Mechanically connected cell-to-cell energy storage array

Abstract

The invention relates to a mechanically connected cell-to-cell energy storage array. A modular multi-cell rechargeable energy storage system (RESS) includes a RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a track structure. The RESS also includes a plurality of mechanically interconnected battery cell blocks disposed in the RESS enclosure. Each battery cell block includes a cell cartridge having at least one interface connector configured to couple the cell cartridge to the track structure such that each battery cell block engages and is aligned and supported by the track structure.

Description

Technical Field

[0001] The present disclosure relates to mechanically connected cell-to-cell arrays for multi-cell rechargeable energy storage systems. Background Art

[0002] Batteries can be broadly divided into primary batteries and secondary batteries. Primary batteries, also called disposable batteries, are intended to be used until exhausted, after which they are simply replaced with new batteries. Secondary batteries, more commonly called rechargeable batteries, employ specific chemical compositions that allow such batteries to be repeatedly recharged and reused, thus offering economic, environmental, and ease-of-use advantages over disposable batteries. A multi-cell rechargeable energy storage system (RESS) typically includes an array of battery cells, such as a battery module, battery pack, etc., with a plurality of secondary battery cells relatively close to each other.

[0003] Large RESS can be used to store electrical energy for future use and act as a buffer between peak power generation and peak system loads, such as in stationary energy storage systems and electric vehicles (EVs). To meet design targets for charging rate, peak output power, and capacity, secondary batteries can be organized into battery systems or arrays in which battery cells are connected in parallel and / or in series and are encapsulated in battery modules and / or battery pack housings. Such RESS typically includes a housing for housing individual battery cells and various internal components, such as cold plates, thermal insulation elements, interconnect boards (ICBs) for linking battery cells, sensing and communication components, and electrical bus bars to establish connections between them. Summary of the invention

[0004] A modular multi-cell rechargeable energy storage system (RESS) includes a RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a track structure. The RESS also includes a plurality of mechanically interconnected battery cell blocks arranged in the RESS enclosure. Each battery cell block includes a cell box having at least one interface connector, the at least one interface connector being configured to couple the cell box to the track structure such that each battery cell block engages with, is aligned with, and is supported by the track structure.

[0005] The track structure may be mounted to the enclosure tray and / or the enclosure cover.

[0006] The track structure may comprise a plurality of parallel guide tracks.

[0007] The interface connector(s) may be configured to slidably engage the parallel guide rails.

[0008] Each interface connector may have a U-shaped, C-shaped, or L-shaped cross-section configured to engage the parallel guide rails.

[0009] In cross-section, each of the parallel guide rails may have a convex rail surface.

[0010] In cross-sectional view, each of the parallel guide tracks may have a concave track surface.

[0011] Each interface connector may be a protrusion configured to slidably engage a recessed track surface of one of the parallel guide tracks.

[0012] The protrusion may be configured to snap into the recessed track surface.

[0013] Each interface connector may have one of an integrally formed feature of the battery box and a bracket attached to the battery box.

[0014] Each battery cell block may additionally include an interlocking flange mounted to the cell box and configured to interconnect adjacent cell blocks. At least one of the interlocking flanges of each battery cell block may incorporate an interface connector to couple the cell box to the rail structure.

[0015] Each battery cell block may be one of a prismatic cell and a cylindrical cell.

[0016] The RESS enclosure may be part of, ie integrated into, the vehicle's main structure.

[0017] Also disclosed is a motor vehicle having a power source and the modular RESS disclosed above, the modular RESS being configured to provide electrical energy to the power source.

[0018] The present invention provides the following technical solutions.

[0019] Technical solution 1. A modular multi-cell rechargeable energy storage system (RESS), comprising:

[0020] A RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a track structure; and

[0021] a plurality of interconnected battery cell blocks, the plurality of interconnected battery cell blocks being arranged in the RESS enclosure;

[0022] Each battery cell block includes a cell box having at least one interface connector, wherein the at least one interface connector is configured to connect the cell box to the track structure so that each battery cell block is engaged with, aligned with, and supported by the track structure.

[0023] Technical Solution 2. A modular RESS according to Technical Solution 1, wherein the track structure is mounted to at least one of the enclosure tray and the enclosure cover.

[0024] Technical Solution 3. A modular RESS according to Technical Solution 1, wherein the track structure comprises a plurality of parallel guide tracks.

[0025] Technical Solution 4. A modular RESS according to Technical Solution 3, wherein the at least one interface connector is configured to slidably engage the parallel guide rails.

[0026] Technical Solution 5. A modular RESS according to Technical Solution 3, wherein, in a cross-sectional view, each of the parallel guide rails has a convex rail surface.

[0027] Technical Solution 6. A modular RESS according to Technical Solution 3, wherein, in a cross-sectional view, each of the parallel guide rails has a concave rail surface.

[0028] Technical Solution 7. A modular RESS according to Technical Solution 6, wherein each interface connector is a protrusion configured to slidably engage the recessed track surface of one of the parallel guide tracks.

[0029] Technical Solution 8. A modular RESS according to Technical Solution 7, wherein the protrusion is configured to snap into the recessed track surface.

[0030] Technical Solution 9. A modular RESS according to Technical Solution 1, wherein each interface connector is one of an integrally formed feature of the battery box and a bracket attached to the battery box.

[0031] Technical Solution 10. A modular RESS according to Technical Solution 1, wherein each battery cell block further comprises an interlocking flange, which is mounted to the battery box and is configured to interconnect adjacent battery cell blocks, and wherein at least one of the interlocking flanges of each battery cell block is combined with the interface connector to connect the battery box to the rail structure.

[0032] Technical Solution 11. A motor vehicle, comprising:

[0033] a power source configured to generate a power source torque;

[0034] A vehicle body structure incorporating as a portion thereof a modular multi-cell rechargeable energy storage system (RESS), the modular multi-cell rechargeable energy storage system (RESS) being configured to supply electrical energy to the power source, the modular RESS comprising:

[0035] A RESS enclosure, the RESS enclosure being surrounded by an external environment, integrated into the vehicle body structure, and having an enclosure tray, an enclosure cover, and a rail structure; and a plurality of interconnected battery cell blocks disposed in the RESS enclosure;

[0036] Each battery cell block includes a cell box having at least one interface connector, wherein the at least one interface connector is configured to connect the cell box to the track structure so that each battery cell block is engaged with, aligned with, and supported by the track structure.

[0037] Technical Solution 12. The motor vehicle according to Technical Solution 11, wherein the track structure is mounted to at least one of the enclosure pallet and the enclosure cover.

[0038] Technical Solution 13. A motor vehicle according to Technical Solution 11, wherein the track structure includes a plurality of parallel guide tracks.

[0039] Technical Solution 14. A motor vehicle according to Technical Solution 13, wherein the at least one interface connector is configured to slidably engage the parallel guide rails.

[0040] Technical Solution 15. A motor vehicle according to Technical Solution 13, wherein, in a cross-sectional view, each of the parallel guide rails has a convex rail surface.

[0041] Technical Solution 16. A motor vehicle according to Technical Solution 13, wherein, in a cross-sectional view, each of the parallel guide rails has a concave rail surface.

[0042] Technical Solution 17. A motor vehicle according to Technical Solution 16, wherein each interface connector is a protrusion configured to slidably engage a recessed track surface of one of the parallel guide tracks.

[0043] Technical Solution 18. A motor vehicle according to Technical Solution 17, wherein the protrusion is configured to snap into the concave track surface.

[0044] Technical Solution 19. A motor vehicle according to Technical Solution 11, wherein each battery cell block also includes an interlocking flange, which is mounted to the battery box and is configured to interconnect adjacent battery cell blocks, and at least one of the interlocking flanges of each battery cell block is combined with an interface connector to connect the battery box to the rail structure.

[0045] Technical Solution 20. A modular multi-cell rechargeable energy storage system (RESS), comprising:

[0046] A RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a track structure; and

[0047] A plurality of interconnected battery cell blocks, the plurality of interconnected battery cell blocks being arranged in the RESS enclosure, wherein:

[0048] Each battery cell block includes a cell case having at least one interface connector configured to slidably couple the cell case to the track structure such that each battery cell block engages, is aligned with, and is supported by the track structure;

[0049] The track structure is mounted to at least one of the enclosure tray and the enclosure cover and includes a plurality of parallel guide tracks; and

[0050] Each interface connector is one of an integrally formed feature of the cell box and a bracket attached to the cell box.

[0051] The above features and advantages and other features and advantages of the present disclosure will become apparent from the following detailed description of the disclosed embodiment(s) and best mode(s) for carrying out the disclosure when taken in conjunction with the accompanying drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 is a schematic top view of an embodiment of a motor vehicle employing multiple power sources and a modular multi-cell rechargeable energy storage system (RESS) configured to generate and store electrical energy in accordance with the present disclosure.

[0053] Figure 2 According to the present disclosure, Figure 1 A schematic side view of a battery cell array enclosure of a rail structure of an RESS is shown in , illustrating the array enclosure having an enclosure tray and an enclosure cover that serves as a floor pan section of a vehicle body structure.

[0054] Figure 3 To be arranged in Figure 2 The RESS capsule shown in Figure 1 Schematic exploded perspective view of the RESS shown in , illustrating a plurality of battery cell blocks arranged in separate modules and engaged with a rail structure.

[0055] Figure 4 is a schematic side view of a battery cell block according to the present disclosure, wherein the battery cell blocks are interconnected to form Figure 1 and Figure 3RESS shown in .

[0056] Figure 5A is a schematic partial cross-sectional front view of a battery cell block according to the present disclosure, the battery cell block having Figure 2 A U-shaped embodiment of an interface connector engaged by a track structure is shown in FIG.

[0057] Figure 5B is a schematic partial cross-sectional front view of a battery cell block according to the present disclosure, wherein the battery cell block has Figure 2 An L-shaped embodiment of an interface connector engaged by a track structure is shown in FIG.

[0058] Figure 5C is a schematic partial cross-sectional front view of a battery cell block according to the present disclosure, the battery cell block having Figure 2 An embodiment of a protrusion of an interface connector engaged by a rail structure is shown in FIG.

[0059] Figure 5D is a schematic partial cross-sectional front view of a battery cell block according to the present disclosure, wherein the battery cell block has Figure 2 Another embodiment of an interface connector engaged with the track structure shown in .

[0060] Figure 5E is a schematic top view of a set of battery cell blocks according to the present disclosure, the battery cell blocks having interlocking flanges incorporating interface connectors for engaging Figure 2 The track structure shown in . DETAILED DESCRIPTION

[0061] One of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," "left," "right," and the like are used descriptively with respect to the drawings and are not intended to limit the scope of the present disclosure as defined by the appended claims. Moreover, the present teachings may be described in terms of functional and / or logical block components and / or various processing steps. It should be appreciated that such block components may include a plurality of hardware, software, and / or firmware components configured to perform the specified functions.

[0062] refer to Figure 1 , depicting a motor vehicle 10 having a powertrain 12. The vehicle 10 may include, but is not limited to, a commercial vehicle, an industrial vehicle, a passenger vehicle, an aircraft, a watercraft, a train, etc. It is also contemplated that the vehicle 10 may be a mobile platform, such as an airplane, an all-terrain vehicle (ATV), a boat, a personal mobility device, a robot, etc., to achieve the purposes of the present disclosure. Figure 1As shown in , motor vehicle 10 also includes a vehicle body structure 10A that is configured to support a powertrain 12 and a vehicle passenger compartment and cargo compartment (not shown). Powertrain 12 includes a power source 14 that is configured to generate a power source torque for propelling vehicle 10 relative to a road surface 18 via driven wheels 16. Power source 14 is depicted as an electric motor-generator; therefore, motor vehicle 10 may be identified as an electric vehicle (EV).

[0063] like Figure 1 As shown in , the powertrain 12 may also include an additional power source 20, such as an internal combustion engine. The power sources 14 and 20 can work together to provide power to the motor vehicle 10. The motor vehicle 10 additionally includes an electronic controller 22 and a modular multi-cell rechargeable energy storage system (RESS) 24, which is configured to generate and store electrical energy through an electrochemical reaction that generates heat for supplying electrical energy to the power sources 14 and 20. In the present disclosure, the RESS 24 is defined as "modular" because the system is composed of interlocking battery cell blocks, as will be described in detail below. The electronic controller 22 can be a central processing unit (CPU) that regulates various functions of the vehicle 10, including the power sources 14 and 20, or the electronic controller 22 can be a powertrain control module (PCM), which is configured to control the powertrain 12 to generate a predetermined amount of power source torque.

[0064] The modular RESS 24 can be connected to the power sources 14 and 20, the electronic controller 22, and other vehicle systems via the high voltage bus 25. Although the RESS 24 is described herein primarily in the context of a motor vehicle, it is not excluded that the subject RESS is used to provide power to other non-automotive or stationary systems. The vehicle body structure 10A can incorporate the modular RESS 24 as an integral part thereof (e.g., Figure 2 ). As a result, in the motor vehicle 10, the RESS 24 can withstand at least some of the structural and / or dynamic loads experienced by the main structure during vehicle operation. The RESS 24 includes one or more sections or arrays 26 of individual battery cells arranged relative to an XYZ coordinate system. Each battery cell array 26 can be configured as a battery module or multiple battery modules bundled into a battery pack.

[0065] Continue to refer Figure 1, the array 26 includes a plurality of interlocking battery cell blocks, such as a first group of battery cell blocks 28 and an adjacent, directly adjacent second group of battery cell blocks 30, each battery cell block extending generally upward, i.e., in the Z direction. Although one array 26 (shown as a battery pack) and two groups of battery cell blocks 28, 30 (shown as separate modules) are specifically indicated, it is not excluded that the RESS 24 has a greater number of such arrays in which a specific number of battery cell blocks are arranged. As shown, the first cell group 28 includes separate battery cell blocks 28-1, 28-2, 28-3, while the adjacent second cell group 30 includes separate battery cell blocks 30-1, 30-2, 30-3. The individual battery cells in the groups 28 and 30 can be prismatic or cylindrical, also referred to as cylindrical cell blocks.

[0066] like Figure 2 As shown in , the RESS 24 also includes a RESS housing or enclosure 32 that is configured to house and retain each of the first battery cell group 28 and the second battery cell group 30. The RESS enclosure 32 is surrounded by an ambient environment 34 (i.e., the environment outside the RESS enclosure) and is configured to withstand at least some of the structural and / or dynamic loads experienced by the vehicle body structure 10A. The RESS enclosure 32 is configured to manage high temperature gases emitted by the battery cells in the cell groups 28, 30, such as during a battery cell thermal runaway event, and exhaust the high temperature gases to the external environment 34. The RESS enclosure 32 includes an enclosure tray 36 and an enclosure cover 38. The enclosure cover 38 is generally positioned above the battery cell blocks 28-1, 28-2, 28-3 and 30-1, 30-2, 30-3, and can additionally serve as a floor chassis section (at the bottom of the vehicle body structure 10A) of the vehicle body structure 10A. Figure 2 ).

[0067] The capsule cover 38 is configured to engage the capsule tray 36 to substantially seal the RESS capsule 32 and its contents from the external environment 34. Figure 2 As shown in FIG, in the motor vehicle 10, the RESS enclosure 32 is arranged in a horizontal XY plane so that the enclosure cover 38 is positioned above the enclosure tray 36 when viewed along the Z axis. The battery cell blocks 28-1, 28-2, 28-3, 30-1, 30-2, 30-3 can be arranged parallel to each other in their respective cell groups 28 and 30 within the RESS enclosure 32. Alternatively, some of the battery cell blocks can be arranged vertically relative to adjacent cell blocks in the cell array 26 to adapt the overall shape of the modular RESS 24 to the available space within the boundaries of the vehicle body structure 10A.

[0068] like Figure 3As shown in , each battery cell block 28-1, 28-2, 28-3, 30-1, 30-2 and 30-3 includes a battery box 40, which defines a battery cell vent 40A and encapsulates the battery cell electrodes, electrolyte and other related components (not shown). Each interlocking battery cell block in the battery cell group 28 and 30 also includes one or more electrically insulating structural connectors 42, which are configured to firmly link or interconnect the battery cell box 40 with the battery cell box of the adjacent battery cell block. The battery cell group generated by such interconnected battery cell blocks in turn enhances the structural rigidity of the RESS 24. Each battery cell block 28-1, 28-2, 28-3, 30-1, 30-2, 30-3 additionally includes a thermal mitigation barrier (TMB) section 44 fixed to the battery cell box 40. The TMB segments 44 of the present subject matter are arranged on a particular side of the cell case 40 such that when the RESS 24 is assembled, the TMB segments are positioned in contact with or pressed against adjacent battery cell blocks and, as a result, at least one TMB segment is sandwiched between a pair of adjacent battery cell blocks.

[0069] Also like Figure 3 As shown in , the battery blocks in each of the first battery cell group 28 and the second battery group 30 are operatively / functionally and mechanically interconnected. Each battery cell block 28-1, 28-2, 28-3, 30-1, 30-2, 30-3 may include modularly connectable elements or components for generating a working battery chain. Such elements may include thermal insulators 46, bus bar sections 48, cold plate sections 50, and thermal interface material (TIM) sections 52, allowing for the construction of battery packs or modules of desired size. When the battery cell blocks in the battery cell groups 28 and 30 are interconnected, as shown in FIG. Figure 3 5, the individual busbar segments 48 are inserted into the busbar subassembly 48-1 disposed within the RESS enclosure 32 (eg, Figure 3 The bus bar subassembly 48-1 is configured to electrically connect the battery cell blocks in the array 26 and transmit electrical signals to and from the battery cell blocks in the array 26. The RESS 24 may also include various sensing devices (such as thermistors, fuses, etc.), which, although not specifically shown, are understood to detect the operation of the battery cell groups 28, 30 or individual battery cell blocks in the array 26.

[0070] Furthermore, when the battery cell blocks in the cell groups 28 and 30 are interconnected, as shown in FIG. Figure 3As shown in FIG. 5 , the cold plate segments 50 that make up the battery cell blocks form a cold plate subassembly 50 - 1 . The resulting cold plate subassembly 50 - 1 is positioned to absorb thermal energy from the battery cell blocks of the present subject matter and maintain the necessary RESS 24 operating conditions. The interlocking battery cell blocks 28 - 1 , 28 - 2 , 28 - 3 , 30 - 1 , 30 - 2 , 30 - 3 may be secured to the RESS enclosure 32 by one or more fasteners 54 , as will be described in detail below. The RESS 24 may also include a mica cover sheet 56 and an intermediate plate 58 , the mica cover sheet 56 being disposed between the enclosure cover 38 and the battery cell array 26 , the intermediate plate 58 having an electrically insulating foam element sandwiched between layers of structural adhesive. The intermediate plate 58 having a structural adhesive layer may be disposed between separate modules, such as 28 and 30 , and provide thermal and electrical isolation between them.

[0071] In addition to the component battery cell blocks being interlocked and functionally connected in the array 26, the resulting battery chain is mounted to the RESS enclosure 32 at each cell box 40. Figure 4 As shown in FIG. 1 , each battery box 40 includes at least one interface connector 62, which can be engaged by one or more fasteners 54. The (one or more) fasteners 54 can be bolts (in Figure 5A shown in), the fixture (in Figure 5B ), welds, etc. Figure 4 As shown in , the RESS enclosure 32 also includes a track structure 64 arranged along the RESS track axis 66. Each of the interface connectors 62 is configured to link or couple the corresponding battery box 40 to the track structure 64. The engagement between the battery box 40 and the track structure 64 via the (one or more) interface connectors 62 is aligned and supported by the track structure corresponding to the battery cell block, and can facilitate the substantially linear slidable movement of the cell block along the track axis 66. Therefore, each cell block in the corresponding cell group 28, 30 is engaged with the track structure 64 and aligned and supported by the track structure 64.

[0072] The track structure 64 may be secured to the track structure 64 by suitable fastening members 68 (in Figure 2) is mounted to the enclosure tray 36 and / or enclosure cover 38. Each battery cell block in the battery pack 28, 30 is electrically insulated from the track structure 64. For example, the interface connector 62 can be made of a non-conductive material that is also relatively rigid and heat-resistant. Such a battery box material can be a polymer, such as acrylonitrile butadiene styrene (ABS) plastic. Such polymer parts can be molded, machined, or 3D printed to achieve the desired shape. In another embodiment, the interface connector 62 can be made of a metal such as Al3000, coated with an e-coating, spray coating, or insulating film for electrical insulation between the battery cell box 40 and the track structure 64.

[0073] like FIG. 5A to FIG. 5E As shown in , the track structure 64 may include one or more guide rails extending along a track axis 66. In embodiments having multiple guide rails (such as a first track 70-1 and a second track 70-2), the guide rails of the present subject matter extend parallel to the track axis 66 and parallel to each other. Although not shown, the guide rails of the present subject matter can be configured as an upper beam adjacent to the enclosure cover 38, a lower beam arranged adjacent to the enclosure tray 36, or a side beam mounted near the interface between the cover and the tray. (Multiple) upper beams adjacent to the enclosure cover 38 (not shown) can be used to further enhance the stability of the battery cell groups 28, 30, such as in embodiments where the track structure 64 is arranged at the lower portion of the RESS enclosure 32 adjacent to the enclosure tray 36. As shown in FIG. Figure 5A As shown in FIG. 1 , in cross-section, each of the guide rails may have an outer convex track surface 72. Alternatively, as shown in FIG. Figure 5C and Figure 5D As shown in FIG. 1 , in cross-section, each of the parallel guide rails may have a concave track surface 74. Figure 5A As shown in FIG. 1 , each guide rail 70 - 1 , 70 - 2 may be a different component mounted to a corresponding enclosure tray 36 or cover 38 , or as shown in FIG. Figure 5C As shown in , each guide track 70 - 1 , 70 - 2 may be formed into the corresponding enclosure tray 36 or cover 38 , such as being stamped or cast together with the corresponding enclosure tray 36 or cover 38 .

[0074] The individual interface connectors 62 may have a U-shaped or C-shaped cross-section 62A (in Figure 5A ), the outer track surface 72 or L-shaped cross section 62B (in Figure 5B ), configured to slidably engage one of the parallel guide rails, such as 70-1, 70-2. Alternatively, Figure 5C and Figure 5DThe individual interface connectors 62 in the embodiments of can be structured as corresponding protrusions 62C or 62D, which are configured to slidably engage the inner track surface 74 of one of the parallel guide rails (e.g., 70-1, 70-2). Figure 5C The protrusion 62C shown in FIG. 1 may have a rigid structure. On the other hand, Figure 5D The protrusion 62D shown in the figure may have a resilient or spring-like structure, such as an expanded mushroom shape, so that the interface connector 62 of the present subject matter can be snapped into the inner track surface 74. The resilient protrusion structure 62C or 62D can be incorporated into the bottom section of the battery box 40 and is configured to fit or snap into the inner track surface 74 for mounting the corresponding battery block thereon. Figure 5D As shown in the embodiment of , alternatively, or in addition to the resilient structure 62D interface connector, the inner track surface 74 itself can be characterized as a resilient, i.e., a spring-like structure that is configured to receive an interface connector of a separate battery cell block. FIG. 5A to FIG. 5D In each of the embodiments, the corresponding battery cell block 28-1, 28-2, 28-3 or 30-1, 30-2, 30-3 can be displaced along the track axis 66 via the interface connector 62 before being interlocked with an adjacent cell block and set in place.

[0075] refer to Figure 5E Each battery cell block 28-1, 28-2, 28-3 or 30-1, 30-2, 30-3 may additionally include (a plurality of) interconnecting flanges 76-1, 76-2 mounted (e.g., welded) to the cell box 40. Each flange 76-1, 76-2 is configured to interlock with an adjacent flange of an adjacent cell block, thereby generating a chain connection between the cell blocks in the corresponding group 28, 30 and / or array 26. For example, Figure 5E As shown in FIG. 1 , the negative side of each cell block may have a stepped flange 76-1, while the positive side of the cell block may have a mating flange 76-2 configured to be captured by the stepped flange. The battery cell blocks interconnected via the flanges of the subject matter in the respective cell groups 28, 30 may be in a direction perpendicular to the track axis 66, such as along Figure 1 , the RESS trays 36 are removed from the RESS enclosure 32 individually or in groups, as shown in the Z-axis. The flanges 76-1, 76-2 may also be secured to each other in the respective groups 28, 30, such as via welds 77. The flanges 76-1 and / or 76-2 may incorporate an interface connector 62E that couples the cell box 40 to the track structure 64 and is further secured via the fastener(s) 54.

[0076] The track structure 64 may define individual parallel slots 64A arranged at predetermined intervals and configured to receive the interface connector 62 of the corresponding battery cell block 28-1, 28-2, 28-3 or 30-1, 30-2, 30-3 to insert the interface connector 62 into a separate track, such as 70-1, 70-2, along the Z axis. Although not shown, the interface connector 62 may be configured as a bracket attached to the battery box 40, or an integrally formed battery box feature, such as an integrally formed battery box feature that is stamped or cast with the battery box. Figure 5D As shown in FIG. 1 , the guide rails may define a plurality of apertures 78 configured to receive fasteners 54. The fasteners 54 may extend through the apertures 78 and complementary apertures 80 in the interface connector 62, such as with respect to FIG. Figure 5C 62C in the connector embodiment 62C to secure the corresponding battery cell box body 40 to the guide rail. The apertures 78 can be arranged at regular intervals to define the positioning of individual battery cells within the RESS enclosure 32. In the assembled RESS 24, the fastened battery cell blocks can be easily removed and replaced, such as in the event of degradation or failure of an individual battery cell. This allows the individual battery cells to be modified and the RESS 24 to be refurbished in the field with minimal disassembly, and in some embodiments, the RESS does not need to be removed from the vehicle 10.

[0077] like Figure 5D As shown in FIG. 1 , one or more fluid conduits 82 may be incorporated into the rail structure 64. The conduits 82 may be in fluid communication with a coolant manifold (not shown) and coolant may be supplied via the manifold of the subject matter using a fluid pump external to the RESS 24. Figure 3 As shown in , the cold plate segments 50 that make up the cell blocks form a cold plate subassembly 50A that is configured to absorb thermal energy and maintain the necessary RESS 24 operating conditions. The resulting cold plate subassembly 50A can be connected to (multiple) pipes 82 to receive and circulate coolant for removing thermal energy from the corresponding battery array 26.

[0078] In general, the modular assembly of the RESS array 26 is facilitated by mounting the interlocking battery cell blocks to the track structure 64 via individual interface connectors 62. The battery cell blocks are coupled to the track structure 64 via the interface connectors 62. Thus, after being aligned and supported, the battery cell blocks can then be positioned and functionally and mechanically interlocked with adjacent battery cell blocks and secured to the track structure 64 via appropriate fastening devices. The cell array composed of interlocking battery cell blocks provides enhanced rigidity to the modular RESS 24, which is useful when the RESS is incorporated into its host environment, such as a vehicle body structure. Individual battery cell blocks can also be disconnected, removed, and replaced from each other, allowing the RESS 24 to be efficiently refitted with new battery cells.

[0079] The detailed description and the accompanying drawings or figures are support and description of the present disclosure, but the scope of the present disclosure is limited only by the claims. Although some of the best modes and other embodiments for implementing the claimed disclosure have been described in detail, there are various alternative designs and embodiments for practicing the present disclosure defined in the appended claims. In addition, the embodiments shown in the drawings, or the features of the various embodiments mentioned in this specification are not necessarily to be understood as embodiments independent of each other. On the contrary, it is possible that each of the features described in one of the examples of an embodiment can be combined with one or more of the other desired features from other embodiments to obtain other embodiments that are not described in words or by reference to the drawings. Therefore, these other embodiments fall within the framework of the scope of the appended claims.

Claims

1. A modular multi-cell rechargeable energy storage system (RESS), comprising: A RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a track structure; and a plurality of interconnected battery cell blocks, the plurality of interconnected battery cell blocks being arranged in the RESS enclosure; Each battery cell block includes a cell box having at least one interface connector, wherein the at least one interface connector is configured to connect the cell box to the track structure so that each battery cell block is engaged with, aligned with and supported by the track structure.

2. The modular RESS according to claim 1, wherein: The track structure is mounted to at least one of the enclosure tray and the enclosure cover.

3. The modular RESS according to claim 1, wherein: The track structure includes a plurality of parallel guide tracks.

4. The modular RESS according to claim 3, wherein: The at least one interface connector is configured to slidably engage the parallel guide rails.

5. The modular RESS according to claim 3, wherein: In cross-section, each of the parallel guide rails has a convex rail surface.

6. The modular RESS according to claim 3, wherein: In cross-sectional view, each of the parallel guide tracks has a concave track surface.

7. The modular RESS according to claim 6, wherein: Each interface connector is a protrusion configured to slidably engage the recessed track surface of one of the parallel guide tracks.

8. The modular RESS according to claim 7, wherein: The protrusion is configured to snap into the recessed track surface.

9. A motor vehicle comprising: a power source configured to generate a power source torque; A vehicle body structure incorporating as a portion thereof a modular multi-cell rechargeable energy storage system (RESS), the modular multi-cell rechargeable energy storage system (RESS) being configured to supply electrical energy to the power source, the modular RESS comprising: A RESS enclosure, the RESS enclosure being surrounded by an external environment, integrated into the vehicle body structure, and having an enclosure tray, an enclosure cover, and a track structure; and a plurality of interconnected battery cell blocks, the plurality of interconnected battery cell blocks being arranged in the RESS enclosure; Each battery cell block includes a cell box having at least one interface connector, wherein the at least one interface connector is configured to connect the cell box to the track structure so that each battery cell block is engaged with, aligned with, and supported by the track structure.

10. A modular multi-cell rechargeable energy storage system (RESS), comprising: a RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a track structure; as well as A plurality of interconnected battery cell blocks, the plurality of interconnected battery cell blocks being arranged in the RESS enclosure, wherein: Each battery cell block includes a cell case having at least one interface connector configured to slidably couple the cell case to the track structure such that each battery cell block engages, is aligned with, and is supported by the track structure; The track structure is mounted to at least one of the enclosure tray and the enclosure cover and includes a plurality of parallel guide tracks; as well as Each interface connector is one of an integrally formed feature of the cell box and a bracket attached to the cell box.

Images