Rechargeable energy storage system having cell and cell holder assembly with mechanical

Abstract

A rechargeable energy storage system includes a cell holder tray including a plurality of battery interlocking features, where the cell holder tray includes a plurality of ventilation passages through the cell holder tray, and the cell holder tray includes a plurality of ventilation channels below the ventilation passages. A plurality of battery cells are each coupled to a respective one of the battery interlocking features above one of the vent passages in the cell support tray, where the plurality of battery cells are encapsulated in a polymer fill.

Description

Technical Field

[0001] The present disclosure relates to a rechargeable energy storage system having a unit with a mechanical interlock interface and a unit support assembly. Background Art

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. To the extent described in this section, the work of the currently named inventors and aspects that may not otherwise be described as prior art at the time of filing are neither expressly nor impliedly regarded as prior art against the present disclosure.

[0003] Currently, battery packs have been provided with a ventilation system that allows ventilation of individual battery cells while isolating the ventilation gas from the remaining battery cells within the group. The ventilation system must remain open for the gas to pass through during a thermal event, such that the gas must be able to reach the ventilation ports of the group. The remainder of the battery pack may be filled with a potting resin (foamed or non-foamed) for electrical isolation, structural performance, and thermal insulation of the battery cells. For battery pack assembly, it is currently challenging to position the units on the unit support. Additionally, it is challenging to control the potting from leaking into the ventilation channels. Summary of the Invention

[0004] A rechargeable energy storage system includes a unit support tray that includes a plurality of battery interlock features. A plurality of battery cells are each coupled to a respective one of the battery interlock features of the unit support tray.

[0005] According to another aspect, the battery interlock features include protrusions that guide the units into their positions on the unit support and have mechanical interlock features that engage the units to mechanically lock them after assembly.

[0006] According to another aspect, an adhesive secures the plurality of battery cells to the unit support tray.

[0007] According to another aspect, the plurality of battery interlock features form a watertight seal between the plurality of battery cells and the unit support tray.

[0008] According to another aspect, a flame retardant elastomer seals the space between the plurality of battery cells and the unit support tray.

[0009] According to another aspect, the plurality of battery interlock features include snap-fit members with the plurality of battery cells.

[0010] According to another aspect, the unit support includes three snap features around each of the plurality of battery cells.

[0011] According to another aspect, the snap fit member is held on the seams of the plurality of battery cells and pulls them downwardly towards the cell support tray.

[0012] According to another aspect, the plurality of battery interlock features include at least one of a chamfered wall or a stepped wall to guide the plurality of battery cells into place.

[0013] According to another aspect, the interlock feature includes a deflectable portion.

[0014] According to another aspect, the interlock feature engages the sides of the plurality of battery cells.

[0015] According to another aspect, the interlock feature engages the bottoms of the plurality of battery cells.

[0016] According to another aspect, the interlock feature engages the sides and bottoms of the plurality of battery cells.

[0017] According to another aspect, the cell support tray includes a plurality of ventilation channels located beneath the cells.

[0018] According to another aspect, the plurality of battery cells are cylindrical.

[0019] According to another aspect, the plurality of battery cells are prismatic.

[0020] According to another aspect, the plurality of battery cells are encapsulated in a polymer potting.

[0021] According to another aspect, the cell support tray includes an upper tray and a lower tray.

[0022] According to another aspect, at least one of the upper tray and the lower tray is made of one of nylon, polycarbonate, and polypropylene.

[0023] According to another aspect of the present disclosure, a rechargeable energy storage system includes a cell support tray including a plurality of battery interlock features, wherein the cell support tray includes a plurality of ventilation passages through the cell support tray and the cell support tray includes a plurality of ventilation channels located beneath the ventilation passages. A plurality of battery cells are each coupled to a respective one of the battery interlock features above one of the ventilation passages in the cell support tray, wherein the plurality of battery cells are encapsulated in a polymer potting.

[0024] Solution 1. A rechargeable energy storage system, comprising:

[0025] A cell support tray including a plurality of battery interlock features; and

[0026] A plurality of battery cells, each coupled to a respective one of the battery interlock features of the cell support tray.

[0027] Solution 2. The rechargeable energy storage system according to Solution 1, wherein the battery interlock feature includes a protrusion that guides the unit into its position on the unit support, and has a mechanical interlock feature that engages with the units to mechanically lock them after assembly.

[0028] Solution 3. The rechargeable energy storage system according to Solution 1, further comprising an adhesive that fixes the plurality of battery units to the unit support tray.

[0029] Solution 4. The rechargeable energy storage system according to Solution 1, wherein the plurality of battery interlock features form a watertight seal between the plurality of battery units and the unit support tray.

[0030] Solution 5. The rechargeable energy storage system according to Solution 1, further comprising a flame-retardant elastomeric sealant between the plurality of battery units and the unit support tray.

[0031] Solution 6. The rechargeable energy storage system according to Solution 1, wherein the plurality of battery interlock features include snap-fit members for the plurality of battery units.

[0032] Solution 7. The rechargeable energy storage system according to Solution 6, wherein the unit support includes three snap features around each of the plurality of battery units.

[0033] Solution 8. The rechargeable energy storage system according to Solution 6, wherein the snap-fit members are held on the seams of the plurality of battery units and pull them downward towards the unit support tray.

[0034] Solution 9. The rechargeable energy storage system according to Solution 6, wherein the plurality of battery interlock features include at least one of a chamfered wall or a stepped wall to guide the plurality of battery units into place.

[0035] Solution 10. The rechargeable energy storage system according to Solution 1, wherein the interlock feature includes a deflecting portion.

[0036] Solution 11. The rechargeable energy storage system according to Solution 1, wherein the interlock feature engages the sides of the plurality of battery units.

[0037] Solution 12. The rechargeable energy storage system according to Solution 1, wherein the interlock feature engages the bottoms of the plurality of battery units.

[0038] Solution 13. The rechargeable energy storage system according to Solution 1, wherein the interlock feature engages the sides and bottoms of the plurality of battery units.

[0039] Solution 14. The rechargeable energy storage system according to Solution 1, wherein the unit support tray includes a plurality of ventilation channels located below the unit.

[0040] Solution 15. The rechargeable energy storage system according to Solution 1, wherein the plurality of battery cells are cylindrical.

[0041] Solution 16. The rechargeable energy storage system according to Solution 1, wherein the plurality of battery cells are prismatic.

[0042] Solution 17. The rechargeable energy storage system according to Solution 1, wherein the plurality of battery cells are encapsulated in a polymer filling.

[0043] Solution 18. The rechargeable energy storage system according to Solution 1, wherein the unit support tray includes an upper tray and a lower tray.

[0044] Solution 19. The rechargeable energy storage system according to Solution 18, wherein at least one of the upper tray and the lower tray is made of one of nylon, polycarbonate, and polypropylene.

[0045] Solution 20. A rechargeable energy storage system, comprising:

[0046] A unit support tray including a plurality of battery interlock features, wherein the unit support tray includes a plurality of ventilation passages through the unit support tray, and the unit support tray includes a plurality of ventilation channels located below the ventilation passages; and

[0047] A plurality of battery cells, each coupled to a respective one of the battery interlock features of the unit support tray, wherein the plurality of battery cells are encapsulated in a polymer filling.

[0048] Other application areas of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and the specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. Brief Description of the Drawings

[0049] The present disclosure will be more fully understood from the detailed description and the drawings, wherein:

[0050] Figure 1 is a schematic diagram of a battery cell support assembly with a mechanical interlock interface according to the principles of the present disclosure;

[0051] Figure 2A and 2B are side and plan views of the mechanical interlock interface during the assembly of the battery therein;

[0052] Figure 3A and 3BIt is a side and plan view of a battery installed in a mechanical interlock interface;

[0053] Figure 4 It is a schematic view of a battery cell support assembly with a mechanical interlock interface according to a second embodiment of the present disclosure;

[0054] Figure 5 It is a perspective view of a battery cell support assembly according to the second embodiment;

[0055] Figure 6 It is a schematic view of a battery cell support assembly with a mechanical interlock interface according to a third embodiment of the present disclosure;

[0056] Figure 7 It is a perspective view of a battery cell support assembly with a mechanical interlock interface according to a fourth embodiment of the present disclosure;

[0057] Figure 8 It is a cross-sectional view of a battery cell support assembly with a mechanical interlock interface according to a fourth embodiment of the present disclosure;

[0058] Figure 9 It is a perspective view of a battery cell support assembly with alignment holes according to a fifth embodiment of the present disclosure; and

[0059] Figure 10 It is a cross-sectional view of a battery cell support assembly with alignment holes according to a fifth embodiment of the present disclosure.

[0060] In the drawings, reference numerals may be reused to identify similar and / or identical elements. Detailed Description

[0061] Referring to Figure 1 、 2A -2B and 3A-3B, a portion of the battery cell support tray 10 is shown for supporting a plurality of battery cells 12 in a battery module. The cell support tray 10 includes a plurality of battery interlock features 14. The battery interlock features 14 may include a generally annular snap ring 16 that may engage an annular groove 18 provided on the wall surface of the plurality of battery cells 12. Referring to Figure 2B , the generally annular snap ring 16 may include a plurality of slots 20, as Figure 2A shown, during insertion of the battery cell, the slots 20 allow flexibility of the snap ring segments 16a-16d to bend away from each other. As Figure 3A and 3B shown, when the snap ring 16 is fully received within the annular groove 18 in the battery cell 12, as Figure 3B shown, the snap ring 16 returns to its original shape. As Figure 1As shown, the cell support tray 10 can be formed by an upper tray portion 10a and a lower tray portion 10b. The upper tray 10a can define a battery interlock feature 14, and the lower tray 10b can define a plurality of ventilation passages 22 and a plurality of channels 24, each of the plurality of ventilation passages 22 communicating with a vent of a battery cell 12, and the plurality of channels 24 communicating with the ventilation passages 22.

[0062] It should be noted that the battery interlock feature 14 can take alternative forms. Referring to Figure 4 and 5 , the battery support tray 30 includes an interlock feature 14, the interlock feature 14 including a snap-in feature 32 that is supported on a flexible sidewall 34 that receives the battery cell 12. During insertion of the battery cell 12, the sidewalls 34 are capable of flexing outwardly to allow the battery cell 12 to be inserted until the snap-in feature 32 is aligned with an annular groove 20 in the battery cell 12. In this case, the snap-in feature 32 engages the annular groove 20 and the flexible sidewalls 34 return to their undeformed state. The sidewalls 34 can be segmented to provide additional flexibility or they can be continuous around each battery cell 12. As Figure 4 shown, the battery cell support tray 30 includes an upper tray portion 30a and a lower tray portion 30b, the upper tray portion 30a defining a ventilation passage 36 for each battery cell, and the lower tray portion 30b for coupling with the upper tray portion 30a to define a ventilation channel 38 located below the ventilation passage 36. Figure 5 A perspective view of the upper tray portion 30a showing an array of flexible sidewalls 34 surrounding the ventilation passage 36 is shown.

[0063] Referring to Figure 6 , the battery cell support tray 40 is shown, the battery cell support tray 40 including a battery interlock feature 14 that can include a generally annular snap ring 16 that can engage an annular groove 18 provided in a wall surface of the plurality of battery cells 12. Additionally, the battery cell support tray 40 further includes an interlock feature 42 that engages an annular groove 44 at the bottom of the battery cell 12. Figure 6 Also shown is a potting 46 encapsulating the battery cell 12.

[0064] Referring to Figure 7 and 8 , the battery cell support tray 50 is shown, the battery cell support tray 50 including a segmented interlock feature 52 for engaging an annular groove 18 provided in a wall surface of the plurality of battery cells 12. The segmented interlock feature 52 can include two or more partial annular segments that include ribs 54 that can engage an annular groove 18 in the battery cell 12.

[0065] Reference Figure 9 and 10 , a battery cell carrier tray 60 is shown, the battery cell carrier tray 60 including a battery alignment hole 62 in the form of a wall structure 64 that guides and surrounds the battery cell 12, instead of a snap feature. The alignment hole 62 is strategically placed to accurately position the battery cell 12 across the cell carrier tray during assembly.

[0066] The interlock features and other systems of the present disclosure allow the battery cells to self-align during the assembly process and mechanically lock the cells to the cell tray to provide a more robust connection of the cells to the cell tray and prevent the fill from leaking into the ventilation channels. It should be noted that adhesives and / or sealants can also be used to secure the battery cell 12 to the cell carrier tray. The sealant, along with the interlock features, can prevent the fill encapsulated around the battery cell from entering the ventilation path and / or ventilation channels. The battery cell carrier tray of the present application can be formed by molding, 3D printing, and / or multi-piece construction. The cell carrier tray can be made of a plastic material, including but not limited to nylon, polycarbonate, and polypropylene. The plastic material can also contain filler materials, such as but not limited to flame retardants, glass fibers, glass bubbles, etc.

[0067] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or its use. The broad teachings of the disclosure can be implemented in a variety of forms. Thus, while the disclosure includes specific examples, the true scope of the disclosure should not be so limited since other modifications will become apparent after study of the drawings, the specification, and the appended claims. It should be understood that one or more steps within a method can be executed in a different order (or concurrently) without changing the principles of the disclosure. Additionally, while each of the embodiments above is described as having certain features, any one or more of those features described with reference to any one embodiment of the disclosure can be implemented in and / or combined with the features of any one of the other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more of the embodiments with each other are still within the scope of the disclosure.

[0068] Various terms are used to describe spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including "connected," "joined," "coupled," "adjacent," "next to," "on top of," "above," "below," and "disposed." Unless explicitly described as "direct," when the relationship between a first and a second element is described in the foregoing disclosure, the relationship may be a direct relationship in which no other intervening elements exist between the first and second elements, but may also be an indirect relationship in which one or more intervening elements exist between the first and second elements (spatially or functionally). 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 non-exclusive logic "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, comprising: A unit support tray, including a plurality of battery interlock features; And A plurality of battery cells, each coupled to a respective one of the battery interlock features of the unit support tray.

2. The rechargeable energy storage system according to claim 1, wherein, The battery interlock features include protrusions that guide the units into their positions on the unit support, and have mechanical interlock features that engage the units to mechanically lock them after assembly.

3. The rechargeable energy storage system according to claim 1, further comprising an adhesive that secures the plurality of battery cells to the unit support tray.

4. The rechargeable energy storage system according to claim 1, wherein, The plurality of battery interlock features form a watertight seal between the plurality of battery cells and the unit support tray.

5. The rechargeable energy storage system according to claim 1, further comprising a flame retardant elastomeric sealant between the plurality of battery cells and the unit support tray.

6. The rechargeable energy storage system according to claim 1, wherein, The plurality of battery interlock features include snap-fit members with the plurality of battery cells.

7. The rechargeable energy storage system according to claim 6, wherein, The unit support includes three snap features surrounding each of the plurality of battery cells.

8. The rechargeable energy storage system according to claim 6, wherein, The snap-fit members are held on the seams of the plurality of battery cells and pull them downwardly towards the unit support tray.

9. The rechargeable energy storage system according to claim 6, wherein, The plurality of battery interlock features include at least one of a chamfered wall or a stepped wall to guide the plurality of battery cells into place.

10. The rechargeable energy storage system according to claim 1, wherein, The interlock features include a deflectable portion.

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