Battery pack and vehicle

Abstract

A battery pack and a vehicle are provided, and more particularly, the present disclosure relates to a battery pack (4) comprising a plurality of battery layers (6) stacked on one another, where a respective one of at least adjacent stacked first (61) and second (62) battery layers of the plurality of battery layers (6) comprises: a plurality of cell stacks (8), the invention relates to a battery pack (1) comprising:-a plurality of cell stacks (8), each cell stack comprising a plurality of battery cells (9) stacked together,-a base plate (10) wherein the plurality of cell stacks (8) are arranged on the base plate (10),-frame means (12) mechanically connected to the base plate (10) and surrounding the plurality of cell stacks (8). The present disclosure also relates to a vehicle (2).

Description

Technical Field

[0001] This disclosure generally relates to energy storage systems. In specific aspects, this disclosure relates to battery packs and vehicles. This disclosure is applicable to heavy-duty vehicles, such as trucks, buses, and construction equipment, as well as other vehicle types. Although this disclosure may be described with respect to specific vehicles, it is not limited to any particular vehicle. Background Technology

[0002] A battery pack typically comprises multiple battery cells connected in series and / or parallel, i.e., electrochemical battery cells. A battery pack may include one or more individual stacks of battery cells. The battery cells may be prismatic or cylindrical.

[0003] Due to trends such as vehicle electrification, there is ongoing effort to develop improved technologies related to battery packs, such as to provide reliable, robust, and / or space-saving cost-effective configurations. Summary of the Invention

[0004] According to a first aspect of this disclosure, a battery pack is provided. The battery pack has a first extension along a first axis, a second extension along a second axis, and a third extension along a third axis, wherein the first axis, the second axis, and the third axis are perpendicular. The battery pack includes a plurality of battery layers stacked on top of each other along the third axis, wherein at least one adjacent stacked first battery layer and a corresponding battery layer in the plurality of battery layers includes:

[0005] - Multiple cell stacks, each cell stack consisting of multiple battery cells stacked together.

[0006] - A substrate, wherein the plurality of battery cells are stacked on the substrate.

[0007] - A frame assembly, mechanically connected to the substrate and surrounding the plurality of cell stacks, as seen in a section perpendicular to the third axis.

[0008] The frame device includes:

[0009] - A pair of sidewalls extending along the first axis, wherein the cell stack is located between the pair of sidewalls along the second axis.

[0010] - A pair of end members extending along the second axis and mechanically connected to the pair of sidewalls, wherein the plurality of cell stacks are located between the pair of end members. A first aspect of this disclosure seeks to provide a reliable, robust, and / or space-saving cost-effective battery pack configuration. Technical benefits may include: the frame arrangement disclosed herein provides effective protection for the battery cells, such that the frame arrangement of multiple battery layers can together at least partially form an outer cover of the battery pack that is sealed from the external environment.

[0011] Optionally, in some examples, including at least one preferred example, the first battery layer and the second battery layer are connected via a sealed connection interface.

[0012] The substrate of one of the first battery layer and the second battery layer is arranged at the sealed connection interface, and

[0013] The sealed connection interface is configured such that:

[0014] The first battery layer and the second battery layer are mechanically connected to each other via their frame assembly, and

[0015] The sealed connection interface completely surrounds the substrate disposed at the sealed connection interface, as seen in a section perpendicular to the third axis. Technical benefits may include enabling a cell-to-pack configuration, which reduces the risk of leakage into the battery pack at the intersections between battery layers. For example, by arranging the substrate disposed at the sealed connection interface so that it is entirely within the battery pack, i.e., also within the sealed connection interface, a more reliable cell-to-pack configuration can be achieved.

[0016] Optionally, in some examples, including at least one preferred example, for at least one of the first and second battery layers, the plurality of battery cells in the respective cell stacks are stacked along the second axis, and the plurality of cell stacks are arranged along the first axis. Technical benefits may include: achieving efficient packaging of the battery cells, for example, achieving high energy density. Alternatively or additionally, technical benefits may include: any expansion forces from the respective cell stacks can be borne by the same structural components (i.e., by a pair of sidewalls) of each cell stack. This can mean a more robust battery pack configuration, for example, allowing the battery pack to be longer along the first axis without significantly negatively impacting the pack's stiffness.

[0017] Optionally, in some examples, including at least one preferred example, the battery cell may include a prismatic battery cell. Alternatively, the battery cell may include a cylindrical battery cell. The prismatic battery cell may include a top surface, a bottom surface, and four intermediate side surfaces connecting the top surface and the bottom surface. The prismatic battery cell may be box-shaped. Using prismatic battery cells stacked into a battery cell stack can form a battery pack configuration with high energy density. In some examples, at least one prismatic battery cell has at least one electrical terminal disposed on the top surface.

[0018] Optionally, in some examples, including at least one preferred example, the frame assembly of the first battery layer and the second battery layer is mechanically connected to each other by one or more first fasteners. Technical benefits may include: achieving a rigid and robust connection in a cost-effective manner, for example, allowing the addition and removal of battery layers without damaging any components of the battery pack.

[0019] Optionally, in some examples, including at least one preferred example, at least one of the one or more first fasteners is disposed in a complementary hole of the frame assembly, wherein one of the complementary holes in one of the frame assemblies has a fastener opening accessible from a side of the frame assembly, the side being located away from the frame assembly in a direction along the first axis or in a direction along the second axis. Technical benefits may include facilitating the manufacture of the battery pack. Technical benefits may additionally or alternatively include: achieving a more space-saving frame assembly.

[0020] Optionally, in some examples, including at least one preferred example, the fastener opening is disposed in a groove on the side. Technical benefits may include facilitating the manufacture of the battery pack. Technical benefits may additionally or alternatively include: achieving a more space-saving frame assembly.

[0021] Optionally, in some examples, including at least one preferred example, the substrate disposed at the sealed connection interface is configured relative to its frame assembly such that the substrate extends within the frame assembly along the third axis. Technical benefits may include achieving a more robust and reliable connection to the frame assembly.

[0022] Optionally, in some examples, including at least one preferred example, the substrate disposed at the sealed connection interface is arranged relative to its frame assembly such that the substrate is entirely within the frame assembly, as seen along the third axis. Technical benefits may include the battery layer having the frame assembly and substrate not extending to another adjacent battery layer. This can facilitate the encapsulation of the battery layers, for example, when mounting / removing the battery layers from each other. Additionally or alternatively, technical benefits may include reducing the risk of damaging components of the battery pack during mounting / removal.

[0023] Optionally, in some examples, including at least one preferred example, the substrate disposed at the sealed connection interface is mechanically connected to its frame assembly via one or more second fasteners. Technical benefits may include: achieving a rigid and robust connection in a cost-effective manner, for example, allowing the addition and removal of the substrate without damaging the substrate and / or frame assembly.

[0024] Optionally, in some examples, including at least one preferred example, the substrate disposed at the sealed connection interface includes one or more attachment flanges disposed at the outer periphery of the substrate, as seen in a section perpendicular to the third axis, wherein the substrate is mechanically connected to its frame assembly via the one or more attachment flanges, and wherein the one or more attachment flanges extend at least partially between the frame assemblies of the first battery layer and the second battery layer. Technical benefits may include achieving a more robust and rigid attachment of the substrate. In some examples, the substrate disposed at the sealed connection interface includes two or more attachment flanges disposed at the outer periphery of the substrate, as seen in a section perpendicular to the third axis, wherein the two or more attachment flanges are offset from each other around the outer periphery, and wherein the two or more attachment flanges extend at least partially between the frame assemblies of the first battery layer and the second battery layer. Technical benefits may include achieving a more robust and rigid attachment of the substrate around the outer periphery.

[0025] Optionally, in some examples, including at least one preferred example, at least one of the first and second battery layers includes a beam member extending along the second axis and mechanically connecting the pair of sidewalls, wherein the beam member is located between adjacent cell stacks. Technical benefits may include improved impact protection.

[0026] Optionally, in some examples, including at least one preferred example, at least one of the first and second battery layers includes a clamping member configured to clamp at least one battery cell toward the substrate on which the at least one battery cell is disposed. Technical benefits may include: achieving robust attachment of the battery cells in the battery layers, for example, mitigating the risk of movement of the battery cells or battery cell stacks during use, such as preventing vibration of the battery cells during use.

[0027] Optionally, in some examples, including at least one preferred example, the clamping member is attached to the beam member. Technical benefits may include: enabling a robust and cost-effective configuration, for example, facilitating the manufacture of the battery pack.

[0028] Optionally, in some examples, including at least one preferred example, the clamping member extends along the first axis such that the clamping member and the crossbeam member form a T-shape, as seen in a section perpendicular to the second axis, wherein at least one of the battery cells in each of adjacent cell stacks relative to the crossbeam member is clamped between the clamping member and the substrate. Technical benefits may include battery cells in two adjacent cell stacks being clamped by the same clamping member. This can imply a more cost-effective and space-efficient configuration.

[0029] Optionally, in some examples, including at least one preferred example, the battery pack includes a pair of covers, each of which is fixed to one of the frame devices such that the plurality of battery layers are positioned between the pair of covers along the third axis, and each of the plurality of cell stacks is surrounded by the frame device and the pair of covers. Technical benefits may include: achieving a closed battery pack structure.

[0030] Optionally, in some examples, including at least one preferred example, the battery pack includes a set of outer gaskets, each of which is located between one of the covers and the frame assembly to which the covers are secured, and each of which is configured to seal between the covers and the frame assembly. Technical benefits may include achieving a closed and sealed battery pack structure.

[0031] Optionally, in some examples, including at least one preferred example, the battery pack includes an intermediate gasket located between the frame devices of the first battery layer and the second battery layer, and wherein the intermediate gasket is configured to seal between the frame devices. Technical benefits may include: achieving an improved sealed connection interface between the frame devices. In some examples, the intermediate gasket forms part of a sealed connection interface as disclosed herein.

[0032] Optionally, in some examples, including at least one preferred example, the substrate of at least one of the first and second battery layers is a cooling plate including at least one coolant conduit for the coolant. Technical benefits may include the ability to effectively cool the battery cells of the first and / or second battery layers. This can result in improved cooling, more efficient cooling, and / or cooling for the battery cells requiring fewer cooling elements.

[0033] Optionally, in some examples, including at least one preferred example, the cooling plate includes a coolant inlet and a coolant outlet fluidly connected to the at least one coolant conduit. In some examples, the coolant inlet and / or the coolant outlet are located at at least one of the pair of end members, such as on one end side of the battery pack.

[0034] Optionally, in some examples, including at least one preferred example, for at least one of the first and second battery layers, the at least one battery layer includes an outer spacer located between one of the sidewalls and one of the cell stacks, and wherein the outer spacer is configured to deform when the cell stack expands. Technical benefits may include allowing the cell stack to expand during use. This can lead to more reliable operation of the battery pack.

[0035] Optionally, in some examples, including at least one preferred example, the at least one battery layer includes an intermediate spacer located between two of the battery cells in the battery pack, and the intermediate spacer is configured to deform as the cell stack expands. Technical benefits may include allowing the cell stack to expand more easily during use. This can lead to more reliable operation of the battery pack.

[0036] Optionally, in some examples, including at least one preferred example, the cell stack is compressed between the pair of sidewalls of the frame assembly via the outer spacer. Technical benefits may include: achieving a compact and reliable package, for example, obtaining high energy density.

[0037] Optionally, in some examples, including at least one preferred example, for at least one of the first and second battery layers, a channel is formed in the sidewall of at least one of the pair of sidewalls, the channel being configured to guide gas discharged from the battery cell toward at least one of the end members. The technical benefit may include: efficient discharge of gas from the battery cell from the battery pack.

[0038] Optionally, in some examples, including at least one preferred example, the battery pack includes a venting unit located at one of the end members and configured to vent gas guided from the battery pack via the channel. Technical benefits may include: gas from the battery cells is effectively vented from one end of the battery pack.

[0039] Optionally, in some examples, including at least one preferred example, the battery pack includes at least one filter unit, wherein the filter unit is in fluid communication with the channel and the venting unit, and wherein the filter unit is configured for particle capture. Technical benefits may include: particles in the battery cells are effectively captured in the filter unit during operation.

[0040] Optionally, in some examples, including at least one preferred example, for each of the first and second battery layers, the plurality of cell stacks are arranged along the first axis such that an auxiliary volume is formed between one of the end members and the plurality of cell stacks. Technical benefits may include: auxiliary components (such as cooling components, electrical components, etc.) can be housed within the auxiliary volume.

[0041] Optionally, in some examples, including at least one preferred example, the first battery layer and the second battery layer are configured such that the auxiliary volume together forms a common open-side space extending along the third axis between the first battery layer and the second battery layer. Technical benefits may include: by configuring the battery pack with a common open-side space surrounded by a frame assembly, more options are available for laying cables, coolant conduits, etc.

[0042] According to a second aspect of this disclosure, a vehicle is provided. The vehicle includes a battery pack according to any example of the first aspect of this disclosure. The advantages and benefits of the second aspect of this disclosure are similar to those of the first aspect of this disclosure.

[0043] Those skilled in the art will understand that the disclosed aspects, examples (including any preferred examples), and / or appended claims can be appropriately combined with each other. Additional features and advantages are disclosed in the following description, claims, and drawings, and will be apparent in part to those skilled in the art or recognized by practicing this disclosure as described herein. Attached Figure Description

[0044] The example is described in more detail below with reference to the accompanying drawings.

[0045] Figure 1 This is an example vehicle shown in the side view, based on the example.

[0046] Figure 2aThis is an example battery pack shown in the side view, based on the example.

[0047] Figure 2b This is an example battery pack shown in the side view, based on the example.

[0048] Figure 3 This is an example battery layer of a battery pack in a top view, based on the example.

[0049] Figure 4a This is an example battery layer of a battery pack in perspective view, based on the example.

[0050] Figure 4b This is an exemplary battery layer of the battery pack shown in the cross-sectional view, based on the example.

[0051] Figure 4c This is an example battery layer of a battery pack in perspective view, based on the example.

[0052] Figure 5a This is an example battery layer of a battery pack in perspective view, based on the example.

[0053] Figure 5b yes Figure 5a The battery layer in the magnified image.

[0054] Figure 6a This is an example battery layer of a battery pack in a top view, based on the example.

[0055] Figure 6b This is an example battery pack shown in the side view, based on the example.

[0056] The accompanying drawings are schematic and may not necessarily be drawn to scale. Unless otherwise stated, similar reference numerals throughout the drawings refer to the same or similar elements. In some drawings, certain reference numerals may be omitted for clarity. Detailed Implementation

[0057] The detailed description set forth below provides information and examples of the disclosed technology in sufficient detail to enable those skilled in the art to practice this disclosure.

[0058] The objective of this disclosure is to provide a reliable, cost-effective, and / or space-saving battery pack. Additionally, the objective of this disclosure is to provide an improved battery pack and / or vehicle that mitigates one or more deficiencies of the prior art or at least provides a suitable alternative. The technical benefits of the battery pack disclosed herein may include: the frame arrangement disclosed herein provides effective protection for the battery cells, such as the frame arrangement of multiple battery layers together forming at least partially a cover for the battery pack that is sealed from the external environment. For example, the battery pack disclosed herein can lead to an improved direct-connection cell packing configuration, for example, reducing the need for using individual battery modules in the battery pack. Alternatively or additionally, the battery pack disclosed herein enables direct-connection cell packing, thereby mitigating the risk of leakage into the battery pack at the intersections between battery layers. For example, a more reliable direct-connection cell packing configuration can be achieved by arranging a substrate disposed at a sealed connection interface such that it is entirely within the battery pack, i.e., also within the sealed connection interface.

[0059] Figure 1 The example vehicle 2 is shown in a side view according to the example. Vehicle 2 in this example is a truck, and more specifically a tractor-trailer for towing one or more trailers (not shown). However, it should be noted that the vehicle can be any other type of vehicle, such as another type of truck, bus, coach, vessel, or construction equipment such as a wheel loader or excavator. Vehicle 2 includes a battery pack 4 according to the example disclosed herein. Battery pack 4 can be at least partially used to drive one or more electric motors (not shown) of vehicle 2. Thus, vehicle 2 can be an electric vehicle or a hybrid vehicle, i.e., a vehicle that is at least partially propelled by electricity. The battery pack 4 disclosed herein can also be used for stationary units, such as buildings and / or any stationary machinery.

[0060] Figure 2a This is based on the example battery pack 4 in the side view, and Figure 2b It is based on the example. Figure 2a The battery pack is shown in the view from the other side. Figures 2a to 2b Battery pack 4 in the middle can be, for example, Figure 1 Battery pack 4 is shown.

[0061] Figure 3 This is an example of battery layer 6 in battery pack 4 as shown in the top view of the example. For example, Figure 3 Battery layer 6 in the middle can be Figures 2a to 2b The battery layer 6 of the battery pack 4 shown.

[0062] For example, refer to Figures 2a to 2b and Figure 3The diagram illustrates a battery pack 4. The battery pack 4 has a first extension along a first axis x, a second extension along a second axis y, and a third extension along a third axis z, wherein the first axis x, the second axis y, and the third axis z are perpendicular. For example, the first axis x may correspond to a longitudinal axis, the second axis y may correspond to a width axis, and the third axis z may correspond to a height axis. The axes x, y, and z may correspond to a Cartesian coordinate system. In some examples, when the battery pack 4 is disposed in a vehicle 2, the height axis z may correspond to the height axis of the vehicle 2. In some examples, the height axis z may be represented as a vertical axis. However, it should be noted that the battery pack 4 may also be oriented in different ways in the vehicle 2 or any other fixed unit.

[0063] The battery pack 4 includes multiple battery layers 6 stacked on top of each other along a third axis z. In the example shown, four battery layers 6 are depicted. However, any number of two or more layers can be used. The configurations of the corresponding battery layers 6 can be similar, identical, or different. Each battery layer 6 preferably includes multiple cell stacks 8. Each cell stack 8 includes multiple battery cells 9 stacked together.

[0064] exist Figure 3 In the example, the cell stack 8 of battery layer 6 includes a plurality of prismatic battery cells 9. The prismatic battery cells 9 are box-shaped, and each of the respective battery cells 9 has a top surface 91, as shown, which may be opposite to battery layer 6 in a direction (such as upward) along a third axis z. The top surface 91 may include at least one electrical terminal 92, as shown. The electrical terminals 92 of the battery cells 8 are connected in series and / or in parallel to achieve a battery pack 4 with a desired voltage level.

[0065] like Figure 3 As shown, multiple battery cells 9 of a corresponding cell stack 8 can be stacked along a second axis y, and multiple cell stacks 8 can be arranged along a first axis x. In the example shown, four cell stacks 8 are arranged along the first axis x.

[0066] For example, refer to Figures 2a to 2b and Figure 3 The respective battery layers 6 in at least the adjacent stacked first battery layer 61 and second battery layer 62 of the plurality of battery layers 6 include:

[0067] - A substrate 10, wherein the plurality of battery cell stacks 8 are arranged on the substrate 10, and

[0068] - A frame assembly 12, mechanically connected to the substrate 10 and surrounding the plurality of cell stacks 8, as seen in a section perpendicular to the third axis z.

[0069] The frame device 12 includes:

[0070] - A pair of sidewalls 14 extending along the first axis x, wherein the cell stack 8 is located between the pair of sidewalls 14 along the second axis y, and

[0071] - A pair of end members 16, which extend along the second axis y and are mechanically connected to the pair of sidewalls 14, wherein the plurality of cell stacks 8 are located between the pair of end members 16.

[0072] For example, such as Figures 2a to 2b As shown, the first battery layer 61 and the second battery layer 62 can be connected via a sealed connection interface CI. In the example shown, a sealed connection interface CI is provided between every two adjacent battery layers 6.

[0073] In this article, the connection interface refers to the interface between two adjacent battery layers, where the battery layers are in contact with each other. Therefore, a sealed connection interface means that the connection interface is sealed, thereby reducing the risk of leakage through the connection interface.

[0074] The substrate 10 of one of the first battery layer and the second battery layer 6 can be disposed at the sealed connection interface CI, and the sealed connection interface CI can be configured such that:

[0075] The first battery layer 61 and the second battery layer 62 are mechanically connected to each other via their frame device 12, and

[0076] The sealed connection interface CI completely surrounds the substrate 10 arranged at the sealed connection interface CI, as seen in a section perpendicular to the third axis z.

[0077] The frame assembly 12 of the first battery layer 61 and the second battery layer 62 can be mechanically connected to each other by one or more first fasteners F1. The one or more first fasteners F1 can be screws, bolts, rivets or any other fasteners. In the example shown, the one or more first fasteners F1 have a longitudinal direction extending along the third axis z.

[0078] At least one of one or more first fasteners F1 (such as all of the first fasteners F1) may be provided in complementary holes 181, 182 of the frame device 12 as shown, wherein one of the complementary holes 181 in one of the frame devices has a fastener opening 1811 that can be accessed from a side 121 of the frame device 12, the side being in the direction along the first axis x or as shown. Figure 2a As shown, it is located away from the frame device 12 in the direction along the second axis y.

[0079] Fastener opening 1811 can be like Figure 2a The fastener opening is provided in a groove 122 on the side 121. In the example shown, each fastener opening is provided in a corresponding groove. In other examples, each groove may have more than one fastener opening. As shown, the groove 122 may be a recess in the originally flat wall surface 123 of the frame assembly 12.

[0080] like Figure 3 As shown, at least one of the first battery layer 61 and the second battery layer 62 may include a clamping member 22 configured to clamp at least one battery cell 9 toward the substrate 10 on which the at least one battery cell 9 is disposed. In the example shown, the clamping member 22 is configured to clamp each battery cell 9 in at least one cell stack 8.

[0081] For example, refer to Figures 2a to 2b The battery pack 4 may include a pair of covers 24 as shown in the figure. Each of the pair of covers 24 is fixed to one of the frame devices 12 such that a plurality of battery layers 6 are located between the pair of covers 24 along a third axis z, and each of a plurality of cell stacks 8 is surrounded by the frame device 12 and the pair of covers 24.

[0082] The battery pack 4 may also include a pair of outer gaskets 38. Each of the pair of outer gaskets 38 is located between one of the covers 24 and the frame assembly 12 to which the covers 24 are fixed, and each of the pair of outer gaskets 38 is configured to seal between the covers 24 and the frame assembly 12.

[0083] As shown in the figure, the battery pack 4 may also include an intermediate gasket 40. The intermediate gasket 40 is located between the frame structure 12 of the first battery layer 61 and the second battery layer 62, and the intermediate gasket 40 is configured to seal between the frame structures 12. In the example shown, the intermediate gasket 40 forms part of a sealed connection interface CI.

[0084] The substrate 10 of at least one of the first battery layer 61 and the second battery layer 62 may be a cooling plate 10, said cooling plate including at least one coolant conduit 26, 28 for coolant. For example... Figures 2a to 2b In the example shown, the cooling plate 10 includes a coolant inlet 26 and a coolant outlet 28 fluidly connected to at least one coolant conduit. Therefore, the substrate 10 can not only be a structural member providing structural support for the battery cell 9, but it can also serve as a cooling plate for the battery cell 9.

[0085] refer to Figure 3The diagram illustrates that at least one of the first battery layer 61 and the second battery layer 62 may include an outer spacer 32. The outer spacer 32 is located between one of the sidewalls 14 and one of the cell stacks 8, and is configured to deform when the cell stack 8 expands. Therefore, the outer spacer 322 is preferably made of an elastic material, such as a polymer-based material. In the example shown, an outer spacer 32 is provided on each outer side of the cell stack 8.

[0086] As shown in the figure, at least one battery layer 6 may also include an intermediate spacer 34. The intermediate spacer 34 is located between two battery cells 9 in the cell stack 8, and the intermediate spacer 34 is configured to deform when the cell stack 8 expands.

[0087] The cell stack 8 can be compressed between a pair of sidewalls 14 of the frame assembly 12 via the outer spacer 32.

[0088] Figure 4a This is an exemplary portion of the battery layer 6 of the battery pack 4 in the perspective view, based on the example. Figure 4b This is an exemplary portion of the battery layer 6 of the battery pack 4 as shown in the example cross-sectional view. The cross-sectional view is perpendicular to the first axis x. Figure 4c This is an exemplary portion of the battery layer 6 of the battery pack 4 in the perspective view, based on the example. Figures 4a to 4c Battery layer 6 in the middle can be Figures 2a to 2b and Figure 3 Any one of the battery layers 6 shown.

[0089] refer to Figure 4b The substrate 10, disposed at the sealed connection interface CI, can be configured relative to its frame assembly 12 such that the substrate 10 extends within the frame assembly 12 along a third axis z. In some examples, such as Figure 4b As shown, the substrate 10 arranged at the sealed connection interface CI can be configured relative to its frame device 12 such that the substrate 10 is completely inside the frame device 12, as seen along the third axis z.

[0090] Figure 4c An example of the frame assembly 12 of the battery layer 6 and the associated substrate 10 is depicted in an inverted view. (Reference) Figure 4c The substrate 10, located at the sealed connection interface CI, can be mechanically connected to its frame assembly 12 via one or more second fasteners F2. The one or more second fasteners F2 can be screws, bolts, rivets, or any other fasteners. In the example shown, the one or more second fasteners F2 are disposed in corresponding holes in a pair of sidewalls 14 of the frame assembly 12. The term "its frame assembly" herein refers to the frame assembly of substrates mechanically connected to the same battery layer.

[0091] The substrate 10 disposed at the sealed connection interface CI may, as further shown, include one or more attachment flanges 101 disposed at the outer periphery P1 of the substrate 10, as seen in a section perpendicular to the third axis z. Thus, the substrate 10 may be mechanically connected to its frame assembly 12 via one or more attachment flanges 101, wherein the one or more attachment flanges 101 extend at least partially between the frame assemblies 12 of the first battery layer 61 and the second battery layer 62. In the example shown, the substrate 10 disposed at the sealed connection interface CI includes two or more attachment flanges 101 disposed at the outer periphery P1 of the substrate 10, as seen in a section perpendicular to the third axis z, wherein the two or more attachment flanges 101 are offset from each other around the outer periphery P1, and wherein the two or more attachment flanges 101 extend at least partially between the frame assemblies 12 of the first battery layer 61 and the second battery layer 62. Figure 4c In the example, the attachment flange 101 is arranged between the sidewalls 14 of the frame assembly 12. It can be seen that the attachment flange 101 may be disposed in a groove in at least one of the adjacent frame assemblies 12.

[0092] Figure 5a This is an exemplary portion of the battery layer 6 of the battery pack 4 in the perspective view, based on the example. Figure 5b yes Figure 5a The battery layer 6 is shown in the magnified image. Figures 5a to 5b The battery layer 6 in the figure can be any one of the battery layers in Figures 2 to 4. Figures 5a to 5b Battery layer 6 is shown in a top view.

[0093] Figures 5a to 5b At least one of the first battery layer 61 and the second battery layer 62 is shown to include a crossbeam member 13 extending along a second axis y and mechanically connecting a pair of sidewalls 14. The crossbeam member 13 is located between adjacent cell stacks 8. Figures 5a to 5b (Not shown in the image).

[0094] like Figure 5b As shown, at least one crossbeam member 13 may include a clamping member 131, the clamping member being configured to hold at least one battery cell 9 toward a substrate 10 on which at least one battery cell 9 is disposed. Figures 5a to 5b (Not shown) Clamping. Therefore, clamping member 131 can be attached to beam member 13. In the example shown, clamping member 131 and beam member 13 are made as a single piece. In other examples, clamping member can be attached to beam member by fasteners or welding.

[0095] like Figure 5bAs further shown, the clamping member 131 may extend along the first axis x such that the clamping member 131 and the crossbeam member 13 form a T-shape, as seen in the section perpendicular to the second axis y, wherein at least one of the battery cells 9 in each of the adjacent cell stacks 8 relative to the crossbeam member 13 is clamped between the clamping member 13 and the substrate 10.

[0096] Figure 6a This is an example of battery layer 6 in battery pack 4 as shown in the top view of the example. Figure 6b This is based on the example battery pack 4 in the side view. Figures 6a to 6b The battery layer 6 and battery pack 4 in the figure can be, for example, any of the battery pack 4 and battery layer 6 shown in Figures 2 to 5.

[0097] like Figure 6b As shown, for at least one of the first battery layer 61 and the second battery layer 62, a channel 42 may be formed in at least one of the sidewalls 14 of a pair of sidewalls 14. The channel 42 may be configured to guide gas discharged from the battery cell 9 toward at least one of the end members 16. Figures 6a to 6b In the middle, the gas guiding path is indicated by the flow arrow pointing from the battery pack 4 to its outside.

[0098] As shown in the figure, at least one battery layer 6 may include an exhaust unit 44, wherein the exhaust unit 44 is located at one of the end members 16 and is configured to exhaust gas guided from the battery pack 4 via the channel 42. As further shown in the figure, at least one battery layer 6 may include at least one filter unit 46, wherein the filter unit 46 is in fluid communication with the channel 42 and the exhaust unit 44, and wherein the filter unit 46 is configured for particle capture.

[0099] Figures 6a to 6b Further depiction shows that, for each of the first battery layer 61 and the second battery layer 62, a plurality of cell stacks 8 can be arranged along a first axis x, such that an auxiliary volume 48 is formed between one of the end members 16 and the plurality of cell stacks 8. As further shown, the first battery layer and the second battery layer 6 can be configured such that the auxiliary volumes 48 together form a common open side space 50, which extends along a third axis z between the first battery layer 61 and the second battery layer 62. In some examples, the auxiliary volumes 48 of all battery layers 6 in the battery pack 4 can together form a common open side space extending along the third axis z between the battery layers 6.

[0100] In the following text, possible features and combinations of features of this disclosure are presented as a series of examples.

[0101] Example 1: A battery pack (4) having a first extension along a first axis (x), a second extension along a second axis (y), and a third extension along a third axis (z), wherein the first axis (x), the second axis (y), and the third axis (z) are perpendicular, the battery pack (4) comprising a plurality of battery layers (6) stacked together along the third axis (z), wherein at least one adjacent stacked first battery layer and a corresponding battery layer of the plurality of battery layers (6) comprises:

[0102] - Multiple cell stacks (8), each cell stack comprising multiple battery cells (9) stacked together.

[0103] - A substrate (10), wherein the plurality of battery cell stacks (8) are arranged on the substrate (10),

[0104] - A frame assembly (12), mechanically connected to the substrate (10) and surrounding the plurality of cell stacks (8), as seen in a section perpendicular to the third axis (z).

[0105] The frame device (12) includes:

[0106] - A pair of sidewalls (14) extending along the first axis (x), wherein the cell stack (8) is located between the pair of sidewalls (14) along the second axis (y).

[0107] - A pair of end members (16) extending along the second axis (y) and mechanically connecting the pair of sidewalls (14), wherein the plurality of cell stacks (8) are located between the pair of end members (16).

[0108] Example 2: According to the battery pack of Example 1, wherein the first battery layer and the second battery layer (6) are connected via a sealed connection interface (CI),

[0109] The substrate (10) of one of the first battery layer and the second battery layer (6) is arranged at the sealed connection interface (CI), and

[0110] The sealed connection interface (CI) is configured such that:

[0111] The first battery layer and the second battery layer (6) are mechanically connected to each other via their frame assembly (12), and

[0112] The sealed connection interface (CI) completely surrounds the substrate (10) arranged at the sealed connection interface (CI), as seen in a section perpendicular to the third axis (z).

[0113] Example 3: According to the battery pack (4) of Example 1 or 2, wherein for at least one of the first battery layer and the second battery layer (6), the plurality of battery cells (9) of the corresponding cell stack are stacked along the second axis (y), and wherein the plurality of cell stacks (8) are arranged along the first axis (x).

[0114] Example 4: The battery pack (4) according to any of the preceding examples, wherein the frame device (12) of the first battery layer and the second battery layer (6) is mechanically connected to each other by one or more first fasteners (F1).

[0115] Example 5: According to the battery pack (4) of Example 4, at least one of the one or more first fasteners (F1) is disposed in complementary holes (181, 182) of the frame device (12), wherein one of the complementary holes (181) of the frame device has a fastener opening (1811) that can be accessed from a side (121) of the frame device (12) which is away from the frame device (12) in a direction along the first axis (x) or in a direction along the second axis (y).

[0116] Example 6: The battery pack (4) according to Example 5, wherein the fastener opening (1811) is provided in a groove (122) on the side (121).

[0117] Example 7: A battery pack (4) according to any of the preceding examples, wherein the substrate (10) disposed at the sealed connection interface (CI) is configured relative to its frame assembly (12) such that the substrate (10) extends along the third axis (z) inside the frame assembly (12).

[0118] Example 8: According to the battery pack (4) of Example 7, the substrate (10) arranged at the sealed connection interface (CI) is configured relative to its frame device (12) such that the substrate (10) is completely inside the frame device (12), as seen along the third axis (z).

[0119] Example 9: A battery pack (4) according to any of the preceding examples, wherein the substrate (10) disposed at the sealed connection interface (CI) is mechanically connected to its frame assembly (12) via one or more second fasteners (F2).

[0120] Example 10: A battery pack (4) according to any of the preceding examples, wherein the substrate (10) disposed at the sealed connection interface (CI) includes one or more attachment flanges (101) disposed at the outer periphery (P1) of the substrate (10), as seen in a section perpendicular to the third axis (z), wherein the substrate (10) is mechanically connected to its frame assembly via the one or more attachment flanges (101), and wherein the one or more attachment flanges extend at least partially between the frame assembly (12) of the first battery layer and the second battery layer (6).

[0121] Example 11: A battery pack (4) according to any of the preceding examples, wherein at least one of the first battery layer and the second battery layer (6) includes a beam member (13) extending along the second axis (y) and mechanically connecting the pair of sidewalls (14), and wherein the beam member (13) is located between adjacent cell stacks (8).

[0122] Example 12: A battery pack (4) according to any of the preceding examples, wherein at least one of the first battery layer and the second battery layer (6) includes clamping members (22, 131) configured to clamp at least one battery cell (9) toward the substrate (10) on which the at least one battery cell (9) is disposed.

[0123] Example 13: The battery pack according to Examples 11 and 12, wherein the clamping member (131) is attached to the beam member (13).

[0124] Example 14: According to the battery pack of Example 13, wherein the clamping member (131) extends along the first axis (x) such that the clamping member (131) and the crossbeam member (13) form a T-shape, as seen in a section perpendicular to the second axis (y), wherein at least one of the battery cells (9) in each of the adjacent cell stacks (8) of the crossbeam member (13) is clamped between the clamping member (13) and the substrate (10).

[0125] Example 15: A battery pack (4) according to any of the preceding examples includes a pair of covers (24), each of which is fixed to one of the frame devices (12) such that the plurality of battery layers (6) are located between the pair of covers (24) along the third axis (z), and each of the plurality of cell stacks (8) is surrounded by the frame device (12) and the pair of covers (24).

[0126] Example 16: The battery pack (4) according to Example 15 includes a set of outer gaskets (38), wherein each of the set of outer gaskets (38) is located between one of the covers (24) and the frame device (12) to which the covers (24) are fixed, and wherein each of the set of outer gaskets (38) is configured to seal between the covers (24) and the frame device (12).

[0127] Example 17: A battery pack (4) according to any of the preceding examples includes an intermediate gasket (40) located between the frame assembly (12) of the first battery layer and the second battery layer (6), and wherein the intermediate gasket (40) is configured to seal between the frame assembly (12).

[0128] Example 18: The battery pack (4) according to any of the preceding examples, wherein the substrate (10) of at least one of the first battery layer and the second battery layer (6) is a cooling plate (10) including at least one coolant conduit (26, 28) for coolant.

[0129] Example 19: According to the battery pack (4) of Example 18, the cooling plate (10) includes a coolant inlet (26) and a coolant outlet (28) fluidly connected to the at least one coolant conduit.

[0130] Example 20: A battery pack (4) according to any of the preceding examples, wherein for at least one battery layer (6) of the first battery layer and the second battery layer, the at least one battery layer includes an outer spacer (32), wherein the outer spacer (32) is located between one of the sidewalls (14) and one of the cell stacks (8), and wherein the outer spacer (32) is configured to deform when the cell stacks (8) expand.

[0131] Example 21: According to the battery pack (4) of Example 20, the at least one battery layer includes an intermediate spacer (34), wherein the intermediate spacer (34) is located between two of the battery cells (9) in the battery pack (8), and wherein the intermediate spacer (34) is configured to deform when the cell stack (8) expands.

[0132] Example 22: A battery pack (4) according to Example 20 or 21, wherein the cell stack (8) is compressed between the pair of sidewalls (14) of the frame assembly (12) via the outer spacer (32).

[0133] Example 23: A battery pack (4) according to any of the preceding examples, wherein for at least one of the first battery layer and the second battery layer (6), a channel (42) is formed in the sidewall of at least one of the pair of sidewalls (14), the channel (42) being configured to guide gas discharged from the battery cell (9) toward at least one of the end members (16).

[0134] Example 24: The battery pack (4) according to Example 23 includes an exhaust unit (44) located at one of the end members (16) and configured to exhaust gas guided from the battery pack (4) via the channel (42).

[0135] Example 25: The battery pack (4) according to Example 24 includes at least one filter unit (46) in fluid communication with the channel (42) and the exhaust unit (44), and wherein the filter unit (46) is configured for particulate capture.

[0136] Example 26: According to any of the preceding examples, for each of the first battery layer and the second battery layer (6), the plurality of cell stacks (8) are arranged along the first axis (x) such that an auxiliary volume (48) is formed between one of the end members (16) and the plurality of cell stacks (8).

[0137] Example 27: According to the battery pack (4) of Example 26, wherein the first battery layer and the second battery layer (6) are configured such that the auxiliary volume (48) together form a common open side space (50) extending between the first battery layer and the second battery layer (6) along the third axis (z).

[0138] Example 28: A vehicle comprising a battery pack according to any one of Examples 1 to 27.

[0139] The terminology used herein is for descriptive purposes only and is not intended to limit this disclosure. As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” are intended to also include the plural forms. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items. It should also be understood that the terms “comprising” and / or “including”, when used herein, indicate the presence of the stated features, integers, actions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and / or groups thereof.

[0140] It should be understood that although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, without departing from the scope of this disclosure, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element.

[0141] In this document, relative terms such as “below,” “above,” “upper,” “lower,” “horizontal,” or “vertical” may be used to describe the relationship between one element and another, as illustrated in the figures. It should be understood that these terms, along with those discussed above, are intended to cover different device orientations in addition to those depicted in the figures. It should be understood that when an element is referred to as “connected” or “coupled” to another element, the element may be directly connected or coupled to the other element, or there may be intermediate elements present. In contrast, when an element is referred to as “directly connected” or “directly coupled” to another element, there are no intermediate elements present.

[0142] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It should also be understood that, unless expressly defined herein, terms used herein shall be interpreted as having the same meaning as they have in the context of this specification and the relevant field, and not in an idealized or overly formal sense.

[0143] It should be understood that this disclosure is not limited to the aspects described above and shown in the accompanying drawings; rather, those skilled in the art will recognize that many changes and modifications can be made within the scope of this disclosure and the appended claims. Aspects have been disclosed in the drawings and description for illustrative purposes only and not for limiting purposes, and the scope of this disclosure is set forth in the appended claims.

Claims

1. A battery pack (4) having a first extension along a first axis (x), a second extension along a second axis (y), and a third extension along a third axis (z), wherein the first axis (x), the second axis (y), and the third axis (z) are perpendicular, the battery pack (4) comprising a plurality of battery layers (6) stacked together along the third axis (z), wherein at least one adjacent stacked first battery layer (61) and a corresponding battery layer of a second battery layer (62) of the plurality of battery layers (6) comprises: - Multiple cell stacks (8), each cell stack comprising multiple battery cells (9) stacked together. - A substrate (10), wherein the plurality of battery cell stacks (8) are arranged on the substrate (10), - A frame assembly (12) mechanically connected to the substrate (10) and surrounding the plurality of cell stacks (8), as seen in a section perpendicular to the third axis (z). The frame device (12) includes: - A pair of sidewalls (14) extending along the first axis (x), wherein the cell stack (8) is located between the pair of sidewalls (14) along the second axis (y). - A pair of end members (16) extending along the second axis (y) and mechanically connecting the pair of sidewalls (14), wherein the plurality of cell stacks (8) are located between the pair of end members (16). The first battery layer (61) and the second battery layer (62) are connected via a sealed connection interface (CI). The substrate (10) of one of the first battery layer (61) and the second battery layer (62) is disposed at the sealed connection interface (CI), and The sealed connection interface (CI) is configured such that: The first battery layer (61) and the second battery layer (62) are mechanically connected to each other via their frame assembly (12), and The sealed connection interface (CI) completely surrounds the substrate (10) arranged at the sealed connection interface (CI), as seen in a section perpendicular to the third axis (z).

2. The battery pack (4) according to claim 1, wherein for at least one of the first battery layer and the second battery layer (6), the plurality of battery cells (9) of the corresponding cell stack are stacked along the second axis (y), and wherein the plurality of cell stacks (8) are arranged along the first axis (x).

3. The battery pack (4) according to any one of the preceding claims, wherein the frame device (12) of the first battery layer and the second battery layer (6) is mechanically connected to each other by one or more first fasteners (F1).

4. The battery pack (4) according to claim 3, wherein at least one of the one or more first fasteners (F1) is disposed in a complementary hole (181, 182) of the frame device (12), wherein one of the complementary holes (181) of the frame device has a fastener opening (1811) accessible from a side (121) of the frame device (12) which is located away from the frame device (12) in a direction along the first axis (x) or in a direction along the second axis (y).

5. The battery pack (4) according to any one of the preceding claims, wherein the substrate (10) disposed at the sealed connection interface (CI) is configured relative to its frame device (12) such that the substrate (10) extends along the third axis (z) inside the frame device (12).

6. The battery pack (4) according to claim 5, wherein the substrate (10) disposed at the sealed connection interface (CI) is arranged relative to its frame device (12) such that the substrate (10) is completely inside the frame device (12), as seen along the third axis (z).

7. The battery pack (4) according to any of the preceding claims, wherein the substrate (10) disposed at the sealed connection interface (CI) is mechanically connected to its frame assembly (12) via one or more second fasteners (F2).

8. The battery pack (4) according to any of the preceding claims, wherein the substrate (10) disposed at the sealed connection interface (CI) includes one or more attachment flanges (101) disposed at the outer periphery (P1) of the substrate (10), as seen in a section perpendicular to the third axis (z), wherein the substrate (10) is mechanically connected to its frame assembly via the one or more attachment flanges (101), and wherein the one or more attachment flanges extend at least partially between the frame assembly (12) of the first battery layer and the second battery layer (6).

9. The battery pack (4) according to any one of the preceding claims, wherein at least one of the first battery layer and the second battery layer (6) includes a beam member (13) extending along the second axis (y) and mechanically connecting the pair of sidewalls (14), and wherein the beam member (13) is located between adjacent cell stacks (8).

10. The battery pack (4) according to any one of the preceding claims, wherein at least one of the first battery layer and the second battery layer (6) includes clamping members (22, 131) configured to clamp at least one battery cell (9) toward the substrate (10) on which the at least one battery cell (9) is disposed.

11. The battery pack according to claims 9 and 10, wherein the clamping member (131) is attached to the beam member (13).

12. The battery pack according to claim 11, wherein the clamping member (131) extends along the first axis (x) such that the clamping member (131) and the crossbeam member (13) form a T-shape, as seen in a section perpendicular to the second axis (y), wherein at least one of the battery cells (9) in each of the adjacent cell stacks (8) of the crossbeam member (13) is clamped between the clamping member (13) and the substrate (10).

13. The battery pack (4) according to any one of the preceding claims, wherein for at least one battery layer (6) of the first battery layer and the second battery layer, the at least one battery layer includes an outer spacer (32), wherein the outer spacer (32) is located between one of the sidewalls (14) and one of the cell stack (8), and wherein the outer spacer (32) is configured to deform when the cell stack (8) expands.

14. The battery pack (4) according to claim 13, wherein the cell stack (8) is compressed between the pair of sidewalls (14) of the frame device (12) via the outer spacer (32).

15. A vehicle comprising a battery pack according to any one of claims 1 to 14.

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