Battery module, battery pack, vehicle, and method for assembling battery module

Abstract

The invention provides a battery module, a battery pack, a vehicle and a method for assembling the battery module. The battery module includes: a stack of battery cells, each battery cell including terminals at opposite ends of a hard shell; a first beam having a first opening; and a first bus bar. The first beams are arranged parallel to the stacking direction with the ends directed towards the stacking direction and opposite the stacking direction. The first terminal of each battery cell faces the first beam, and the first bus bar electrically connects the first terminals of at least two of the battery cells and is disposed between the stack and the first beam. The first opening is aligned with a position where the first bus bar is connected to the first terminal.

Description

Technical Field

[0001] Aspects of embodiments of the present disclosure relate to a battery module having a side terminal, a battery pack including the battery module, a vehicle including the battery module, and a method for assembling the battery module. Background Art

[0002] Recently, vehicles for transporting goods and people have been developed that use electricity as a source of locomotion. Such electric vehicles are cars that are permanently or temporarily propelled by an electric motor using energy stored in rechargeable batteries. Electric vehicles can be powered solely by batteries (so-called battery electric vehicles or BEVs), or can include a combination of an electric motor and, for example, a conventional internal combustion engine (so-called plug-in hybrid electric vehicles or PHEVs). BEVs and PHEVs use high-capacity rechargeable batteries designed to provide power for propulsion for a sustained period of time.

[0003] A single battery cell includes an electrode assembly, which includes a positive electrode, a negative electrode, and a separator interposed between the electrodes. A solid or liquid electrolyte allows ions (e.g., lithium ions) to move during charging and discharging of the battery cell. The electrode assembly is located in (or housed in) an outer casing and includes electrode terminals, which are located on the outside of the outer casing for establishing an electrically conductive connection with the electrodes. The shape of the outer casing can be, for example, cylindrical or rectangular.

[0004] A battery module is formed of (or includes) a plurality of battery cells connected in series or in parallel with one another. For example, a battery module can be formed by interconnecting the electrode terminals of a plurality of battery cells in an arrangement or configuration depending on the desired power amount, thereby providing a high-power rechargeable battery.

[0005] Battery modules can be constructed in either a block or modular design. In a block design, each battery is connected to a common current collector structure and a common battery management system, and the cells are arranged in a housing. In a modular design, multiple battery cells are connected together to form a submodule, and several submodules are connected together to form a battery module. In automotive applications, battery systems typically include multiple battery modules connected in series to provide the desired voltage.

[0006] A battery pack is a group of any number of (usually identical) battery modules or individual battery cells. The battery modules and the battery cells therein can be configured in series, parallel, or a mixture of the two to provide the desired voltage, capacity, and / or power density. The components of a battery pack include individual battery modules and interconnects that provide electrical conductivity between the battery modules.

[0007] The battery system may also include a battery management system (BMS), which is any suitable electronic system that manages rechargeable batteries, battery modules, and battery packs, for example, by protecting the batteries from operating outside their safe operating areas, monitoring their status, calculating secondary data, reporting that data, controlling their environment, authenticating them, and / or balancing them. For example, the BMS may monitor the battery status represented by voltage (such as the total voltage of the battery pack or battery module, the voltage of each cell), temperature (such as the average temperature of the battery pack or battery module, the coolant inlet temperature, the coolant output temperature, or the temperature of each cell), coolant flow (such as flow rate, cooling liquid pressure), and current. Additionally, the BMS can calculate values ​​based on the above information, such as minimum and maximum cell voltages, state of charge (SOC) or depth of discharge (DOD) to indicate the battery's charge level, state of health (SOH; variously defined measures of a battery's remaining capacity as a percentage of its original capacity), state of power (SOP; the amount of power available within a defined time interval given current power usage, temperature, and other conditions), state of safety (SOS), maximum charge current as charge current limit (CCL), maximum discharge current as discharge current limit (DCL), and the internal impedance of the cell (to determine the open circuit voltage).

[0008] The BMS can be centralized, such that a single controller is connected to the battery cells via multiple wires. The BMS can also be distributed, such that a BMS board is installed at each cell, with only a single communication cable between the battery and the controller (e.g., connected between the battery and the controller). As another example, the BMS can have a modular construction including several controllers, each controller handling a certain number (e.g., a group) of cells, with communication occurring between the controllers. A centralized BMS is the most economical, but has the least scalability and suffers from a large number of wires. A distributed BMS is the most expensive, but is the simplest to install and provides the cleanest assembly. A modular BMS offers a compromise between the advantages and disadvantages of the other two topologies.

[0009] The BMS can protect the battery pack from operating outside its safe operating area. Operation outside the safe operating area can be indicated by overcurrent, overvoltage (for example, during charging), overtemperature, undertemperature, overvoltage, and ground fault or leakage current detection. The BMS can prevent operation outside the safe operating area of ​​the battery by including an internal switch (such as a relay or solid-state device) that opens if the battery operates outside its safe operating area, requests devices connected to the battery to reduce or even terminate use of the battery, and actively controls the environment, such as by using (or controlling) heaters, fans, air conditioners, or liquid cooling circuits.

[0010] Mechanical integration of this battery pack involves, for example, suitable mechanical connections between the individual components of the battery module and between them and the vehicle's supporting structure. These connections must be designed to remain functional and safe throughout the battery system's average service life. Furthermore, installation space and interchangeability standards must be met, particularly in mobile applications.

[0011] Mechanical integration of the battery module can be achieved by providing a carrier frame and positioning the battery module thereon. Securing the battery cells or battery module can be achieved by using mating recesses in the frame and / or by mechanical interconnectors (e.g., bolts or screws). In other examples, the battery module is restrained by fastening side panels to the lateral sides of the carrier frame. Additionally, cover plates can be secured on top of and below the battery module.

[0012] The battery pack's carrier frame is attached to the vehicle's load-bearing structure. When the battery pack is secured to the vehicle's floor, a mechanical connection can be established from the underside, for example, by bolts passing through the battery pack's carrier frame. The frame is typically made of aluminum or an aluminum alloy to reduce the overall weight of the construction.

[0013] Battery systems according to the related art, despite any modular structure, typically include a battery housing that serves as an outer shell to seal the battery system from environmental influences and provide structural protection for the components of the battery system. The battery system equipped with the housing is typically installed as a whole into its application environment, such as an electric vehicle. Therefore, replacing a defective system component, such as a defective battery sub-module, requires first disassembling the entire battery system and removing its housing. Even defects in small and / or inexpensive system components may require disassembly and replacement of the entire battery system and its separate repair. Because high-capacity battery systems are expensive, large and heavy, such a process is cumbersome and storage of bulky battery systems (such as in a mechanic's workshop) is difficult.

[0014] Static control of battery power output and charging may not be sufficient to meet the dynamic power requirements of various electrical appliances connected to the battery system. Therefore, a stable information exchange between the battery system and the controller of the electrical appliance can be achieved. This information includes the actual state of charge (SoC), potential electrical performance, charging capability and internal resistance of the battery system, as well as the actual or predicted power demand or surplus of the electrical appliance. Therefore, the battery system typically includes a battery management system (BMS) for obtaining and processing such information at the system level, and also includes multiple battery module managers (BMMs), which are part of the battery module of the system and obtain and process relevant information at the module level. The BMS typically measures the system voltage, system current, local temperature at different locations within the system housing, and insulation resistance between the live component and the system housing. And the BMM typically measures the individual cell voltages and temperatures of the battery cells in the battery module.

[0015] Thus, a BMS / BMM is provided for managing the battery pack, such as by protecting the batteries from operating outside their safe operating area (or safe operating parameters), monitoring their status, calculating secondary data, reporting that data, controlling their environment, authenticating them, and / or balancing them.

[0016] In the event of an abnormal operating state, the battery pack can typically be disconnected from the load connected to the terminals of the battery pack. To this end, the battery system also includes a battery disconnect unit (BDU) electrically connected between the battery module and the battery system terminals. Therefore, the BDU is the main interface between the battery pack and the electrical system of the load (such as a vehicle). The BDU includes an electromechanical switch that opens or closes the high current path between the battery pack and the electrical system. The BDU provides feedback, such as voltage and current measurements, to a battery control unit (BCU) that accompanies the battery module. The BCU controls the switches in the BDU by using a low current path based on feedback received from the BDU. The BDU can control the current flow between the battery pack and the electrical system and sense the current. The BDU can also manage external charging and pre-charging.

[0017] To ensure proper thermal control of the battery pack, a thermal management system can be utilized to safely use at least one battery module by effectively emitting, dissipating, and / or dissipating heat generated from its rechargeable batteries. If heat emission / heat discharge / heat dissipation is not adequately performed, temperature deviations occur between different battery cells, which may result in the battery module being unable to generate the desired amount of power. In addition, an increase in internal temperature may cause abnormal reactions to occur therein, thereby degrading the charging and discharging performance of the rechargeable battery and shortening the life of the rechargeable battery. Therefore, cell cooling for effectively emitting / discharging / dissipating heat from the cells is desirable.

[0018] The exothermic decomposition of a cell assembly can lead to what is known as thermal runaway. In general, thermal runaway describes a process that is accelerated by increased temperature, which in turn releases energy that further increases the temperature. Thermal runaway occurs when a temperature increase changes conditions in a way that causes a further increase in temperature, usually with destructive consequences. In rechargeable battery systems, thermal runaway is associated with a strongly exothermic reaction that is accelerated by the temperature increase. In thermal runaway, the temperature of the battery cell rises very quickly and the stored energy is released very suddenly. In extreme cases, thermal runaway can cause the battery cell to explode and start a fire. In other cases, it can cause the battery cell to be damaged beyond repair.

[0019] When a battery cell is heated above a critical temperature (e.g., above 150°C), it can transition to a thermal runaway state. Typically, temperatures outside the safety zone on the low or high side can cause irreversible damage to the battery and, therefore, can trigger thermal runaway. Thermal runaway can also occur due to an internal or external short circuit in the battery or poor battery maintenance. For example, overcharging or rapid charging can cause thermal runaway.

[0020] During thermal runaway, a failed battery cell can reach temperatures exceeding 700°C. Furthermore, large amounts of hot gases are ejected from the interior of the failed battery cell through the exhaust openings in the cell housing into the battery pack. The main components of the exhaust gases are H2, CO2, CO, electrolyte vapor, and other hydrocarbons. Therefore, the exhaust gases are flammable and potentially toxic. The exhaust gases also cause the gas pressure within the battery pack to increase. In the worst case, the high temperature causes the process to spread to adjacent cells and cause a fire in the battery pack. At this stage, the fire may be difficult to extinguish.

[0021] A battery management system (BMS) ensures safe operation and optimal performance of secondary batteries and helps reduce or minimize the possibility of thermal runaway. For example, if the BMS detects that the temperature is too high, it can regulate the temperature by controlling the cooling fan. Alternatively, if the battery or cell cannot be cooled and safe conditions cannot be restored, the BMS can shut down the necessary cells to protect the entire system.

[0022] As mentioned above, secondary batteries (e.g., Li-ion batteries) in battery electric vehicles are mounted in specially designed housings, where the individual cells are electrically connected to each other. Furthermore, the housing typically provides thermal management for the battery cells and protects them from mechanical intrusion or damage. In the case of prismatic or pouch-shaped cells, the housing or its subassemblies maintain a certain degree of compression on these cells and resist expansion forces of the cells to prevent accelerated aging.

[0023] In one design, multiple battery cells are arranged in modules. These serve as subassemblies of the battery housing, interconnecting the battery cells to a circuit and carrying (or absorbing) the expansion force of one or more stacks of battery cells. The stack of battery cells may include multiple prismatic or pouch-shaped cells and cell spacers (or distance keepers) or compression pads. In the related art, the battery module generally does not contribute significantly to the rigidity of the housing, which means that the housing protects the module from mechanical abusing load cases by carrying and transmitting all external loads.

[0024] In newer designs, one or more stacks of battery cells can be inserted directly into the battery housing that carries the expansion forces. This design is called "cell-to-pack" or "cell-to-vehicle" and offers reduced cost and higher volumetric and gravimetric energy density at the pack level, but requires more complex assembly and reduced ability to disassemble later. These disadvantages are particularly problematic for side-terminal batteries (prismatic or pouch-shaped), where the cell interconnecting busbars must be applied to the stack of battery cells on two opposing sides before the battery cell stack is inserted into the housing. Summary of the Invention

[0025] A battery module is needed that has a structure that provides similar energy density to the above-described cell-to-pack approach but provides simplified assembly, particularly for side-terminated (e.g., side posts) cells. Furthermore, a battery module is needed that has a lightweight design and also provides improved load transfer capabilities. Furthermore, a battery pack that includes such a battery module is needed. Furthermore, a method for simply assembling such a battery module is needed.

[0026] Embodiments of the present disclosure provide a battery module having a structure that provides energy density similar to that of a cell-to-pack approach but provides simplified assembly, particularly for side terminal (e.g., side post) battery cells. In addition, embodiments of the present disclosure provide a battery module having a lightweight design that also exhibits improved load transfer capability. In addition, embodiments of the present disclosure provide a battery pack including such a battery module. In addition, embodiments of the present disclosure provide a method for simply assembling such a battery module.

[0027] The present disclosure is defined by the appended claims and their equivalents. The following description is subject to such limitations. Any disclosure outside the scope of the claims and their equivalents is intended for illustrative and comparative purposes.

[0028] According to an embodiment of the present disclosure, a battery module includes: a stack of battery cells, the stack including a plurality of battery cells arranged in a row along a stacking direction; each of the battery cells including a hard case having a parallelepiped shape, the parallelepiped shape having a pair of major side surfaces arranged opposite each other, a first terminal side surface and a second terminal side surface arranged opposite each other, and a lower side surface and an upper side surface arranged opposite each other, the major side surfaces of each battery cell being arranged perpendicular to the stacking direction; each of the battery cells further including a first terminal arranged on the first terminal side surface and a second terminal arranged on the second terminal side surface, the first terminal forming one electrode column of the battery cell and the second terminal forming an opposite electrode column of the battery cell; a first beam having one or more first openings and a second beam having one or more second openings; at least one first bus bar and at least one second bus bar. Each of the first and second beams is arranged parallel to the stacking direction and has a first end pointing opposite the stacking direction and a second end pointing in the stacking direction. The stack is arranged between the first and second beams. The first terminal side surface of each battery cell faces the first beam, and the second terminal side surface of each battery cell faces the second beam. Each of the first bus bars electrically connects a first terminal of at least two of the battery cells and is arranged between the stack and the first beam, and each of the second bus bars electrically connects a second terminal of at least two of the battery cells and is arranged between the stack and the second beam. The first opening is located at a position where the first bus bar is connected to the first terminal, and the second opening is located at a position where the second bus bar is connected to the second terminal.

[0029] According to another embodiment of the present disclosure, a battery pack includes at least one battery module as described above.

[0030] Another embodiment of the present disclosure provides a vehicle, comprising at least one of the above-mentioned battery modules and / or at least one of the above-mentioned battery packs.

[0031] Another embodiment of the present disclosure provides a method for assembling a battery module as described above. The method includes: arranging battery cells into a stack in a stacking direction so that the main side of each battery cell is arranged perpendicular to the stacking direction; attaching a first bus bar to a first beam and attaching a second bus bar to a second beam; arranging the first beam along the stack so that each of the first terminal sides faces the first beam and the first beam is oriented so that each of the first bus bars is positioned between the first beam and the stack; arranging the second beam along the stack so that each of the second terminal sides faces the second beam and the second beam is oriented so that each of the second bus bars is positioned between the second beam and the stack; moving the first beam toward the stack so that the first bus bar abuts the first terminal located in the area of ​​the first bus bar and connects the first bus bar to the first terminal located in the area of ​​the first bus bar via the first opening; moving the second beam toward the stack so that the second bus bar abuts the second terminal located in the area of ​​the second bus bar and connects the second bus bar to the second terminal located in the area of ​​the second bus bar via the second opening.

[0032] Other aspects and features of the present disclosure can be learned from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Aspects and features of the present disclosure will become apparent to those skilled in the art by describing in detail embodiments of the present disclosure with reference to the accompanying drawings, in which:

[0034] Figure 1A is a perspective view of a side-post battery cell according to an embodiment of the present disclosure.

[0035] Figure 1B is a perspective view of a side-post battery cell according to another embodiment of the present disclosure.

[0036] Figure 2 is a schematic perspective view of a battery module according to an embodiment of the present disclosure.

[0037] Figure 3 yes Figure 2 Schematic exploded view of the assembly of the first beam and the first busbar carrier of the battery module shown in .

[0038] Figure 4 Schematically shows Figure 2 A partial exploded view of the battery module shown in .

[0039] Figure 5 Schematically shows Figure 2 A partial perspective view of the battery module shown in FIG.

[0040] Figure 6 Schematically shows Figure 2 A partial perspective view of the battery module shown in FIG.

[0041] Figure 7 Schematically shows Figure 2 Exploded view of the battery module shown in .

[0042] Figure 8 A cross-sectional view schematically illustrates a battery pack according to another embodiment of the present disclosure.

[0043] Figure 9 A perspective view schematically shows a battery module according to another embodiment of the present disclosure.

[0044] Figure 10A Schematically shows Figure 9 A perspective view of the first beam of the battery module shown in FIG.

[0045] Figure 10B Schematically shows Figure 9 Another perspective view of the first beam of the battery module shown in .

[0046] Figure 11 yes Figure 10A An enlarged view of the first beam is shown in FIG.

[0047] Figure 12 A perspective view schematically illustrates a plurality of bus bars and other components connected to the bus bars.

[0048] Figure 13 Schematically shows the Figure 9 A perspective view of a battery pack with a battery module shown in FIG.

[0049] Reference numerals

[0050] 1,2 battery modules

[0051] 10,10' battery cells

[0052] 10a, 10a' hard shell

[0053] 11 First lateral side / first terminal side

[0054] 12 Second lateral side / second terminal side

[0055] 13,14 Main side

[0056] 15 lower side

[0057] 16 Upper side

[0058] 20 Cell Isolator including Module Management Controller (MMC)

[0059] 20a connector

[0060] 21,22 Monomer spacer

[0061] 31,32 End Plate

[0062] 41,42 belt

[0063] 41' strip

[0064] 41a Strip Connector

[0065] 41b bulge

[0066] 51,51 Busbar cover

[0067] 71,72 Protection components

[0068] 100 battery pack

[0069] 101,101' First beam

[0070] 101a first recess

[0071] 102 Second Beam

[0072] 102a Second recess

[0073] 111 First busbar carrier

[0074] 112 Second busbar carrier

[0075] 150a, 150b Support pillars

[0076] 151a, 151b Vertical parts of support pillars

[0077] 160 base plate

[0078] 162a, 162b support bracket

[0079] 164a, 164b Cross Brackets

[0080] 170 exhaust plate

[0081] 180 cooling plate

[0082] 190 side panels

[0083] 190a Lower part of the side panel

[0084] 190b Upper side panel

[0085] 201 First Bus

[0086] 301 First Bolt or Screw

[0087] 302 Second bolt or screw

[0088] 311 First protrusion of the first end plate

[0089] 312 second protrusion of the first end plate

[0090] 400 bracket or bolt

[0091] 1011a, 1011b Shoulders

[0092] 1012 Pillar

[0093] 1012' Thick Pillar

[0094] 1013a, 1013b drilling

[0095] 1116 grabber

[0096] 1022' Thick Pillar

[0097] 1022a incision

[0098] AA dashed line

[0099] B1 and B2 areas

[0100] C1, C2 connector board

[0101] M1,M2,M3,M4,M5,M6 battery modules

[0102] O1 First opening

[0103] O2 Second opening

[0104] S1, S2 submodules

[0105] U1,U2,U3 pre-assembled units

[0106] V exhaust outlet

[0107] x,y,z axes of the Cartesian coordinate system DETAILED DESCRIPTION

[0108] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Aspects and features of the embodiments and methods of implementing the embodiments will be described with reference to the accompanying drawings. However, the present disclosure may be implemented in a variety of different forms and should not be construed as limited to the embodiments illustrated herein. Rather, these embodiments are provided as examples so that this disclosure will be thorough and complete and will fully convey the aspects and features of the disclosure to those skilled in the art.

[0109] Therefore, processes, elements, and techniques that are not considered necessary for one of ordinary skill in the art to have a complete understanding of the aspects and features of the present disclosure may not be described or may be described only briefly.

[0110] It should be understood that when an element or layer is referred to as being “on,” “connected to,” or “coupled to” another element or layer, it can be directly on, directly connected to, or coupled to the other element or layer, or one or more intervening elements or layers may be present. When an element or layer is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers. For example, when a first element is described as being “coupled to” or “coupled to” a second element, the first element can be directly coupled to or coupled to the second element, or the first element can be indirectly coupled to or coupled to the second element via one or more intervening elements.

[0111] In the accompanying drawings, for clarity of explanation, the sizes of various elements, layers, etc. may be exaggerated. The same reference numerals represent the same elements. As used herein, the term "and / or" includes any and all combinations of one or more associated listed items. In addition, when describing the embodiments of the present disclosure, the use of "may" relates to "one or more embodiments of the present disclosure". Expressions such as "at least one of ... " and "any one of ... " modify the entire element list when following the element list, without modifying the individual elements in the list. For example, the expression "at least one of a, b or c" represents only a, only b, only c, a and b both, a and c both, b and c both, a, b and c all or its variant. As used herein, the term "use (use)", "use ... (using)" and "used (used)" can be considered to be synonymous with the term "utilize (utilize)", "utilize ... (utilizing)" and "utilized (utilized)" respectively.

[0112] It should be understood that although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms are used to distinguish an element, component, region, layer or part from another element, component, region, layer or part. Therefore, without departing from the teachings of the example embodiments, the first element, component, region, layer or part discussed below can be referred to as a second element, component, region, layer or part.

[0113] In this document, the terms "upper" and "lower" are defined according to the z-axis in the accompanying drawings. For example, the upper cover is located on the upper part of the z-axis and the lower cover is located below it. However, for ease of description, spatial relative terms such as "below", "below", "lower", "above", "upper", etc. may be used herein to describe the relationship between one element or feature and another or more elements or features as shown in the figures. It should be understood that in addition to the orientation shown in the figures, the spatial relative terms are intended to cover different orientations of the device in use or operation. For example, if the device in the drawings is turned over, the elements described as "below" or "below" other elements or features will be oriented as "above" or "on" other elements or features. Therefore, the term "below" can cover both the above and below orientations. The device can be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptors used herein should be interpreted accordingly.

[0114] The terms used herein are for the purpose of describing the embodiments of the present disclosure and are not intended to limit the present disclosure. As used herein, the singular forms "a" and "an" are intended to also include the plural forms, unless the context clearly indicates otherwise. It will be further understood that when used in this specification, the terms "includes," "including," "comprises," and / or "comprising" specify the presence of the features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0115] As used herein, the terms "substantially," "approximately," and similar terms are used as terms of approximation rather than terms of degree, and are intended to take into account the inherent variations in measured or calculated values ​​that one of ordinary skill in the art would recognize. Furthermore, if the term "substantially" is used in conjunction with a feature that can be expressed using a numerical value, the term "substantially" means a range of + / - 5% of the value centered around that value.

[0116] Any suitable hardware, firmware (e.g., an application specific integrated circuit), software, or a combination of software, firmware, and hardware can be utilized to implement the electronic devices and / or any other related devices or components according to the embodiments of the present disclosure described herein. In addition, the various components of these devices can be implemented on flexible printed circuit films, tape carrier packages (TCPs), printed circuit boards (PCBs), or formed on a substrate. The electrical connections or interconnections described herein can be implemented by wires or conductive elements on, for example, a PCB or another circuit carrier. The conductive elements can include metallizations, such as surface metallizations and / or pins, and / or can include conductive polymers or ceramics. In addition, electrical energy can be transmitted via a wireless connection, such as by using electromagnetic radiation and / or light.

[0117] In addition, the various components of these devices can be processes or threads running on one or more processors in one or more computing devices, executing computer program instructions and interacting with other system components for performing the various functions described herein. The computer program instructions are stored in a memory that can be implemented in a computing device using standard memory devices such as, for example, random access memory (RAM). The computer program instructions can also be stored in other non-transitory computer-readable media such as, for example, a CD-ROM, a flash drive, etc.

[0118] Furthermore, those skilled in the art will recognize that the functionality of various computing devices may be combined or integrated into a single computing device, or that the functionality of a particular computing device may be distributed across one or more other computing devices without departing from the scope of the exemplary embodiments of the present disclosure.

[0119] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure belongs. It will be further understood that, unless expressly defined as such herein, terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and / or this specification, and should not be interpreted in an idealized or overly formal sense.

[0120] According to an embodiment of the present disclosure, a battery module includes: a stack of battery cells, the stack including a plurality of battery cells arranged in a row along a stacking direction; each of the battery cells including a hard shell having a parallelepiped shape, the parallelepiped shape having a pair of main side surfaces arranged opposite each other, a first terminal side surface and a second terminal side surface arranged opposite each other, and a lower side surface and an upper side surface arranged opposite each other, the main side surfaces of each battery cell being arranged perpendicular to the stacking direction; each battery cell including a first terminal arranged on the first terminal side surface and a second terminal arranged on the second terminal side surface, the first terminal forming one electrode column of the battery cell, and the second terminal forming an opposite electrode column of the battery cell; a first beam having one or more first openings and a second beam having one or more second openings; one or more first bus bars and one or more second bus bars. Each of the first and second beams is arranged parallel to the stacking direction and has a first end pointing opposite the stacking direction and a second end pointing in the stacking direction. The stack is arranged between the first and second beams. The first terminal side surface of each battery cell faces the first beam, and the second terminal side surface of each battery cell faces the second beam. Each of the first bus bars is electrically connected to first terminals of at least two of the battery cells through at least two first connectors and is arranged between the stack and the first beam, and each of the second bus bars is electrically connected to second terminals of at least two of the battery cells through at least two second connectors and is arranged between the stack and the second beam. The first opening is aligned with a corresponding first connector of the first connectors, and the second opening is aligned with a corresponding second connector of the second connectors.

[0121] Therefore, embodiments of the present disclosure provide a battery module comprising so-called "side-terminal battery cells". The battery module exhibits an energy density similar to that of a cell-to-pack approach while also providing simplified assembly. In addition, the battery module includes a load transfer capability, which increases the possibility of lightweight design. The above-mentioned battery module includes a structure that provides an energy density similar to that of a cell-to-pack approach while allowing simplified assembly, particularly for side terminal / side-terminal battery cells. In addition, the battery module can utilize a hard shell (e.g., a relatively rigid housing, cylinder, or can) of the side terminal battery cells to achieve further load transfer capability laterally across the battery module, resulting in significant load transfer capability in all three spatial directions. This results in a significant increase in the potential for lightweight design.

[0122] One aspect of embodiments of the present disclosure can be briefly summarized as providing a structurally integrated modular assembly concept for battery cell stacks including side terminal battery cells.

[0123] For example, the first opening provides access to the location where the first connection is located, and the second opening provides access to the location where the second connection is located. Thus, during manufacture of the battery module and / or when repairing the battery module, the first opening as well as the second opening provide access to the location where the connection is to be made (or, during repair of the battery module, released).

[0124] In various embodiments, some or all of the first and second connections can be established by welding (e.g., by fusion welding). In addition, some or all of the first and second connections can be established by screwing or clamping.

[0125] In various embodiments, some or all of the first and second connections may be covered with a bus bar cover that ensures sufficient creep distance.

[0126] According to an embodiment of the present disclosure, the battery module is adapted to transmit a compressive load along a stacking direction (eg, in the stacking direction or against the stacking direction).

[0127] According to an embodiment of the present disclosure, when the battery cells each include a hard case, the battery module is suitable for transmitting a compressive load acting transversely to the stacking direction and a compressive load acting perpendicularly to the terminal side of the battery cells.

[0128] According to an embodiment of the present disclosure, the battery module is further configured to absorb shear forces acting in a direction transverse to the stacking direction and / or in a direction transverse to a direction perpendicular to the sides of the first and second terminals. When the battery module is mounted in the battery pack via a beam, the shear forces may be applied to the battery module by the load cases of the battery pack, and when the battery modules each include a hard shell, the shear forces may be applied to the battery module by the battery cells.

[0129] In a battery module, according to an embodiment of the present disclosure, the first terminal side and the second terminal side of each battery cell can be arranged to be perpendicular to a first lateral direction that is not parallel to the stacking direction, and the lower side and the upper side of each battery cell can be arranged to be perpendicular to the second lateral direction, which is not parallel to the stacking direction and each of the first lateral directions.

[0130] In various embodiments of the battery module, the stacking direction is perpendicular to the first transverse direction. In various embodiments of the battery module, the stacking direction is perpendicular to the second transverse direction. In various embodiments of the battery module, the first transverse direction is perpendicular to the second transverse direction. In some embodiments of the battery module, any two of the stacking directions (the first transverse direction and the second transverse direction) are perpendicular to each other. In the latter embodiment, the hard shell of each of the battery cells has a rectangular parallelepiped shape.

[0131] In various embodiments of the battery module, the hard shell of at least one battery cell is made of metal. In some embodiments of the battery module, the hard shell of each of the battery cells is made of metal.

[0132] In various embodiments of the battery module, for each battery cell, the (roughly or substantially equal sized) major side may be the side with the largest area among the sides of the battery cell (e.g., the lower side, the upper side, the first terminal side, and the second terminal side).

[0133] In various embodiments of the battery module, for each battery cell, the (approximately or substantially equal sized) terminal side (e.g., the first terminal side and the second terminal side) can be the side with the smallest area among the sides (e.g., the main side, the lower side, and the upper side) of the battery cell.

[0134] In some embodiments of the battery module, a first opening is located at each location of the first electrical connection, and / or a second opening is located at each location of the second electrical connection.

[0135] For the sake of understandability, the terms "lower side" and "upper side" are used. However, without changing or departing from the above description, the term "lower side" can be replaced by, for example, the term "first lateral side" or "first cover side", and the term "upper side" can be replaced by, for example, the term "second lateral side" or "second cover side".

[0136] In various embodiments, the first beam has a lower shoulder and an upper shoulder, each shoulder extending in a stacking direction and spaced apart from each other. The lower shoulder can be connected to the upper shoulder by a plurality of struts. In such embodiments, the first opening can be formed by gaps between the struts (relative to the stacking direction) and by gaps between the lower shoulder and the upper shoulder (relative to a direction perpendicular to the stacking direction).

[0137] In various embodiments, the second beam has a lower shoulder and an upper shoulder, each shoulder extending in the stacking direction and spaced apart from each other. The lower shoulder can be connected to the upper shoulder by a plurality of struts. In such embodiments, the first opening can be formed by gaps between the struts (relative to the stacking direction) and by gaps between the lower shoulder and the upper shoulder (relative to a direction perpendicular to the stacking direction).

[0138] In various embodiments, the battery module may be configured to be clamped with respect to a direction perpendicular to the lower and upper sides of the battery cell by using the first beam and / or the second beam.

[0139] In one embodiment, the battery module further includes a first end plate and a second end plate. The first end plate is attached to the first end of the first beam and the first end of the second beam, and when viewed in the stacking direction, the first end plate abuts the battery cell arranged at the first position in the row of battery cells. The second end plate is attached to the second end of the first beam and the second end of the second beam, and when viewed in the stacking direction, the second end plate abuts the battery cell arranged at the last position in the row of battery cells.

[0140] In this manner, the battery cells of the battery module can be compressed along the stacking direction, and the load caused by this compression is absorbed by the beams due to the attachment (e.g., mechanical connection) between the first and second end plates and the first and second beams. In addition, expansion forces generated by expansion of the battery cells relative to the stacking direction (e.g., during use of the battery module or due to aging of the battery cells in the battery module) can then be transferred to the beams through the end plates and then absorbed by the beams.

[0141] In the above embodiment, because the beams and the end plates carry the load, bus bar welding can be performed on both terminal sides in the final pre-compressed state of the stack of battery cells.

[0142] In various embodiments of the battery module, the first end plate may include a first mounting point. For example, the first mounting point may be configured to mount the battery module in the battery pack. Correspondingly, the second end plate may include a second mounting point. For example, the second mounting point may be configured to mount the battery module in the battery pack.

[0143] In various embodiments of the battery module, the first end plate and / or the second end plate may include at least one pocket and / or at least one holder configured to accommodate or hold a cell sensing and / or balancing board.

[0144] In various embodiments of the battery module, the first end plate and / or the second end plate may be made of a polymer material.

[0145] In various embodiments of the battery module, the first end plate and / or the second end plate may be made of a metal material.

[0146] In one embodiment of the battery module, when viewed in the stacking direction, the electrode polarities of the first terminals alternate. In addition, the sum of the number of the first busbars and the number of the second busbars is equal to (N−1), where N represents the number of battery cells included in the battery module. When viewed in the stacking direction and for each natural number k (where 1≤k<N / 2), the first terminal of the (2k) - th battery cell is electrically connected via one of the first busbars to the first terminal of the (2k + 1) - th battery cell. In addition, when viewed in the stacking direction and for each natural number k (where 1≤k≤N / 2), the second terminal of the (2k−1) - th battery cell is electrically connected via one of the second busbars to the second terminal of the (2k) - th battery cell.

[0147] Since, for each battery cell, the second terminal forms a pole having an electrode polarity opposite to that of its first terminal, when viewed in the stacking direction, the electrode polarities of the second terminals also alternate in the above - described embodiment.

[0148] For example, in such an embodiment, the battery cells of the module are electrically connected in series.

[0149] In the above - described embodiment, the first terminal of the first battery cell (when viewed in the stacking direction) may form the first terminal of the battery module. In addition, when the number of battery cells in the battery module is odd, the second terminal of the last battery cell (when viewed in the stacking direction) may form the second terminal of the battery module. In another embodiment, when the number of battery cells in the battery module is even, the first terminal of the last battery cell (when viewed in the stacking direction) may form the second terminal of the battery module. [[ID=ID=10]]

[0150] In the above - described embodiment, the electrode polarity of the first terminal of the battery cell first arranged when viewed in the stacking direction may be negative (therefore, in such an embodiment, the electrode polarity of the second terminal of the battery cell first arranged when viewed in the stacking direction is positive). In another embodiment, the electrode polarity of the first terminal of the battery cell first arranged when viewed in the stacking direction may be positive (therefore, in the latter embodiment, the electrode polarity of the second terminal of the battery cell first arranged when viewed in the stacking direction is negative).

[0151] For example, when viewed in the stacking direction, the first terminal of the first battery cell forms a negative pole, the first terminal of the second battery cell forms a positive pole, the first terminal of the third battery cell forms a negative pole, and so on. Then, the positive pole of the first battery cell (for example, the second terminal of the first battery cell) is connected to the negative pole of the second battery cell (for example, the second terminal of the second battery cell). In addition, the positive pole of the second battery cell (for example, the first terminal of the second battery cell) is connected to the negative pole of the third battery cell (for example, the first terminal of the third battery cell), and so on.

[0152] In another embodiment of the battery module, the electrical polarity of each of the first terminals is the same (e.g., negative), and furthermore, the electrical polarity of each of the second terminals is the same and opposite to the polarity of the first terminal. In addition, in this embodiment, the battery module includes only two bus bars—a single first bus bar and a single second bus bar. The first bus bar is connected to each of the first terminals, and the second bus bar is connected to each of the second terminals. For example, in such an embodiment, the battery cells are connected in parallel to each other. Here, the first bus bar can form the first terminal of the battery module, and the second bus bar can form the second terminal of the battery module.

[0153] In one embodiment, the battery module further includes: a first cell connection unit including a first bus bar carrier holding the first bus bar; and / or a second cell connection unit including a second bus bar carrier holding the second bus bar.

[0154] The first busbar carrier can be made of an insulating material such as plastic. Thus, the first busbars are electrically insulated from each other and from the first beam. Furthermore, the insulating first busbar carrier can cover the entire first terminal side of each battery cell, thereby providing increased electrical isolation of the battery cell from the first beam (if the latter is made of a conductive material) and also providing tolerance compensation.

[0155] In some embodiments, an insulating layer may be interposed between any one of the first bus bars and the first bus bar carrier.

[0156] Accordingly, the second busbar carrier can be made of an insulating material such as plastic. Thus, the second busbars are electrically insulated from each other and from the second beam. Furthermore, the insulating second busbar carrier can cover the entire second terminal side of each battery cell, thereby providing increased electrical isolation of the battery cell from the second beam (if the latter is made of a conductive material) and also providing tolerance compensation.

[0157] In some embodiments, an insulating layer may be interposed between any one of the second bus bars and the second bus bar carrier.

[0158] Some or all of the first busbars may be overmolded or clamped or glued into the first busbar carrier. Furthermore, some or all of the second busbars may be overmolded or clamped or glued into the second busbar carrier.

[0159] In one embodiment, the first cell connection unit is arranged between the stack and the first beam, and / or the second cell connection unit is arranged between the stack and the second beam.

[0160] In one embodiment, the battery module further comprises: a first cover arranged on a side of the first beam facing away from the stack; and / or a second cover arranged on a side of the second beam facing away from the stack.

[0161] Thus, the first beam and the first bus bar visible / accessible through the opening in the first beam are covered by the first cover and are thus protected by the first cover. Similarly, the second beam and the second bus bar visible / accessible through the opening in the second beam are covered by the second cover and are thus protected by the second cover.

[0162] In one embodiment, for at least one pair of adjacent battery cells included in the stack, a cell spacer is disposed between the pair of battery cells.

[0163] Cell spacers (also called spacer sheets) may be included to improve the thermal and / or structural (mechanical) performance of the battery module. For example, in various embodiments, a cell spacer may be inserted into the stack after every n battery cells.

[0164] In one embodiment of the battery module, one of the cell spacers includes a module management controller.

[0165] In one embodiment, a battery module includes a first submodule and a second submodule. The first submodule is separated from the second submodule by a cell spacer including a module management controller. When viewed in the stacking direction, the first submodule includes stacked battery cells in front of the cell spacer including the module management controller, and the second submodule includes stacked battery cells behind the cell spacer including the module management controller.

[0166] In various embodiments, the battery cells in the first submodule are connected in series and / or the battery cells in the second submodule are connected in series. In various embodiments, the battery cells in the first submodule are connected in series, and the battery cells in the second submodule are connected in parallel. In various embodiments, the battery cells in the first submodule are connected in parallel, and the battery cells in the second submodule are connected in series. In various embodiments, the battery cells in the first submodule are connected in series, and / or the battery cells in the second submodule are connected in parallel.

[0167] In one embodiment of the battery module, the battery cells are each thermally connected to at least one module cooling plate.

[0168] In various embodiments, a lower module cooling plate is provided along the lower sides of the battery cells, and each of the battery cells abuts the lower side of the lower module cooling plate. Additionally or alternatively, an upper module cooling plate is provided along the upper sides of the battery cells, and each of the battery cells abuts the upper side of the upper module cooling plate.

[0169] Here, for the sake of understandability, the terms "lower module cooling plate" and "upper module cooling plate" are used. Alternatively, and without changing or departing from the above embodiment, the term "lower module cooling plate" may be replaced by, for example, the term "first module cooling plate," and the term "upper module cooling plate" may be replaced by, for example, the term "second module cooling plate."

[0170] The lower module cooling plate may be glued onto the entire surface of the stack formed by the lower sides of the battery cells or onto substantially the entire surface of the stack formed by the lower sides of the battery cells. Correspondingly, the upper module cooling plate may be glued onto the entire surface of the stack formed by the upper sides of the battery cells or onto substantially the entire surface of the stack formed by the upper sides of the battery cells.

[0171] In one embodiment, the battery module further includes: a module exhaust plate provided along the lower side of the battery cells; and a module cooling plate provided along the upper side of the battery cells. Each battery cell abuts the module exhaust plate with its lower side, and the module cooling plate is thermally connected to each upper side of the battery cells.

[0172] In the above embodiment, the module exhaust plate may be glued to the entire surface of the stack formed by the lower sides of the battery cells or substantially the entire surface of the stack formed by the lower sides of the battery cells. In addition, the module cooling plate may be glued to the entire surface of the stack formed by the upper sides of the battery cells or substantially the entire surface of the stack formed by the upper sides of the battery cells.

[0173] The aforementioned plates (e.g., cooling plates and / or vent plates) also provide the final (mechanical) support for the battery cells included in the battery module against impact loads. Otherwise, i.e., without the plates, the battery cells would be held in place solely by busbar welds. Therefore, in the aforementioned embodiments including at least one plate (e.g., at least one of the cooling plates and / or vent plates), the impact resistance of the battery module is improved compared to a bare module without the plates.

[0174] According to another embodiment of the present disclosure, a battery pack includes at least one battery module as described above.

[0175] Embodiments of the battery pack may include at least one pack cooling plate. For example, one or more module cooling plates of a battery module included in the battery pack may be formed from respective portions of the pack cooling plate.

[0176] For example, the battery pack may include a lower pack cooling plate. At least some of the lower module cooling plates of at least some of the battery modules may then form part of the lower pack cooling plate. Alternatively or additionally, the battery pack may include an upper pack cooling plate. At least some of the upper module cooling plates of at least some of the battery modules may then form part of the upper pack cooling plate.

[0177] Embodiments of the battery pack may include at least one pack vent plate. For example, one or more module vent plates of a battery module included in the battery pack may be formed from respective portions of the pack vent plate.

[0178] In some embodiments, the battery pack further comprises a battery pack housing configured to accommodate at least one battery module as described above. The battery pack housing may comprise a load-bearing structure, and the at least one battery module may form a portion of the load-bearing structure.

[0179] In an embodiment of the battery pack, the first beams of at least some of the battery modules may serve as reinforcement ribs for the battery pack housing. Alternatively or additionally, the second beams of at least some of the battery modules may serve as reinforcement ribs for the battery pack housing.

[0180] In various embodiments of the battery pack, at least some of the battery modules included in the battery pack are mounted and / or secured to the battery pack housing via at least one of their respective end plates. Each battery module included in the battery pack is mounted and / or secured to the battery pack housing via at least one of its end plates (and in some embodiments, via each of its end plates).

[0181] For example, at least some of the battery modules are fixed to the (remaining) load-bearing structure of the battery housing via at least one of their respective end plates.

[0182] In various embodiments of the battery pack, the load-bearing structure includes shoulders or cross-braces, at least some of the cross-braces being configured to transfer compressive forces to the beams of the battery module.

[0183] Another embodiment of the present disclosure provides a vehicle, comprising at least one battery module and / or at least one battery pack as described above. The vehicle may be a hybrid vehicle or a fully electric vehicle.

[0184] Another embodiment of the present disclosure provides a method for assembling a battery module as described above. The method includes providing a first beam having one or more first openings, a second beam having one or more second openings, one or more first bus bars, one or more second bus bars, and a plurality of battery cells, each battery cell including a hard shell having a parallelepiped shape, the parallelepiped shape having a pair of main sides arranged opposite to each other, a first terminal side and a second terminal side arranged opposite to each other, and a lower side and an upper side arranged opposite to each other. Each battery cell includes a first terminal arranged on the first terminal side and a second terminal arranged on the second terminal side. The method also includes arranging the battery cells in a stack pointing in the stacking direction so that the main side of each battery cell is arranged perpendicular to the stacking direction; attaching the first bus bar to the first beam and attaching the second bus bar to the second beam; arranging the first beam along the stack so that each of the first terminal side faces the first beam and the first beam is oriented so that each of the first bus bars is positioned between the first beam and the stack; arranging the second beam along the stack so that each of the second terminal side faces the second beam and the second beam is oriented so that each of the second bus bars is positioned between the second beam and the stack; moving the first beam toward the stack so that the first bus bar abuts the first terminal located in the area of ​​the first bus bar and connects the first bus bar to the first terminal located in the area of ​​the first bus bar through the first opening; moving the second beam toward the stack so that the second bus bar abuts the second terminal located in the area of ​​the second bus bar and connects the second bus bar to the second terminal located in the area of ​​the second bus bar through the second opening.

[0185] In various embodiments, the method may further include providing at least one cell spacer. In such embodiments, the method may include arranging the cell spacer at a position between some of the battery cells relative to the stacking direction.

[0186] The method may further include properly aligning the battery cells and holding the battery cells in place by suitable clamping devices.

[0187] The method may further comprise pre-compressing the stack of battery cells relative to the stacking direction. When the stack further comprises cell separators, the method may comprise pre-compressing the stacked assembly of battery cells and cell separators relative to the stacking direction.

[0188] In various embodiments of the method, the method may further include providing a first bus bar carrier. In such embodiments, the method may include securing the first bus bar to the first bus bar carrier and attaching the first bus bar carrier (with the secured bus bar) to the first beam.

[0189] In various embodiments, the method may further include providing a second bus bar carrier. In such embodiments, the method may include securing the second bus bar to the second bus bar carrier, and attaching the second bus bar carrier (with the secured bus bar) to the second beam.

[0190] In some embodiments of the method, the connection of the first bus bar to the first terminal is performed by welding, and / or the connection of the second bus bar to the second terminal is performed by welding.

[0191] In an embodiment, the method may further include providing a first end plate and a second end plate, arranging the first end plate in front of the first battery cell when viewed in the stacking direction, and arranging the second end plate behind the last battery cell when viewed in the stacking direction.

[0192] The method may include pre-compressing the stacked assembly of the battery cells and the first and second end plates relative to the stacking direction, and compressing the stacked assembly of the battery cells and the first and second end plates relative to the stacking direction or increasing the pre-compression of the stacked assembly of the battery cells and the first and second end plates such that each of the first and second end plates contacts the first and second beams. The method may include securing each of the first and second end plates to each of the first and second beams.

[0193] In various embodiments of the method, the fixing of the end plates to the beams may be performed using bolts, screw connections or welding.

[0194] Thus, embodiments of the method may include one or more of the following steps:

[0195] The battery cells, cell separators, end plates, and in some cases, spacer plates are arranged together and pre-compressed.

[0196] The beam with the busbar carrier is attached from the side.

[0197] The compression on the end plates is further increased to strengthen the contact condition between the beam and the end plates.

[0198] The beams and end plates are coupled together (eg, by bolting, welding, etc.).

[0199] The battery cells are aligned (as they can only be clamped from one side up to this step) and held in place with appropriate clamping devices.

[0200] The bus bars are welded from the outside through the openings in the beams on both sides.

[0201] If not implemented into a busbar carrier, the single-cell sensing sensor and other sensors may be attached to the busbar.

[0202] Bus bar covers may be applied to increase the creep distance of electrical components.

[0203] The battery module may be inserted into the outer housing structure and attached to the cooling plate and / or vent plate using adhesive and / or gap filling material (eg, thermal interface material).

[0204] The battery module may be coupled to the housing via additional connections (eg, bolts, pins, welds, etc.) to increase structural integrity.

[0205] Figure 1A is a perspective view of a side-post battery cell 10 ′ according to an embodiment of the present disclosure, which may be used in a battery module for an electric vehicle or a hybrid vehicle, for example. Figure 1A A Cartesian coordinate system with x, y, and z axes is depicted in FIG. Figure 1A As shown in FIG, the battery cell 10' has a parallelepiped (e.g., prism) shape. The housing 10a' is a hard shell that can be made of a metal material. The housing 10a' can be a can or a cylinder with six planar outer sides. The housing 10a' has a pair of congruent main sides arranged opposite to each other (of the pair of main sides, only the side 14 facing the x direction is in the Figure 1A Each major side is perpendicular to the x-axis. In addition, the housing 10a' has a lower side ( Figure 1A The lower side and the upper side 16 are congruent and arranged opposite each other and perpendicular to the z-axis. Finally, the housing 10a' has a pair of congruent lateral sides arranged opposite each other (of the pair of sides, only the side 11 facing the opposite y-direction is in the Figure 1A is visible in the ).

[0206] The pair of congruent lateral sides comprises a first lateral side 11 facing in the opposite y direction and a second lateral side facing in the y direction (at Figure 1A The first terminal T1 is arranged on the first lateral side 11 of the housing 10a'. Similarly, the second terminal T2 (at Figure 1A 1 and 10b) are arranged on the second lateral side. Therefore, throughout this disclosure, the first lateral side 11 may be referred to as the "first terminal side" and the opposite second lateral side may be referred to as the "second terminal side". Terminals T1, T2 allow electrical connection to the battery cell 10'. The first terminal T1 can be the negative terminal of the battery cell 10' (e.g., the negative electrode post), and the second terminal T2 can be the positive terminal of the battery cell 10' (e.g., the positive electrode post). In this battery cell form, the main side (e.g., side 14 and the opposite side) has the largest area among the sides of the housing 10a', and the terminal side (e.g., the lateral side) has the smallest area among the sides of the housing 10a'.

[0207] The exhaust outlet V is arranged on (or in) the upper side 16 of the housing 10a'. Therefore, the upper side 16 can be referred to as the "exhaust side" of the battery cell 10' or the housing 10a'. In the event of a thermal event (such as thermal runaway) within the battery cell 10', the exhaust gas can be discharged from the battery cell 10' through the exhaust outlet V. Inside the battery cell 10', the valve (in Figure 1A A valve (not shown) may be installed in the exhaust outlet V (e.g., may be installed at an upstream position of the exhaust outlet V), and the valve may be configured to open (or burst) when the gas pressure inside the battery cell 10' exceeds a reference (or predefined) value, and may be configured to remain closed otherwise (i.e., when the gas pressure inside the battery cell 10' is lower than the reference value). Therefore, before being discharged through the exhaust outlet V, the exhaust gas may pass through the exhaust valve arranged inside the battery cell 10'.

[0208] In some embodiments of the side post battery cell 10', the second terminal T2 may have a shape that is the same as the shape of the first terminal T1 but is a mirror image of the first terminal T1, with the mirror image being relative to the xz plane of the coordinate system. For example, each of the first terminal T1 and the second terminal T2 has a flat shape extending along an area parallel to the xz plane. When viewed along the y direction, the first terminal T1 and / or the second terminal T2 may have a rectangular shape, such as a square shape. In other embodiments, the second terminal T2 may have a shape that is different from the shape of the first terminal T1.

[0209] In some embodiments of the side-post battery cell 10', the battery cell 10' has an appearance that is symmetrical with respect to a first virtual plane parallel to the xz plane of the coordinate system (wherein the first virtual plane is positioned at the center between the first terminal side surface 11 and the second terminal side surface relative to the y direction). In addition, the appearance of the battery cell 10' may be symmetrical with respect to a second virtual plane parallel to the yz plane (wherein the second virtual plane is positioned at the center between the pair of first side surfaces relative to the x direction), and / or, except for the vent V, may be symmetrical with respect to a third virtual plane parallel to the xy plane (wherein the third virtual plane is positioned at the center between the pair of second lateral side surfaces relative to the z direction).

[0210] Figure 1B FIG1 shows a perspective view of a side-post battery cell 10 according to another embodiment of the present disclosure, which can be used in a battery module of an electric vehicle or a hybrid vehicle, for example. The structure of the battery cell 10 is similar to Figure 1A The structure of the battery cell 10' shown in FIG. The battery cell 10 includes a housing 10a, which is a hard shell made of, for example, a metal material. Figure 1A Compared with the battery cell 10' shown in Figure 1B The battery cell 10 shown in FIG has a more elongated shape, that is, the ratio of the extension along the y-axis (or length) to the extension along the z-axis (or width) is greater. In addition, the exhaust outlet is arranged on the lower side of the battery cell 10, so that Figure 1B Not visible in.

[0211] Figure 1A The battery cell 10 ′ and Figure 1B The battery cell 10 shown in FIG. 1 is an embodiment of a side-post battery cell that may be used in a battery module according to an embodiment of the present disclosure, which will be described below.

[0212] Figure 2 is a schematic perspective view of a battery module 1 according to an embodiment of the present disclosure. A Cartesian coordinate system having x, y, and z axes is included to facilitate the following description. The battery module 1 is shown as a large module in a longitudinal configuration for use in an electric vehicle (EV) in its fully assembled state, but the present disclosure is not limited thereto. The battery module 1 shown includes a stack of 45 side-post battery cells 10, each of which has a parallelepiped shape. For example, the battery cells 10 may each correspond to Figure 1B . With respect to the coordinate system, the battery cells 10 are stacked along the x-direction (e.g., adjacent to each other in the x-direction), which will be referred to as the "stacking direction" hereinafter. Cell spacers 21, 22 (also referred to as "spacers") may be inserted between some or each pair of adjacent battery cells 10. Cell spacers 21, 22 may be inserted behind each battery cell 10 to improve thermal and structural performance. In the illustrated embodiment, cell spacers are inserted into the stack after every 15 battery cells 10.

[0213] In the stack, the side post cells 10 are each oriented so that their respective major sides (at Figure 2 (not visible in the figure) are arranged orthogonal to the x-direction, i.e. perpendicular to the stacking direction. In addition, their respective terminal sides ( Figure 2 The battery cells 10 are arranged perpendicular to the y direction so that the first terminal side faces the y direction and the second terminal side faces the opposite y direction. Figure 2 This will be explained in more detail below.

[0214] The battery module 1 also includes a first beam 101 and a second beam 102. Each of the beams 101, 102 has a longitudinal shape oriented in the x-direction and is attached to the stack. The first beam 101 extends along the first terminal side of each battery cell 10, and the second beam 102 extends along the second terminal side of each battery cell 10. The first beam 101 and the second beam 102 are each configured to provide structural rigidity to the battery module 1. For example, the beams 101, 102 can be made of a metal material. In order to facilitate the process of connecting the busbars to the terminals of the battery cells, each of the beams 101, 102 can have a plurality of openings O1, O2 (see, e.g. Figure 3 ). This will be referenced below Figure 3 Explain in more detail.

[0215] The first beam 101 has a plurality of first recesses 101a to facilitate fixing (e.g., clamping) the battery module 1 in the battery pack. For example, each recess 101a is formed as a semicircular notch provided in the first beam 101 (see also, for example, FIG. Figure 3 and Figure 6 For the same reason, the second beam 102 has a plurality of similar second recesses 102a.

[0216] The first busbar carrier 111 ( Figure 2 Not visible in, see e.g. Figure 3 ) is arranged between the first terminal side of the battery cell 10 and the first beam 101. Similarly, the second busbar carrier ( Figure 2 The first bus bar carrier 111 and the second bus bar carrier 112 each have a longitudinal shape oriented in the x-direction. Figure 3 As explained in more detail, the busbar carriers 111, 112 are configured to carry (eg, support or secure) the busbars. One or more sensors are arranged on the busbars. The sensors are integrated or attached to the strips 41, 42 (see for example Figure 6 ), the strips 41, 42 can be easily implemented into the battery module 1. Other electrical and / or electronic components can also be embedded in these strips 41, 42. Busbar covers 51, 52 (see e.g. Figure 7 ) can be attached to the beams 101, 102 to protect the busbars and increase the creep distance of the electronic components integrated or attached to the strips 41, 42. This will be referred to below Figure 7 Explain in more detail.

[0217] Multifunctional end plates 31, 32 (see e.g. Figure 5) are coupled to the ends of the beams 101, 102. The first end plate 31 is coupled to the ends of the first beam 101 and the second beam 102 that are directed opposite to the x-direction, and the second end plate 32 is coupled to the opposite ends of the first beam 101 and the second beam 102 that are directed in the x-direction. The coupling of the end plates 31, 32 to the beams 101, 102 can be provided by bolting, screwing, welding, or similar fastening techniques. This will be referred to below. Figure 5 Describe in more detail.

[0218] Figure 3 Schematically shows Figure 2 1 and 1 . Figure 3 As shown in FIG, the first beam 101 has a pair of shoulders: a lower shoulder 1011a and an upper shoulder 1011b, each extending parallel to the x-axis of the coordinate system. Lower shoulder 1011a and upper shoulder 1011b are connected by a plurality of struts 1012 arranged periodically (e.g., repeatedly) along the x-direction, with the ends of each strut 1012 extending along the z-direction. Due to this arrangement, an opening O1 is formed between any two adjacent struts in the x-direction and is bounded in the z-direction by lower shoulder 1011a and upper shoulder 1011b. Thus, the first beam 101 has a plurality of first openings O1, which provide access to a plurality of first busbars 201 (only one of the busbars 201 is labeled with a reference numeral to simplify the drawing). These first busbars 201 are held in place behind the first beam 101 (when viewed in the y-direction) by a first busbar carrier 111.

[0219] As referenced above Figure 2 As described above, the first busbar carrier 111 is configured to be placed between the first terminal side of the battery cell 10 of the battery module 1 and the first beam 101. Therefore, in the assembled state of the battery module 1, the first busbar carrier 111 abuts against the first beam 101. Figure 3 Indicated by an arrow pointing against the y-direction. During manufacturing, before starting to assemble the battery module 1, a busbar carrier 111 in which the busbars 201 are placed is pre-assembled. The first busbar carrier 111 has a plurality of cutouts 111a located at positions intended to be placed on (e.g., to be aligned with) the first terminals of the battery cells 10 when the battery module 1 is assembled (see, e.g., Figure 2 ). Thus, during manufacturing, when the first busbar carrier 111 and the first beam 101 are correspondingly arranged or aligned beside the first terminal side of the battery cell 10 (eg, as Figure 2), the bus bar 201 can be (at least partially) accessed from the outside (when viewed in the y-direction) through the first opening O1 in the first beam 101 and one or more cutouts 111a located behind the first opening O1, thus allowing the first bus bar 201 to be connected to the corresponding first terminals arranged behind the first bus bar 201 (when again viewed in the y-direction, the first terminals are located at the Figure 2 and Figure 3 not visible in the ).

[0220] Therefore, due to the above-mentioned access to the bus bar 201 provided by the first opening O1 in the first beam 101 and the cutout 111a in the first bus bar carrier 111, the first bus bar 201 can be coupled (e.g., welded) to the corresponding first terminal arranged behind the first bus bar 201 (when viewed in the y-direction) by a welding tool (e.g., a welding torch or a blowpipe), which reaches the welding area of ​​the bus bar 201 through the first opening O1 in the first beam 101 and the cutout 111a in the first bus bar carrier 111.

[0221] The first busbar 201 may be attached to the first busbar carrier 111 by, for example, overmolding, clamping or gluing. Furthermore, the first busbar carrier 111 may be fixed to the first beam 101 by, for example, clamping or gluing.

[0222] The second beam 102 (see e.g. Figure 4 ), the arrangement and assembly of the second bus bar carrier 112 and the plurality of second bus bars 202 are similar to those described above with respect to the first beam 101, the first bus bar carrier 111 and the plurality of first bus bars 201, with the only difference being that the shape and arrangement of the components are mirrored relative to a virtual plane parallel to the xz plane of the coordinate system.

[0223] In order to electrically isolate the busbars 201 , 202 from the beams 101 , 102 , which are made of a metallic material and are therefore electrically conductive, the busbar carriers 111 , 112 are each made of an insulating material, such as plastic.

[0224] Figure 4 Schematically shows Figure 2 The battery module 1 is shown in a partially exploded view, in which the busbar covers 51 and 52 are omitted. Figure 4The view can be understood as a state of the assembly during the manufacture of the battery module 1. In the state shown, the battery module 1 includes three pre-assembled units U1, U2, U3. The first pre-assembled unit U1 is a stack of multiple battery cells 10 and cell separators 21, 22 arranged in a row along the x-direction, and the stack is limited by a pair of first end plates 31 and second end plates 32 (relative to the x-direction), as described above. The second pre-assembled unit U2 includes a first beam 101 that has been attached to a first busbar carrier 111 that carries a plurality of first busbars 201. The third pre-assembled unit U3 includes a second beam 102 that has been attached to a second busbar carrier 112 that carries a plurality of second busbars 202.

[0225] With the three pre-assembled units U1, U2, and U3 described above, further assembly of the battery module 1 shown in FIG1 is relatively simple, as described below. The second pre-assembled unit U2 is pushed onto the first terminal side of the battery cell 10 (as indicated by the arrow pointing in the y-direction), so that the side of the second pre-assembled unit U2 facing the y-direction abuts the first terminal side of all battery cells 10. Similarly, the third pre-assembled unit U3 is pushed onto the second terminal side 12 of the battery cell 10 (as indicated by the arrow pointing in the opposite y-direction), so that the side of the third pre-assembled unit U3 facing the opposite y-direction abuts the second terminal side 12 of all battery cells 10. The first bus bar 201 is then secured to the first terminal of the battery cell 10 by a suitable connecting tool (e.g., a welding torch / blowpipe) guided through the first opening O1 in the first beam 111 and the cutout 111a in the first bus bar carrier 111 to the welding area of ​​the first bus bar 201. Similarly, the second bus bar 202 is fixed to the second terminal of the battery cell 10 by a suitable connecting tool guided through the second opening O2 in the second beam 102 and the cutout 112a in the second bus bar carrier 112 to the welding area of ​​the first bus bar 202. Finally, the first end plate 31 is fixed (for example, by using screws, see for example Figure 5 ) to the end of the first beam 101 pointing opposite to the x-direction and to the end of the second beam 102 pointing opposite to the x-direction, and similarly, the second end plate 32 is fixed (for example, by using screws, see for example Figure 5 and Figure 6 ) to the ends of the first beam 101 pointing in the x-direction and to the ends of the second beam 102 pointing in the x-direction. During the above-described process of assembling the three units U1, U2, and U3, the individual battery cells 10 can be held in place by a jig (e.g., to prevent the battery cells 10 from sliding in the z-direction), and / or the first pre-assembled unit U1 (e.g., the stack of battery cells 10 and cell spacers 21, 22 and the first and second end plates 31, 32) can be compressed in the x-direction.

[0226] Figure 5Schematically shows Figure 2 A partial perspective view of the battery module 1 is shown in FIG, without the strap 41 and the busbar cover 51, to provide a detailed view of the connection between the first end plate 31 and the first beam 101. Figures 2 to 4 The spatial arrangement of the stacked battery cells 10, the first end plates 31, the first beams 101, the first busbar carriers 111 and the first busbars 201 relative to one another is described. Figure 5 As shown in FIG, the first end plate 31 is fixed to the first beam 101 by using a first bolt (or screw) 301 and a second bolt (or screw) 302. For example, the first bolt (or screw) 301 is inserted through a through hole provided in a first protrusion 311 of the first end plate 31 into a first bore 1013a provided in a corresponding end portion of the lower shoulder 1011a of the first beam 101 (see also, for example, FIG. Figure 3 ). Accordingly, the second bolt (or screw) 302 is inserted into the second bore 1013b provided in the corresponding end portion of the upper shoulder 1011b of the first beam 101 through the through hole provided in the second protrusion 312 of the first end plate 31 (see also, for example, Figure 3 ).

[0227] It will be appreciated that similar fixings may also be provided in a corresponding manner between the first end plate 31 and the second beam 102, and between the second end plate 32 and the first beam 101 (see, for example, Figure 6 ), and between the second end plate 32 and the second beam 102.

[0228] The aforementioned fixation between the end plates 31, 32 and the beams 101, 102 provides a sufficiently strong mechanical connection, so that the expansion force caused by the expansion of the battery cells 10 can be absorbed by the end plates 31, 32 and redirected to the beams 101, 102 through the aforementioned connection. This expansion force acts against the x-direction on the first end plate 31 and in the x-direction on the second end plate 32. In addition, due to the rigidity of the first and second beams 101, 102, the expansion force is absorbed by the first and second beams 101, 102.

[0229] Figure 5 An example fixation is shown, by which each of the first bus bars 201 is carried (e.g., held in place) by the first bus bar carrier 111. For each bus bar 201, a plurality of struts extending along the z-direction may be provided by the first bus bar carrier 111, and the struts are configured such that the corresponding bus bar 201 may be clamped between these struts. Figure 5 As shown in FIG, the plurality of pillars are a pair of first pillars 1111 and second pillars 1112. A third pillar is provided between the first pillars 1111 and the second pillars 1112. Figure 5The first leg 1111 and the second leg 1112 on one side of the bus bar 201 are clamped between the first leg 1111 and the second leg 1112 on the other side of the bus bar 201. It should be understood that a similar clamping mechanism can also be used to attach the second bus bar 202 to the second bus bar carrier 112.

[0230] The first bus bar carrier 111 can be extended (or lengthened) against the x-direction by means of a snatch 1116, into which the first end plate 31 can be clamped. As described above, this can be useful for holding the first end plate 31 in place during manufacturing before the end plate 31 is secured to the beams 101, 102, for example, using bolts and / or screws. It should be understood that the first bus bar carrier 111 can also be similarly extended in the x-direction to hold the second end plate 32 in place, and that the second bus bar carrier 112 can be configured or arranged accordingly.

[0231] Figure 6 Schematically shows Figure 2 FIG1 is a partial perspective view of the battery module 1 shown in FIG1 , without the bus bar cover 51 and showing the corner area where the second end plate 32 is attached to the first beam 101. Figure 2 As depicted, the battery module 1 includes one or more battery cell sensors (e.g., temperature sensors) and other sensors (e.g., voltage sensors, current sensors) attached to the first busbar 201. In the illustrated embodiment, the sensors are integrated into or attached to a first tape 41, which can be secured to an appropriate location (e.g., a predefined location) on the busbar 201. In the figures, the tape 41 is shown only partially secured to the first rail 101. For example, the first tape 41 can be formed as an adhesive tape that can be glued to the outer side of the first rail 101 (e.g., the side facing away from the stack). The first tape 41 then contacts portions of the busbar 201 through the opening O1 in the first rail 101 and the cutout 111a in the first busbar carrier 111. Thus, by providing sensors at the corresponding locations, the sensors integrated into or attached to the first tape 41 can be connected (e.g., electrically and / or thermally) to the busbar 201 at the desired (or predefined) location. The first band 41 may include signal lines for transmitting signals generated by the sensors to a controller, such as a module management controller (MMC). The first band 41 may include further electrical or electronic components, such as a control unit. It will be appreciated that a corresponding second band 42 ( Figure 6 ), and the second strip 42 is configured to be attached on the outside of the second beam 102 and have additional sensors to be connected to the second bus bar 202 (see e.g. Figure 7).

[0232] Figure 7 Schematically shows Figure 2 The exploded view of the battery module 1 shown in FIG. Figure 7 As shown in FIG, the bus bar covers 51, 52 are shown in a state of being separated from the main body of the battery module 1. As described above, the battery module 1 includes a first bus bar 201 ( Figure 7 1 , 102). The first strip 41 includes sensors (not visible in the figure) and, correspondingly, a second strip 42 includes sensors connected to the second busbar 202. To increase the creep distance of these sensors (and, in various embodiments, additional electrical and / or electronic components integrated in or attached to the first and second strips 41, 42) and to protect these sensors and components from external mechanical loads, busbar covers 51, 52 can be attached to the beams 101, 102. The busbar covers 51, 52 also protect the busbars 201, 202 from external mechanical, electrical, or thermal shocks that might otherwise pass through the strips 41, 41 via the openings O1, O2 in the beams 101, 102 and the cutouts in the busbar carriers 111, 112 to impact the busbars 201, 202.

[0233] The first bus bar cover 51 may have a ]-shaped cross-sectional profile (relative to a section parallel to the yz plane of the coordinate system and when viewed in the x direction) and is attached to the side of the first beam 101 facing away from the stack of battery cells 10 and cell spacers 21, 22. Figure 7 In FIG, 5 , the first busbar cover 51 is shown by an arrow pointing in the y direction next to the first busbar cover 51. In addition, the second busbar cover 52 may have a [-shaped cross-sectional profile (relative to a section parallel to the yz plane and when viewed in the x direction) and be attached to the side of the second beam 102 facing away from the stack of battery cells 10 and cell spacers 21, 22. This is shown in FIG. Figure 7 This is shown by the arrow pointing against the y-direction next to the second busbar cover 52 .

[0234] The first bus bar cover 51 includes a slot or space 51 a at a position configured to be located over the first recess 101 a of the first beam 101, which provides access to the recess 101 a when the bus bar cover 51 is attached to the first beam 101. In this manner, even when the first beam is covered by the first bus bar cover 51, the brackets or bolts 400 (see, e.g., FIG. Figure 8 ) may also engage with the recess 101 a. For similar reasons, the second bus bar cover 52 includes a corresponding slot or space 51 b at a location configured to be located on the second recess 102 a of the second beam 102.

[0235] In other embodiments, first and second strips 41, 42 with sensors may be omitted, and in some embodiments, first and second strips 41, 42 with other electrical and / or electronic components may be omitted. In such embodiments, first bus bar cover 51 protects only first bus bar 201 from external influences / impacts, and second bus bar cover 52 protects only second bus bar 202 from external influences / impacts. Furthermore, in various embodiments, only one of first and second bus bar covers 51, 52 may be used. This applies to embodiments including first and / or second strips 41, 42, as well as embodiments omitting strips 41, 42.

[0236] Figure 8 is a schematic cross-sectional view of a battery pack 100 according to another embodiment of the present disclosure. In the illustrated embodiment, the battery pack 100 includes a housing 100a that houses the battery pack 100 as previously described. Figures 2 to 7 The multiple battery modules 1 are arranged in a row along the y direction. Figure 8 Only a portion of the battery pack 100 is shown. Specifically, only the rightmost battery module (relative to the Figure 8 ), which includes a battery cell 10, a first beam 101 and a second beam 102. In addition, the first beam 101' of the adjacent battery module 1 is visible.

[0237] Multiple battery modules 1 are housed in the housing 100a of the battery pack 100. The housing 100a includes a base plate 160, an exhaust plate 170, and a cooling plate 180. Each of the base plate 160, the exhaust plate 170, and the cooling plate 180 extends parallel to the xy plane of a coordinate system, which is provided in the accompanying drawings to facilitate the following description. The exhaust plate 170 is arranged at a distance (e.g., a certain distance) above the base plate 160. The exhaust plate 170 is supported by a plurality of support brackets 162a, 162b disposed on the base plate 160. A pair of support brackets, namely a first support bracket 162a and a second support bracket 162b, are mounted below each battery module 1 housed in the housing 100. With this arrangement, a channel C extending in the x-direction is formed below each battery module 1. Channel C is bounded in the y-direction by the first support bracket 162a and the second support bracket 162b, and in the z-direction by the base plate 160 and the exhaust plate 170. The housing 100 further includes a pair of side plates for limiting the housing 100 relative to the y direction. Figure 8 , only the right side plate 190 is shown, which has a lower portion 190a and an upper portion 190b.

[0238] Each of the battery modules 1 is placed on the exhaust plate 170. Therefore, each of the battery cells 10 of the battery module 1 rests its lower side 15 against the exhaust plate 170. The exhaust plate 170 may have a plurality of cutouts located at positions of exhaust outlets provided in the lower side of the battery cells 10 (e.g., aligned with the exhaust outlets) with respect to the x-direction and the y-direction (see, for example, FIG. Figure 1A and Figure 1B ). These cutouts are located below the exhaust outlet of the battery cell 10 with respect to the z-direction. Therefore, the exhaust gases and / or other materials discharged or ejected from the exhaust outlet in the event of a thermal event enter the channel C through the above-mentioned cutouts in the exhaust plate 170. In addition, the exhaust plate 170 provides mechanical support for the battery module (and its components, such as individual battery cells 10, cell separators, etc.) arranged thereon, in particular with respect to the z-direction. Cross supports 164a, 164b can also be provided in the gap between the base plate 160 and the exhaust plate 170 to further increase the mechanical stability of the housing 100a against shear forces acting on the housing 100a parallel to the yz plane of the coordinate system. In Figure 8 In the cross-sectional view shown in , each cross brace 164a, 164b is arranged diagonally in the region of the channel C between the base plate 160 and the exhaust plate 170 relative to the y-axis and the z-axis of the coordinate system.

[0239] The cooling plate 180 is arranged on the plurality of battery modules 1 so that the upper side 16 of any one of the battery cells 10 is in thermal contact with the cooling plate 180 . Figure 8 In the embodiment shown in FIG, the upper side 16 of the battery cells 10 each abuts from below against the lower surface of the cooling plate 180. The cooling plate 180 can be thermally connected to a cooling system that is configured to actively cool the cooling plate 180 during operation of the battery pack 100. The cooling plate 180 provides mechanical support for the battery module (and its components, such as the individual battery cells 10, cell spacers, etc.) disposed thereunder, particularly with respect to the z-direction.

[0240] Each battery module 1 may also be held in place by one or more brackets 400 that may engage corresponding recesses 101a, 102a provided in the first and second beams 101, 102 of each battery module 1 (see, e.g., FIG. Figure 2 、 Figure 3 and Figure 6 Each of the brackets 400 can be configured to be placed between two adjacent battery modules 1 with respect to the y direction, such as Figure 8 In such an embodiment, the brackets 400 may each have a symmetrical shape so that they allow placement and / or clamping of each of two adjacent battery modules 1. Figure 8As shown in FIG, the second beam 102 of the rightmost battery module 1 and the first beam 101′ of another battery module 1 arranged on the left next to the rightmost battery module 1 are simultaneously held by one of the brackets 400. In various embodiments, the bracket 400 may be formed as a bolt that is configured to be (at least partially) inserted into the semicircular recesses 101a, 102a provided in the first beam 101 and the second beam 102, and as described above with reference to, for example Figure 2 、 Figure 3 and Figure 6 As stated.

[0241] As in Figure 8 As can be further seen in FIG, the rightmost battery module 1 is held in place on its right side by the housing 100a of the battery pack 100 with respect to the y-direction. For example, the rightmost battery module 1 is held in place by its first beam 101 against the vertical portions 151a, 151b of the support struts 150a, 150b, which are placed on the right side plate 190 of the battery pack 1. For example, the lower shoulder 1011a of the first beam 101 (see also, for example, FIG. Figure 3 ) is supported by the lower portion 151a of the lower support post 150a placed on the lower portion 190a of the right side plate 190 of the battery pack 1. Accordingly, the upper shoulder 1011b of the first beam 101 (see also, for example, Figure 3 ) is supported by the upper portion 151b of the upper support strut 150b placed on the upper portion 190b of the right side plate 190 of the battery pack 1. Therefore, the load applied to the right side plate 190 from the outside is directly transmitted to the shoulders 1011a, 1011b of the first beam 101 through the lower support strut 150a and the upper support strut 150b, and the shoulders 1011a, 1011b in turn transmit the load to the housing 10a of each battery cell 10 included in the rightmost battery module 1. From there, the load can be similarly transmitted to the y direction through the subsequently arranged battery modules 1. It should be understood that a similar structure can also be present on the opposite side of the battery pack 100, for example, between the leftmost side plate of the battery pack 100 and the leftmost battery module 1 arranged in the battery pack 100.

[0242] Therefore, if the outer shells 10a of the individual battery cells 10 each exhibit sufficient stability, the battery module 1 itself contributes to the rigidity of the housing 100a of the battery pack 100, and thus contributes to the mechanical stability. Therefore, the outer shells 10a of the individual battery cells 10 are each formed as a hard shell made of a suitable material (such as metal or metal alloy).

[0243] Figure 2 The battery module 1 shown in FIG can transmit the compressive load transverse to the cell stacking direction (eg, Figure 2The load should therefore be introduced into the upper and lower shoulders of the beam (see e.g. Figure 8 The battery module 1 can also be clamped in the z direction near the beam by means of bolt connections or the like (see for example Figure 6 and Figure 8 Furthermore, the battery module 1 is configured to absorb shear forces acting parallel to the xz plane and / or the yz plane, which occur during bending load cases of the battery pack 100. However, these characteristics are also provided by another embodiment of the battery module according to the present disclosure, which will be referred to below. Figures 9 to 13 Provide a description.

[0244] Figure 9 A perspective view of a battery module according to another embodiment of the present disclosure is schematically shown. Figures 2 to 7 The battery module 1 described, Figure 9 The battery module 2 shown in FIG includes a stack of battery cells 10 arranged along the x direction, and a cell separator 20 is inserted at a certain position between two adjacent battery cells 10. The stack is limited at its ends by a first end plate 31 and a second end plate 32, similar to the above reference Figure 2 The described embodiment. Figure 9 In the embodiment shown in , the cell spacer 20 is inserted at the center position of the stack (relative to the x-direction), thereby dividing the stack of battery cells 10 into two equally sized sub-stacks, wherein the first sub-stack includes the battery cells arranged between the first end plate 31 and the cell spacer 20, and the second sub-stack includes the battery cells between the cell spacer 20 and the second end plate 31.

[0245] However, with the reference above Figures 2 to 7 Unlike the described embodiments, the battery cells 10 are not electrically interconnected to form a single circuit (e.g., a series connection of the battery cells 10 included in the stack or a parallel connection of the battery cells 10). Instead, the battery cells 10 in the first sub-stack are interconnected to form a first circuit, and the battery cells 10 in the second sub-stack are interconnected to form a second circuit. The first circuit and the second circuit are not (at least not directly) electrically connected to each other. For example, the battery cells 10 in the first sub-stack form a first sub-module S1, and the battery cells 10 in the second sub-stack form a second sub-module S2.

[0246] Despite being electrically isolated, the first and second submodules S1 and S2 share common structural elements. For example, first and second beams 101 and 102 are arranged on the lateral sides of the stack (e.g., the sides facing the y-direction and the sides facing the opposite y-direction), thereby providing lateral support for the battery cells 10 in the first sub-stack / first submodule S1 and the battery cells 10 in the second sub-stack / second submodule S2, as well as the cell spacers 20. Furthermore, the first and second busbar carriers are each shared by either sub-stack / submodule S1 or S2.

[0247] exist Figure 9 In the embodiment shown in FIG, the cell separator 20 includes a module management controller (MMC) integrated in the cell separator 20. The MMC is configured to receive signals generated by sensors arranged in the battery module 2. The MMC can also be configured to evaluate the signals and control processes that affect the battery module 2, for example, thermal control such as cooling or limiting electrical loads. The MMC can be connected to a controller including Figure 9 The BMS or BMU of the battery pack or battery system of the battery module 2 shown in FIG.

[0248] Figure 10A Schematically shows Figure 9 , a perspective view of a first beam 101 of a battery module 2 is shown in FIG, into which a first busbar carrier 111 is implemented. The first busbar carrier 111 carries (or accommodates) a plurality of busbars 201, similar to the above description of Figure 3 A busbar carrier is described. Figure 10A The side of the busbar carrier 111 visible in FIG is configured to be attached to a battery cell stack. Figure 10A As can be seen in FIG, the individual sensing devices (integrated in strips or ribbons 41 ') are implemented into the busbar carrier 111, which is different from Figure 6 The strip 41' may also include other electrical or electronic components, such as signal lines, etc. At a central position relative to the x-direction, a strip connector 41a is mounted on the strip 41', and the strip connector 41a is configured to be Figure 9 The battery module 2 shown in FIG establishes a connection of the signal line to the module management controller (MMC) in the cell spacer 20. It should be understood that the second beam 102 together with the second carrier 112 (as well as the second bus bar 202 and possible additional cell sensing devices) can have a similar structure (see for example Figure 9 ).

[0249] Figure 10B Schematically shows Figure 9 Another perspective view of the first beam 101 of the battery module 2 shown in FIG, wherein the busbar carrier 111 is attached (relative to Figure 10B(view from the back) to the first beam 101. The first beam 101 has Figure 3 The structure of the beam depicted in FIG is substantially similar in that it has a lower shoulder 1011a and an upper shoulder 1011b, each shoulder extending along the x-direction and connected to each other by a plurality of struts 1012 arranged between the shoulders 1011a, 1011b, thereby leaving an opening in the first beam through which the first busbar 201 can be accessed. At a central position relative to the x-direction, for example, at a position relative to Figure 9 At the location of the cell spacer 20 (including MMC) in the assembled battery module 2 shown in FIG, a pillar 1012′ that is thicker (with respect to the x-direction) than the remaining pillars 1012 is formed to cover the MMC 20 at its lateral side facing the first beam 101. It should be understood that the second beam 102 together with the second carrier 112 (as well as the second bus bar 202 and possible additional cell sensing devices) can have a similar structure, however, except that the thicker central pillar 1022′ includes a cutout 1022a that allows one or more connectors 20a (which can be collected in a plug) to pass through the cutout 1022a (see, for example Figure 9 ) one or more high voltage (HV) connectors.

[0250] Figure 11 yes Figure 10A An enlarged view of the first beam 101 is shown in FIG, showing the area around the strip connector 41a. Figure 11 As can be seen in FIG, a protrusion 41b protrudes from the first busbar carrier 111. A strip connector 41a formed as a plug is positioned on the protrusion 41b. The strip 41' comprises a first sub-strip 411' and a second sub-strip 412' electrically isolated from each other. The first sub-strip 411' abuts against the busbar 201 configured to be connected to the battery cells of the first sub-module S1 (see, for example, FIG. Figure 9 ). Accordingly, the second sub-strip 412' abuts against the busbar 201 configured to be connected to the battery cells of the second sub-module S2 (see, for example Figure 9 Thus, by connecting the strip connector 41 a to the MMC, the MMC is able to receive signals from sensors (integrated in or arranged on the strip 41 ′) measuring the status of the battery cells of the first submodule S1 and the status of the battery cells of the second submodule S2 .

[0251] Figure 12A perspective view of a frame structure of a plurality of busbars 201, 202 and other components 41', 42' connected to the busbars 201, 202 is schematically shown. The frame includes a plurality of first busbars 201, a plurality of second busbars 202, a first strip 41', a corresponding second strip 42' connected to the second busbars 202, a strip connector 41a and a connector 20a. Here, the connector 20 is configured as a high voltage (HV) connector. Figure 12 As can be seen in the figure, the individual first bus bars 201 (which are then aligned parallel to the x-axis of the coordinate system) are separated from each other by gaps. Correspondingly, the individual second bus bars 202 (which are then aligned parallel to the x-axis of the coordinate system) are also separated from each other by gaps. In addition, the plurality of first bus bars 201 are arranged relative to the plurality of second bus bars 202 with respect to the y-direction. However, relative to the x-direction, the plurality of second bus bars 202 are shifted a distance (e.g., a certain distance) relative to the plurality of first bus bars 201, so that each of the individual bus bars 201 is arranged relative to the gap between a pair of second bus bars 202 with respect to the y-direction. However, at the center of the depicted arrangement relative to the x-direction (indicated by the dotted line AA), the gaps between adjacent first bus bars 201 and between adjacent second bus bars 202 are enlarged. Therefore, when the battery cell 10 is inserted between the plurality of first bus bars 201 and the plurality of second bus bars 202 (so that each of the battery cells 10 is as shown in FIG. 2 ), the gaps between adjacent first bus bars 201 and the gaps between adjacent second bus bars 202 are enlarged. Figure 9 The arrangement of the first bus bar 201 and the second bus bar 202 provides the battery cells 10 arranged in the first region B1 with respect to the x-direction (eg, as described above with reference to FIG. 1 ). Figure 9 The first sub-stack of the battery cells 10 is connected in series. Figure 9 At the same time, the arrangement of the first bus bar 201 and the second bus bar 202 provides the battery cells 10 arranged in the second area B2 with respect to the x direction (for example, as shown above with reference to Figure 9 The second sub-stack of the battery cells 10) is connected in series to form Figure 9 The second sub-module S2 of the battery module 2 is shown in FIG.

[0252] Furthermore, the HV connector 20a includes a first connector plate C1 and a second connector plate C2. The first connector plate C1 is electrically connected to a bus bar 202a (included in or from the plurality of second bus bars 202) arranged in the first area B1 and located adjacent to the center position marked by the dotted line AA, and the second connector plate C2 is electrically connected to a bus bar 202b (included in or from the plurality of second bus bars 202) arranged in the second area B2 and located adjacent to the center position marked by the dotted line AA. These connector plates C1 and C2 protrude in the y direction and are configured to protrude through the cutout 1022a in the second beam 102, as described above with reference to FIG. Figure 9 and Figure 11 On the other hand, between a pair of first bus bars 201a, 201b arranged adjacent to the center position marked by the dotted line AA, an enlarged gap L is provided, which is configured to receive the power from Figure 9 The battery module 2 shown in FIG. 2 is another entity of the connector plates C1 and C2.

[0253] In this way, the connector plates C1, C2 provide a high voltage path for both submodules S1, S2, which enables module-to-module connection by simple rotation of the two entities of the battery module 2 to be connected relative to each other or by simply plugging the two entities of the battery module 2 together (e.g., in FIG. Figure 9 ). Then, after connecting the first entity of battery module 2 to the second entity of battery module 2, connector plate C1 establishes an electrical connection between the central second bus bar 202a of the first submodule S1 of the first entity and the central first bus bar 201a of the first submodule S1 of the second entity. Correspondingly, connector plate C2 establishes an electrical connection between the central second bus bar 202b of the second submodule S2 of the first entity and the central first bus bar 201b of the second submodule S2 of the second entity.

[0254] therefore, Figure 9 The above-described assembly of the battery module 2 shown in FIG allows a relatively simple and rapid assembly of the battery module 2 as shown in FIG. Figure 13 The battery pack shown in FIG. 1 includes a Figure 9 The six battery modules M1 to M6 of the embodiment depicted in FIG. Figure 13 When assembling the battery pack shown in FIG. 1 , one can start with the first battery module M1 on the far right (with respect to the view provided in the accompanying drawings). Then, the second battery module M2 (in the order corresponding to the y direction) can be attached to the first battery module M1 and arranged as described above with reference to FIG. Figure 12The first battery module M1 is electrically connected to the first battery module M3 in the manner described above. Accordingly, the third battery module M3 is attached and electrically connected to the second battery module M2. The remaining battery modules M4, M5 and M6 are similarly implemented. Subsequently, the first protection element 71 is attached to the first end plate 31 of the battery modules M1 to M6, and the first end plate 31 faces the reverse x direction (for example, see Figure 9 The second protection element 72 is attached to the second end plate 32 of the battery modules M1 to M6, and the second end plate 32 faces the x direction (see, for example, Figure 9 The first protection element 71 and the second protection element 72 each extend parallel to the y direction along the entire extension of the battery pack relative to the y direction, thereby each forming a longitudinal impact absorbing structure that protects the battery modules M1 to M6 from external impacts (particularly from impact loads).

Claims

1. A battery module, comprising: a stack of battery cells, the stack comprising a plurality of battery cells arranged in rows along a stacking direction; each of the battery cells includes a rigid case having a parallelepiped shape, the parallelepiped shape having a pair of main sides arranged opposite to each other, a first terminal side and a second terminal side arranged opposite to each other, and a lower side and an upper side arranged opposite to each other, each of the battery cells further includes a first terminal arranged on the first terminal side and a second terminal arranged on the second terminal side, the first terminal forms one electrode post of the battery cell, and the second terminal forms the opposite electrode post of the battery cell; a first beam having a first opening; a second beam having a second opening; a first bus bar; and a second bus bar, wherein each of the first beam and the second beam is arranged parallel to the stacking direction and has a first end pointing against the stacking direction and a second end pointing in the stacking direction, wherein the stack is arranged between the first beam and the second beam, wherein the first terminal side of each of the battery cells faces the first beam, and the second terminal side of each of the battery cells faces the second beam, wherein the first bus bar electrically connects the first terminals of at least two battery cells of the battery cells and is arranged between the stack and the first beam, and the second bus bar electrically connects the second terminals of at least two battery cells of the battery cells and is arranged between the stack and the second beam, and wherein the first opening is aligned with a position where the first bus bar is connected to the first terminal, and the second opening is aligned with a position where the second bus bar is connected to the second terminal.

2. The battery module according to claim 1, further comprising a first end plate and a second end plate, in, the first end plate is attached to the first end of the first beam and the first end of the second beam, and when viewed in the stacking direction, the first end plate abuts against the battery cell arranged at a first position in the row of battery cells, and wherein the second end plate is attached to the second end of the first beam and the second end of the second beam, and when viewed in the stacking direction, the second end plate abuts against the battery cell arranged at the last position in the row of battery cells.

3. The battery module according to claim 1, wherein: When viewed in the stacking direction, the electrode polarities of the first terminals alternate along the row of battery cells. wherein the sum of the number of the first bus bars and the number of the second bus bars is equal to N - 1, where N represents the number of the battery cells, wherein when viewed in the stacking direction and for each natural number k, where 1 ≤ k < N / 2, the first terminal of the 2k-th battery cell is electrically connected to the first terminal of the 2k + 1-th battery cell via one of the first bus bars, and When viewed in the stacking direction and for each natural number k, where 1≤k≤N / 2, the second terminal of the 2k-1th battery cell is electrically connected to the second terminal of the 2kth battery cell via one of the second bus bars.

4. The battery module according to claim 1, further comprising: a first cell connection unit including a first bus bar carrier holding the first bus bar; as well as The second cell connecting unit includes a second bus bar carrier holding the second bus bar.

5. The battery module according to claim 4, wherein: The first cell connection unit is arranged between the stack and the first beam, and Wherein, the second monomer connection unit is arranged between the stack and the second beam.

6. The battery module according to claim 1, further comprising: a first cover arranged on a side of the first beam facing away from the stack; as well as A second cover is arranged on a side of the second beam facing away from the stack. 7 . The battery module according to claim 1 , further comprising cell spacers disposed between adjacent pairs of the battery cells.

8. The battery module according to claim 7, wherein: The cell spacer includes a module management controller.

9. The battery module according to claim 8, further comprising a first sub-module and a second sub-module, in, The first sub-module is separated from the second sub-module by the monomer spacer, and Wherein, when viewed in the stacking direction, the first submodule includes the battery cells in the stack in front of the cell spacer, and the second submodule includes the battery cells in the stack behind the cell spacer.

10. The battery module according to claim 1, wherein: The battery cells are each thermally connected to a module cooling plate.

11. The battery module according to claim 1, further comprising: a module exhaust plate, located on the lower side of the battery cell; as well as a module cooling plate, located on the upper side of the battery cell; wherein each of the battery cells abuts against the module exhaust plate at the lower side, and The module cooling plate is thermally connected to the upper side of each of the battery cells.

12. A vehicle comprising a battery module according to any one of the preceding claims.

13. A battery pack comprising the battery module according to any one of claims 1 to 11.

14. A vehicle comprising the battery pack according to claim 13.

15. A method for assembling a battery module, the battery module comprising: a first beam having a plurality of first openings; a second beam having a second plurality of openings; a plurality of first bus bars, a plurality of second bus bars, and a plurality of battery cells, each of the battery cells including a hard shell having a parallelepiped shape, the parallelepiped shape having a pair of main sides arranged opposite to each other, a first terminal side and a second terminal side arranged opposite to each other, and a lower side and an upper side arranged opposite to each other, each of the battery cells further including a first terminal arranged on the first terminal side and a second terminal arranged on the second terminal side, the method comprising: arranging the battery cells into a stack aligned in a stacking direction such that the major side of each of the battery cells is arranged perpendicular to the stacking direction; attaching the first bus bar to the first beam and attaching the second bus bar to the second beam; arranging the first beam along the stack so that each of the first terminal sides faces the first beam, the first beam being oriented so that each of the first bus bars is positioned between the first beam and the stack; arranging the second beam along the stack so that each of the second terminal sides faces the second beam, the second beam being oriented so that each of the second bus bars is positioned between the second beam and the stack; moving the first beam toward the stack so that the first bus bar abuts the first terminal located in the region of the first bus bar and connecting the first bus bar to the first terminal located in the region of the first bus bar, the connection to the first bus bar being performed via a respective first opening of the first openings; and The second beam is moved toward the stack so that the second bus bar abuts the second terminal located in the area of ​​the second bus bar and the second bus bar is connected to the second terminal located in the area of ​​the second bus bar, the connection to the second bus bar being performed via a corresponding second opening of the second openings.

16. The method according to claim 15, further comprising: Arranging the first end plate in front of a first battery cell among the battery cells when viewed in the stacking direction, and arranging the second end plate behind a last battery cell among the battery cells when viewed in the stacking direction; pre-compressing the assembly of the battery cell, the first end plate, and the second end plate in the stacking direction; further compressing the assembly of the battery cell and the first and second end plates in the stacking direction such that each of the first and second end plates contacts the first and second beams; and Each of the first and second end plates is secured to each of the first and second beams.

Images