1C illustrates a battery unit with a panel mounted thereto in accordance with the principles of the present disclosure;

[0057] Figure 1D illustrates the assembly of a bottom shear plate of a rechargeable energy storage system according to the principles of the present disclosure;

[0058] Figure 1E illustrates an inversion of a rechargeable energy storage system according to the principles of the present disclosure;

[0059] Figure 1F An inverted rechargeable energy storage system in a vehicle according to the principles of the present disclosure is illustrated;

[0060] Figure 2A illustrates a press-fit feature for mounting a battery cell to a top shear plate in accordance with the principles of the present disclosure;

[0061] Figure 2B illustrates an alternative press-fit feature for mounting a battery cell to a top shear plate in accordance with the principles of the present disclosure;

[0062] Figure 2C illustrates a screw-in mating feature for mounting a battery cell to a top shear plate in accordance with the principles of the present disclosure;

[0063] Figure 2D illustrates a slide-in fit feature for mounting a battery cell to a top shear plate in accordance with the principles of the present disclosure; and

[0064] Figure 3 is a schematic cross-sectional view of a rechargeable energy storage system.

[0065] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0066] refer to Figures 1A-1E , a process for assembling an inverted rechargeable energy storage system 10 for a vehicle 12 will be described. Figure 1A As shown in FIG. 1 , the top shear plate 14 of the rechargeable energy storage system 10 is positioned with the bottom surface facing upward, and the side enclosure members 16 are mounted to the bottom surface 14a of the top shear plate 14. The side enclosure members 16 can be mounted to the top shear plate 14 in whole or in part. Figure 1B As shown in , a plurality of battery cells 18 are mounted to the bottom surface 14a of the top shear plate 14 using corresponding mating features. Figure 1C As shown in FIG. 1 , the panel 20 is mounted to the installed battery cells 18. The panel 20 can include busbars for connecting to the terminals on the plurality of battery cells. The panel 20 can be a continuous plate or a mesh plate. It is connected to the side enclosures to protect the battery from falling off the top shear plate during service. Figure 1D As shown in FIG. 1 , the bottom shear plate 22 is fixed to the side enclosure member 16 to form a sealed enclosed rechargeable energy storage system 10. Figure 1E As shown in , the rechargeable energy storage system is inverted so that the battery cells 18 are suspended from the bottom surface of the top shear plate 14. Figure 1F As shown in FIG. 1 , the inverted rechargeable energy storage system 10 is installed in a vehicle 12 by mounting the rechargeable energy storage system to the body or frame of the vehicle 12. The top shear panel 14 can optionally serve as the floor of the passenger compartment of the vehicle 12.

[0067] refer to Figure 2A, shows a first exemplary press-fit feature 30, 32 for mounting a battery cell 18 to a top shear plate 14 according to the principles of the present disclosure. In particular, the shear plate 14 includes a plurality of openings 30 that can include resilient features 34, such as spring-biased ledges 34a, 34b on opposite sides of the openings 30. The plurality of battery cells 18 further include one or more protruding features 32 that can define a rim having a recessed area 36 that can receive the spring-biased ledges 34a, 34b to retain the protruding features 32 within the openings 30. It should be noted that the resilient features 34 can be in alternative forms to releasably engage the protruding features 32.

[0068] refer to Figure 2B , a second exemplary press-fit feature 40, 42 for mounting a battery cell 18 to a top shear plate 14 according to the principles of the present disclosure is shown. In particular, the shear plate 14 includes a plurality of openings 40, which can include ribs 44. The plurality of battery cells 18 further include one or more protruding features 42, which can define a flexible flange 46 that can be inserted over the ribs 44 and expand to retain the protruding features 42 within the openings 40. It should be noted that the flexible flange 46 can take alternative forms to releasably engage the protruding features 42.

[0069] refer to Figure 2C , a third exemplary screw-in mating feature 50, 52 for mounting a battery cell 18 to a top shear plate 14 according to the principles of the present disclosure is shown. In particular, the shear plate 14 includes a plurality of openings 50, which can include a threaded surface or a bayonet surface. The plurality of battery cells 18 further include one or more protruding features 52, which can define a threaded surface or a bayonet surface that can be rotatably engaged with the threaded surface or the bayonet surface to retain the protruding features 52 within the openings 50.

[0070] refer to Figure 2D , a third exemplary slide-in mating feature 60, 62 for mounting a battery cell 18 to a top shear plate 14 according to the principles of the present disclosure is shown. In particular, the shear plate 14 includes a plurality of slots 60, which can include pairs of ribs. The plurality of battery cells 18 further include flanges 62 that can be slidably received in the slots to hold the battery cell 18 to the top shear plate 14.

[0071] Figure 3is a schematic partial cross-sectional view of the rechargeable energy storage system 10 showing the battery cells 18 suspended below the top shear plate 14 with the electrode tabs 70 of the battery cells engaging the panel 20. The bottom shear plate 22 encloses the rechargeable energy storage system 10.

[0072] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because other modifications will become apparent when studying the drawings, the specification and the following claims. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in any of the other embodiments and / or combined with the features of any of the other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the arrangement of one or more embodiments to each other is still within the scope of the present disclosure.

[0073] Spatial and functional relationships between elements (e.g., between modules, battery cells, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "immediately adjacent," "on top of," "above," "below," and "disposed." Unless explicitly described as "directly," when describing a relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship in which no other intervening elements exist between the first element and the second element, but can also be an indirect relationship in which one or more intervening elements exist (either spatially or functionally) between the first element and the second element. As used herein, the phrase at least one of A, B, and C should be interpreted to mean a logical (A or B or C) using a non-exclusive logical or, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

Claims

1. A rechargeable energy storage system for a vehicle, the rechargeable energy storage system comprising: Bottom shear plate; a side wrapping member having a bottom end connected to the bottom shear panel; a top shear plate connected to a top end of the side enclosure member; as well as A plurality of battery cells are suspended from a bottom portion of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate.

2. The rechargeable energy storage system according to claim 1, wherein: The top shear panel is the vehicle floor.

3. The rechargeable energy storage system according to claim 1, wherein: The corresponding mating features include a threaded protrusion on one of the plurality of battery cells and the shear plate, and a threaded aperture on the other of the plurality of battery cells and the shear plate.

4. The rechargeable energy storage system according to claim 1, wherein: The corresponding mating features include a protrusion on the plurality of battery cells and an aperture on the shear plate, wherein one of the protrusion and the aperture includes a resilient retention feature.

5. The rechargeable energy storage system according to claim 4, wherein: The resilient retention feature includes a pair of ledges that engage recesses in the projection.

6. The rechargeable energy storage system according to claim 1, wherein: The corresponding mating features include flanges on the plurality of battery cells and grooves on the shear plate for receiving the flanges of the plurality of battery cells.

7. The rechargeable energy storage system according to claim 1, wherein: The plurality of battery cells have electrode terminals facing the bottom shear plate.

8. An electric vehicle, comprising: a vehicle body, the vehicle body supporting a plurality of wheels, A rechargeable energy storage system supported by the vehicle body and comprising: Bottom shear plate; a side wrapping member having a bottom end connected to the bottom shear panel; a top shear plate connected to a top end of the side enclosure member; a plurality of battery cells suspended from a bottom of the top shear plate by corresponding mating features that secure the plurality of battery cells to the top shear plate; and One of a mesh panel or a continuous panel is located directly below the plurality of battery cells and connected to the side enclosure members.

9. The electric vehicle according to claim 8, wherein: The top shear panel is the vehicle floor.

10. The electric vehicle according to claim 8, wherein: The corresponding mating features include a threaded protrusion on one of the plurality of battery cells and the shear plate, and a threaded aperture on the other of the plurality of battery cells and the shear plate.

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