Interconnection plate frame for battery module

Abstract

An interconnect plate frame for a battery module having at least one first battery cell having a positive terminal and a negative terminal, the interconnect plate frame including a first frame member defining a first slot aligned with the positive terminal of the first battery cell, a second frame member connected to the first frame member, a first frame member defining a first slot aligned with the negative terminal of the first battery cell, a second frame member defining a second slot aligned with the negative terminal of the first battery cell, and a splice joint defined by a connection of the first frame member and the second frame member, where the splice joint extends between the first slot and the second slot through a series connection between the battery cells.

Description

Technical Field

[0001] The present disclosure relates to an interconnect board (ICB) frame for a battery module. More specifically, the present disclosure relates to an ICB frame whose frame members are interconnected at splice joints between battery cells connected in series within a battery module. Background Art

[0002] Electric and hybrid vehicles use high-voltage battery systems that include multiple battery cells, typically packaged as multiple battery modules within a battery pack. The battery pack is typically located midway between the front and rear wheels under the vehicle body. These electric and hybrid vehicles typically require multiple battery modules to provide sufficient power to meet vehicle power and energy requirements. Power and / or range requirements may result in an increase in the length of the battery module to accommodate enough batteries to meet these requirements. This in turn results in an increase in the length of components within the battery module, such as the plate frame used to position and support the busbars connected to the battery cells. The increase in the length of the plate frame may pose challenges to assembly, transportation, and manufacturing.

[0003] Therefore, there is a need in the art for an improved plate frame that accommodates all battery module sizes. Summary of the invention

[0004] The present disclosure provides an interconnection board frame for a battery module. The battery module includes at least one first battery cell having a positive terminal and a negative terminal. The interconnection board frame includes: a first frame member, the first frame member defining a first slot aligned with the positive terminal of the first battery cell; a second frame member connected to the first frame member, the second frame member defining a second slot aligned with the negative terminal of the first battery cell; and a splice joint defined by the connection of the first frame member and the second frame member, wherein the splice joint extends between the first slot and the second slot.

[0005] In one aspect, a retaining device is disposed on the first frame member and the second frame member, wherein the retaining device fixes the first frame member and the second frame member in all directions.

[0006] In another aspect, the retaining device includes a snap connector connected to the first frame member and a hole provided in the second frame member, wherein the snap connector is disposed within the hole.

[0007] In another aspect, the interconnected board frames have a length and a width, and the splice joint extends across the width.

[0008] In another aspect, the splice joint includes a first transverse portion connected to a longitudinal portion connected to a second transverse portion, wherein the first transverse portion is adjacent to the first groove, the second transverse portion is adjacent to the second groove, and the longitudinal portion is disposed between the first groove and the second groove.

[0009] In another aspect, the longitudinal portion is perpendicular to the first and second lateral portions.

[0010] In another aspect, the splice joint is spaced apart from the first groove and the second groove.

[0011] In another aspect, the first slot includes a first window extending therethrough, and the second slot includes a second window extending therethrough.

[0012] In another aspect, the first groove is offset from the second groove along the width.

[0013] In another embodiment, a battery module is provided. The battery module includes a first battery cell having a positive terminal and a negative terminal, an interconnect board (ICB) frame disposed on the first battery cell. The ICB frame includes a first frame member defining a first slot aligned with the positive terminal of the first battery cell, a second frame member connected to the first frame member, a second frame member defining a second slot aligned with the negative terminal of the first battery cell, and a splice joint defined by the connection of the first frame member and the second frame member, wherein the splice joint extends between the first slot and the second slot.

[0014] In one aspect, a plurality of bus bars are disposed in the first slot or the second slot.

[0015] In another aspect, the first slot includes a first window extending therethrough, the second slot includes a second window extending therethrough, and the bus bar is connected to the positive terminal and the negative terminal through the first window and the second window.

[0016] In another aspect, a retaining device is disposed on the first frame member and the second frame member, wherein the retaining device secures the first frame member and the second frame member in all directions.

[0017] In another aspect, the retaining device includes a snap connector connected to one of the first frame member and the second frame member and a hole provided in the other of the first frame member and the second frame member, wherein the snap connector is disposed within the hole.

[0018] In another aspect, the splice joint includes a first transverse portion connected to a longitudinal portion connected to a second transverse portion, wherein the first transverse portion is adjacent to the first groove, the second transverse portion is adjacent to the second groove, and the longitudinal portion is disposed between the first groove and the second groove.

[0019] In another aspect, the longitudinal portion is perpendicular to the first and second lateral portions.

[0020] In another embodiment, a battery module for a vehicle is provided. The battery module includes a plurality of battery cells, a plurality of busbars connected to the plurality of battery cells, wherein the battery cells are connected in series through the plurality of busbars, and an interconnection board (ICB) frame is disposed between the plurality of battery cells and the plurality of busbars. The ICB frame includes a first frame member defining a plurality of first slots aligned with the positive or negative poles of the plurality of battery cells; a second frame member connected to the first frame member; a second frame member defining a plurality of second slots aligned with the positive or negative terminals of the plurality of battery cells; and wherein the first frame is connected to the second frame member across one of the series connections between the plurality of battery cells.

[0021] In one aspect, the plurality of first slots and the plurality of second slots are arranged in two rows along the length of the ICB frame.

[0022] In another aspect, a retaining device is disposed on the first frame member and the second frame member, wherein the retaining device secures the first frame member and the second frame member in all directions.

[0023] In another aspect, the retaining device includes a snap connector connected to one of the first frame member and the second frame member and a hole provided in the other of the first frame member and the second frame member, wherein the snap connector is disposed within the hole.

[0024] Further areas of applicability will become apparent from the description provided herein.It should be understood that the 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

[0025] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0026] Figure 1 is a schematic diagram of an exemplary motor vehicle having a battery pack and an interconnected plate frame according to the principles of the present disclosure;

[0027] Figure 2 is a perspective exploded view of a battery module with interconnected plate frames within a battery pack.

[0028] Figure 3 is a top view of the interconnected board frame;

[0029] Figure 4 is an enlarged top view of a portion of an interconnect board frame.

[0030] Figure 5 is a perspective view of an end portion of a first frame member of an interconnected board frame;

[0031] Figure 6is a perspective view of an end portion of a second frame member of an interconnected panel frame;

[0032] Fig. 7A is along Figure 4 A cross-sectional view of the interconnection board frame viewed in the direction of arrow 7A-7A;

[0033] Figure 7B is along Figure 4 A cross-sectional view of the interconnection board frame viewed in the direction of arrow 7B-7B in FIG.

[0034] Figure 7C is along Figure 4 A cross-sectional view of the interconnection board frame viewed in the direction of arrow 7C-7C. DETAILED DESCRIPTION

[0035] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0036] refer to Figure 1 , a battery pack 10 having an interconnected plate frame (discussed in more detail below) according to the principles of the present disclosure is shown. The battery pack 10 is shown together with an exemplary vehicle 12. Preferably, the vehicle 12 is an electric vehicle or a hybrid vehicle having wheels 14 driven by a motor / inverter 16. The motor / inverter 16 receives power from the battery pack 10. Although the vehicle 12 is shown as a passenger road vehicle, it should be understood that the battery pack 10 can be used with various other types of vehicles. For example, the battery pack 10 can be used in a marine vehicle such as a ship or an aviation vehicle such as a drone or a passenger aircraft. In addition, the battery pack 10 can be used as a stationary power source that is separate and independent from the vehicle. The battery pack 10 generally includes a battery tray 18 connected to the vehicle 12. The battery tray 18 provides structural support for one or more battery modules 20. The battery pack 10 may also include a battery thermal management system and a battery management system (not shown).

[0037] Go to Figure 2 , the battery module 20 generally includes a plurality of battery cells 22, a plurality of bus bars 24, and a pair of interconnect board (ICB) frames 26. The battery cells 22, bus bars 24, and ICB frames 26 may be stored within a housing (not shown). The battery module 20 is oriented to have a row of battery cells 22 extending along a length "L" and one or more rows of battery cells 22 disposed along a width "W". Although two rows of battery cells 22 are shown, each having a plurality of battery cells 22 and two ICB frames 26, it should be understood that any number of battery cells 22, bus bars 24, and ICB frames 26 may be employed within the battery module 20 without departing from the scope of the present disclosure.

[0038] The battery cells 22 are lithium-ion battery cells. However, it should be understood that any type of battery cell 22 may be employed. In addition, the battery cells 22 may be cylindrical battery cells, prismatic can battery cells, or soft pack battery cells. In general, the battery cells 22 each include a housing 28 having a top surface 30. A positive terminal 32 and a negative terminal 34 are disposed on the top surface 30. The negative terminal 34 is connected to an anode current collector (not shown) within the battery cell 22. The positive terminal 32 is connected to a cathode current collector (not shown) within the battery cell 22.

[0039] The busbars 24 are electrical conductors for connecting the individual battery cells 22 in series or in parallel. Each busbar 24 typically includes a plurality of contact pads 25. In the example provided, the busbar 24 includes four contact pads 25. The busbars 24 are laser welded (or otherwise fixedly connected) to the positive terminal 32 and the negative terminal 34 of the battery cell 22 at the contact pads 25. The configuration of the busbars 24 and the orientation of the battery cells 22 determine the series and parallel connections therebetween.

[0040] Figure 3 and Figure 4 An ICB frame 26 having a plurality of bus bars 24 is shown. The ICB frame 26 is configured to position and hold the bus bars 24 relative to the battery cells 22 during assembly. Preferably, the ICB frame 26 is formed of plastic. The ICB frame 26 is disposed between the bus bars 24 and the battery cells 22 along the length of the battery module 20, with one ICB frame 26 for each row of battery cells 22. The ICB frame 26 generally includes a first frame member 36 connected to a second frame member 38 at a splice joint 40. Although only one splice joint 40 is shown, the ICB frame 26 may include more than one splice joint 40 (e.g., Figure 3 ) to separate the ICB frame 26 into multiple frame members. The location and design of the splice joints 40 allow the ICB frame 26 to be manufactured, transported, and installed as shorter frame members or modules without the need for additional components or busbars, as will be described in more detail below.

[0041] The first frame member 38 includes a first distal end 42 and an insertion end 44 opposite the first distal end 42. The first frame member 36 also includes a plurality of first slots 46 formed therein. The first slots 46 are arranged in two rows 48, 50. The first slots 46 in each row 48, 50 are offset from one another along the length of the battery module 20. Each first slot 46 is defined by a plurality of first windows 52 extending through the first frame member 38, as shown in FIG. Figure 2As shown. Each first window 52 is aligned with one positive terminal 32 or negative terminal 34 on one battery cell 22. Each first slot 46 may include any number of first windows 52. In the example provided, the first slot 46 includes four windows 52. The type of terminals and the number of battery cells 22 associated with the first slot 46 may vary. In the example provided, each first slot 46 is aligned with two positive terminals 32 and two negative terminals 34 in four battery cells 22 (in Figure 4 The “+” and “-” symbols are used to indicate alignment.

[0042] Each first slot 46 is sized to receive and retain a bus bar 24. Each first window 52 is sized to receive therein a contact pad 25 of a corresponding bus bar 24. Thus, in the example provided, the battery cells 22 are connected in series (represented by the dashed line "S") and in parallel (represented by the dashed line "P").

[0043] Go to Figure 5 , the insertion end 44 of the first frame member 36 includes two transverse edges 60, 62 and one longitudinal edge 64. The transverse edges 60, 62 are arranged perpendicular to the longitudinal edge 64. Each of the edges 60, 62 and 64 includes an insert retaining device 66. The insert retaining device 66 includes a tab 68 and a snap connector 70 extending from the tab 68. The height "h" of the tab 68 and the snap connector 70 does not exceed the thickness "t" of the first frame member 36.

[0044] return Figure 3-Figure 4 , the second frame member 38 includes a second distal end 80 and a receiving end 82 opposite the second distal end 80. The second frame member 38 also includes a plurality of second slots 84 formed therein. The second slots 84 are arranged in two rows 48, 50. The second slots 84 in each row 48, 50 are offset from each other along the length of the battery module 20. Each second slot 84 is defined by a plurality of second windows 90 extending through the second frame member 38, as shown in FIG. Figure 2 As shown. Each second window 90 is aligned with one positive terminal 32 or negative terminal 34 on one battery cell 22. Each second slot 84 may include any number of second windows 90. In the example provided, the second slot 84 includes four second windows 90. The type of terminal associated with the second slot 84 and the number of battery cells 22 may vary. In the example provided, each second slot 84 is aligned with two positive terminals 32 and two negative terminals 34 in four battery cells 22 (in Figure 4 The “+” and “-” symbols are used to indicate alignment.

[0045] Each second slot 84 is sized to receive and retain a bus bar 24. Each second window 90 is sized to accommodate therein a contact pad 25 of a corresponding bus bar 24. Thus, in the example provided, the battery cells 22 are connected in series (represented by the dashed line "S") and in parallel (represented by the dashed line "P").

[0046] Go to Figure 6 The receiving end 44 of the second frame member 36 includes two transverse edges 92, 94 and a longitudinal edge 96. The transverse edges 92, 94 are arranged perpendicular to the longitudinal edge 96. Each of the edges 92, 94, 96 includes a receiving retaining device 98. Each receiving retaining device 98 includes a housing 100 and an aperture 102, the housing 100 being used to receive the tab 68 ( Figure 5 ), the aperture 102 is sized to receive the snap connector 70 ( Figure 5 )one. Figure 7A-7C The interaction between the retaining devices 66, 98 is shown. The retaining devices 66, 98 secure the first frame member 36 to the second frame member 38 in various orientations. In addition, because each frame feature 36, 38 has an insert retaining device 66 or a receiving retaining device 98, errors during assembly are reduced.

[0047] Back to Figure 4 , the splice joint 40 is an interface between the insertion end 44 of the first frame member 36 and the receiving end 82 of the second frame member 38. The splice joint 40 is located between the series connections S rather than the parallel connections P. Therefore, the splice joint 40 is separated from the first slot 46 and the second slot 84. The splice joint 40 is characterized by having a first transverse portion 110, a second transverse portion 112, and a longitudinal portion 114. The first transverse portion 110 and the second transverse portion 112 are perpendicular to the longitudinal portion 114. The first transverse portion is disposed between a first slot 46 and a second slot 84 in the same row 48. The second transverse portion 112 is disposed between a first slot 46 and a second slot 84 in the same row 50. The longitudinal portion 114 is disposed between a first slot 46 in one row 50 and a second slot 84 in another row 48. Therefore, the splice joint 40 cuts off the series connection between the battery cells 22 rather than the parallel connection.

[0048] The ICB frame 26 with the splice joint 40 and the retaining devices 66, 98 has many benefits, including eliminating the need for internal connections between the busbars 24 because the splice joint is located between the parallel connections of the battery cells 22. The retaining devices 66, 98 ensure retention in each axis (i.e., direction) to ensure that the first frame member 36 is fixed to the second frame member 38. In addition, because the height of the retaining devices 66, 98 is less than the thickness of the ICB frame 26, the packaging of the ICB frame 26 is not increased. The ICB frame 26 with the splice joint 40 reduces the production cycle during installation at the manufacturing plant, provides error proofing and sequential operation during installation (i.e., a first frame member 36 cannot be connected to another first frame member 36), can receive the ICB frame 26 as an assembly without loose parts, and allows long battery modules 20 (e.g., a module of approximately fifty-four battery cells in length).

[0049] The description of the disclosure is merely exemplary in nature, and variations that do not depart from the gist of the disclosure are intended to be within the purview of the disclosure; such variations should not be regarded as a departure from the spirit and scope of the disclosure.

Claims

1. An interconnection board frame for a battery module, the battery module having at least one first battery cell, the first battery cell having a positive terminal and a negative terminal, the interconnection board frame comprising: a first frame member defining a first slot aligned with a positive terminal of the first battery cell; a second frame member connected to the first frame member, the second frame member defining a second slot aligned with the negative terminal of the first battery cell; as well as A splice joint is defined by the connection of the first frame member and the second frame member, wherein the splice joint extends between the first slot and the second slot.

2. The interconnection board frame according to claim 1, further comprising holding devices provided on the first frame member and the second frame member, wherein the holding devices fix the first frame member and the second frame member in various directions.

3. The interconnection board frame according to claim 2, wherein: The retaining device includes a snap connector connected to the first frame member and a hole provided in the second frame member, wherein the snap connector is arranged in the hole.

4. The interconnection board frame according to claim 1, wherein: The interconnected board frames have a length and a width, and the splice joint extends across the width.

5. The interconnection board frame according to claim 1, wherein: The splice joint includes a first transverse portion connected to a longitudinal portion, the longitudinal portion connected to a second transverse portion, wherein the first transverse portion is adjacent to the first slot, the second transverse portion is adjacent to the second slot, and the longitudinal portion is disposed between the first slot and the second slot.

6. The interconnection board frame according to claim 5, wherein: The longitudinal portion is perpendicular to the first and second transverse portions.

7. The interconnection board frame according to claim 1, wherein: The splice joint is spaced from the first groove and the second groove.

8. The interconnection board frame according to claim 1, wherein: The first slot includes a first window extending therethrough, and the second slot includes a second window extending therethrough.

9. The interconnection board frame according to claim 1, wherein: The first groove is offset from the second groove along the width.

10. A battery module, comprising: a first battery cell having a positive terminal and a negative terminal; An interconnection board ICB frame is arranged on the first battery unit, and the ICB frame includes: a first frame member defining a first slot aligned with a positive terminal of the first battery cell; a second frame member connected to the first frame member, the second frame member defining a second slot aligned with a negative terminal of the first battery cell; and A splice joint is defined by the connection of the first frame member and the second frame member, wherein the splice joint extends between the first slot and the second slot.

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