BATTERY MODULE CELL CARRIER AND ASSEMBLY METHOD

Abstract

Cell carrier (201) for a battery module (100), the cell carrier comprising: a multi-sided rectangular base (203) comprising: a plurality of through-holes (205) arranged in a predetermined pattern, each through-hole including an inner sidewall (805) configured to hold one of a plurality of battery cells (103); and Side walls (211a, 211b), each of the side walls (211a, 211b) comprising a plurality of locks (213, 214) formed integrally along an inner surface of the respective side wall and spaced apart from one another in a direction parallel to the respective side edge, wherein each of the plurality of locks (213, 214) comprises a pair of projections extending from the inner surface and angled toward each other to form part of a sliding connection.

Description

INTRODUCTION

[0001] The present disclosure relates to a cell carrier for a battery module, a battery module including the cell carrier, and a method for assembling a battery module, and more particularly to a one-piece cell carrier that enables a reduction in the parts of a battery module and a reduction in the assembly steps when assembling the battery module.

[0002] US 2021 / 0 184 190 A1 relates to a battery pack including battery cells and a ceramic foil. The battery cells are arranged in a plurality of rows, wherein the battery cells are arranged in a row spaced apart from each other with a separation gap therebetween. The ceramic foil extends and surrounds at least any one row of the battery cells, wherein the ceramic foil comprises non-adhesive portions surrounding the battery cells and an adhesive portion extending across the separation gap between adjacent non-adhesive portions of the non-adhesive portions.

[0003] US 2020 / 0 227 696 A1 discloses a battery pack provided with a battery core pack having a plurality of battery cells held by a holding portion of a cell holder, and a case for accommodating the battery core pack. The cell holder has a peripheral wall portion surrounding the holding portion. A plurality of slits extending along the circumferential direction on an end surface of the peripheral wall portion are provided on the peripheral wall portion.

[0004] US 2021 / 0 126 302 A1 relates to a battery pack with a heating element, which can be an electrical strip heater. The heating element is activated when battery temperatures are near or below the minimum discharge or charge temperatures. The heating element simultaneously serves to heat the battery cells and as a separator for a group of cells assembled into a lightweight battery pack. In installations where heating elements are not desired, inactive separators can be provided as an alternative, reducing costs and avoiding the need to reconfigure other battery pack components.

[0005] US 2019 / 0 296 407 A1 relates to a multi-zone thermocouple battery module temperature monitoring system configured to determine a plurality of temperatures at different locations along a depth of the battery module. The system includes a number of temperature probes, each having a first temperature sensor aligned with a base of a group of cells in the module and a second temperature sensor aligned with an upper portion of the group of cells in the module. The provision of upper and lower temperature sensors for the battery cells in each probe of the system enables a battery management system to detect and record a temperature gradient of the battery cells in the module at a number of different locations.These recordings can determine a gradient and temperature difference between the upper and lower battery cell sections above an operational threshold difference and instruct a thermal management system to return the battery module to limits within the operational threshold.

[0006] WO 2021 / 178196 A2 discloses a battery pack comprising battery cell magazines and a battery management system for controlling the charging and discharging of the associated battery pack. The battery cell magazines comprise a magazine housing and associated battery cells. The magazine housing defines a plurality of battery cell recesses for receiving the battery cells. The battery management system is configured to equalize the charge level of a battery stack of battery packs. SUMMARY

[0007] The present invention is based on the object of simplifying the assembly of a battery module.

[0008] This object is achieved by a cell carrier according to claim 1, a battery module according to claim 7 or a method according to claim 16.

[0009] The dependent claims provide preferred embodiments of the invention.

[0010] It is advantageous to tightly package battery cells in large-format, high-voltage battery modules to provide battery modules with high energy density. In one approach, battery cells can be inserted into a carrier layer of a battery module before sidewalls are attached to the sides of the battery module (e.g., using an adhesive). However, in some embodiments, it would be advantageous to reduce the number of parts required to assemble a battery module, for example, to simplify assembly.

[0011] To solve one or more of these problems, a cell carrier for a battery module, a battery module including the cell carrier, and a method for assembling the battery module are provided. The cell carrier includes a multi-sided base that includes a plurality of through-holes arranged in a predetermined pattern. Each through-hole includes an inner sidewall configured to hold one of a plurality of battery cells.

[0012] In some embodiments, the inner sidewall may be disposed around a lower portion of the one battery cell; and the multi-sided base may be a rectangular base including opposing sidewalls, each formed along a respective side edge of the rectangular base. In some embodiments, the rectangular base and the sidewalls may be integrally formed as a single part.

[0013] In some embodiments, the multi-sided base may be a rectangular base including sidewalls; each of the sidewalls may include a plurality of locks integrally formed along an inner surface of the respective sidewall and spaced apart from each other in a direction parallel to the respective side edge; and each of the plurality of locks may include a pair of protrusions extending from the inner surface and angled toward each other to form part of a sliding joint. In some embodiments, each of the plurality of locks may be configured to receive a y-shaped connector of a p-group separator or an edge support structure, and the y-shaped connector may be configured to slide between respective pairs of protrusions to form the sliding joint.

[0014] In some embodiments, the rectangular base may further include a front wall formed along a front edge of the rectangular base and a rear wall opposite the front wall and formed along a rear edge of the rectangular base. In some embodiments, the rectangular base, the side walls, the front wall, and the rear wall may be integrally formed as a single part.

[0015] In some embodiments, the multi-sided base may further include: a front wall including a first plurality of brackets arranged in a first pattern, the first plurality of brackets configured to attach a first component to the front wall; and a rear wall including a second plurality of brackets arranged in a second pattern, the second plurality of brackets configured to attach a second component to the rear wall. In some embodiments, the first pattern may be different from the second pattern, and the first component may be different from the second component.

[0016] In some embodiments, the cell carrier may include a plastic material and may be formed as a single part by injection molding.

[0017] In some embodiments, a battery module is provided. The battery module includes a one-piece cell carrier configured to interconnect a plurality of battery cells. The one-piece cell carrier includes: a base including a plurality of through-holes, each including an inner sidewall configured to be disposed around and retain a lower portion of one of the plurality of battery cells; and one or more walls formed integrally with the base, each along a respective edge of the base.

[0018] In some embodiments, the one or more walls may include a first sidewall formed along a first edge of the base and a second sidewall opposite the first sidewall and formed along a second edge of the base. The first sidewall may include a first plurality of latches integrally formed along an interior surface of the first sidewall and spaced apart from each other in a direction along the first edge of the base, and the second sidewall may include a second plurality of latches integrally formed along an interior surface of the second sidewall and spaced apart from each other in a direction along the second edge of the base.

[0019] In some embodiments, the battery module may further include a first edge support structure and a second edge support structure. The first edge support structure may be configured to attach to the first plurality of latches of the first sidewall and support first battery cells of the plurality of battery cells adjacent to the first sidewall, and the second edge support structure may be configured to attach to the second plurality of latches of the second sidewall and support second battery cells of the plurality of battery cells adjacent to the second sidewall.

[0020] In some embodiments, the battery module may further include a plurality of p-group separators. Each of the plurality of p-group separators may include at least one segment configured to be disposed in a free space between adjacent parallel groups of the plurality of battery cells. Each of the plurality of p-group separators may further include a first connector disposed at a first end of the p-group separator and configured to be attached to a first latch, and a second connector disposed at a second end of the p-group separator and configured to be attached to a second latch.

[0021] In some embodiments, the one or more walls may include a first sidewall formed along a first edge of the base and a second sidewall opposite the first sidewall and formed along a second edge of the base. In some embodiments, the first lock may include a first pair of projections extending from an inner surface of the first sidewall and angled to form a first portion of a first sliding connection, and the second lock may include a second pair of projections extending from the inner surface of the second sidewall and forming a first portion of a second sliding connection.In some embodiments, each of the first connectors may include a first Y-shaped connector configured to slide between a respective first pair of protrusions to form a first sliding connection, and each of the second connectors may include a second Y-shaped connector configured to slide between a respective second pair of protrusions to form the second sliding connection.

[0022] In some embodiments, the battery module may further include a bus bar and an insulation clip, and the one or more walls may further include: a third sidewall formed along a third edge of the base, the third sidewall including an insulation clip retainer; and a fourth sidewall opposite the third sidewall and formed along a fourth edge of the base, the fourth sidewall including a bus bar retainer. In some embodiments, the insulation clip may be mounted to the insulation clip retainer, and the bus bar may be mounted to the bus bar retainer.

[0023] In some embodiments, the battery module may further include a thermistor. In some embodiments, the third sidewall may include a thermistor pocket integrally formed therein, and the thermistor may be mounted in the thermistor pocket.

[0024] In some embodiments, the battery module may further include the plurality of battery cells. In some embodiments, each of the plurality of battery cells may include a cylindrical sidewall, and each of the inner sidewalls may include a cylindrical inner sidewall corresponding to the cylindrical sidewalls of the plurality of battery cells.

[0025] In some embodiments, the battery module may further include a cold plate, and the cold plate may be attached to a bottom surface of each of the plurality of battery cells.

[0026] In some embodiments, the one-piece cell carrier may include a plastic material and may be formed as a single part by injection molding.

[0027] In some embodiments, a method of assembling a battery module is provided. The method includes providing a one-piece cell carrier, a plurality of battery cells, and an adhesive. The one-piece cell carrier includes a rectangular base including a first side, a second side opposite the first side, and a plurality of through-holes arranged in a predetermined pattern, each through-hole extending from the first side to the second side and having an inner sidewall configured to be disposed around and retain a lower portion of one of the plurality of battery cells.The method further includes: inserting each of the plurality of battery cells into a respective through-hole such that an upper end of each of the plurality of battery cells extends from the first side and a lower end of each of the plurality of battery cells extends from the second side; selectively applying adhesive to at least one of the plurality of batteries and the rectangular base such that the adhesive bonds each inner sidewall to a respective lower portion of one of the plurality of batteries; and curing the adhesive.

[0028] In some embodiments, the one-piece cell carrier may further include a first sidewall formed integrally with the rectangular base along a first edge of the rectangular base, and a second sidewall opposite the first sidewall and formed integrally with the rectangular base along a second edge of the rectangular base. In some embodiments, the method may further include providing a first edge support structure configured to support battery cells along the first edge and a second edge support structure configured to support battery cells along the second edge, and prior to inserting each of the plurality of battery cells into a respective through-hole, attaching the first edge support structure to an interior side of the first sidewall and attaching the second edge support structure to an interior side of the second sidewall.

[0029] In some embodiments, the method may further include providing a plurality of p-type separators, each including at least one segment configured to be disposed in a free space between adjacent parallel groups of battery cells. In some embodiments, the method may further include, after attaching the first edge support structure and the second edge support structure and before inserting each of the plurality of battery cells into a respective through-hole, attaching a first end of each of the plurality of p-type separators to the inside of the first sidewall and attaching a second end, opposite the first end, of each of the plurality of p-type separators to the inside of the second sidewall.

[0030] In some embodiments, the method may further include providing a cooling plate and, after inserting each of the plurality of battery cells into a respective through-hole, attaching the cooling plate to lower ends of each of the plurality of battery cells. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The above and other objects and advantages of the present disclosure will become more apparent upon consideration of the following detailed description taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: Fig. 1 shows an example of a battery module; Fig. 2 shows a perspective view of a cell carrier of a battery module assembly according to some embodiments of the present disclosure; Fig. 3A a plan view of the cell carrier of Fig. 2 according to some embodiments of the present disclosure; Fig. 3B is an elevation view of the outer surface of the front wall of the cell carrier of Fig. 2 according to some embodiments of the present disclosure; Fig. 3C is an elevation view of the outer surface of the rear wall of the cell carrier of Fig. 2 according to some embodiments of the present disclosure; Fig. 4 shows a perspective view of the first and second edge support structures and first and second p-group separators of a battery module assembly according to some embodiments of the present disclosure; Fig. 5 a perspective view of the battery module assembly of Fig. 2 after inserting the edge support structure of Fig. 4 according to some embodiments of the present disclosure; Fig. 6 a perspective view of the battery module assembly of Fig. 5 after inserting the conductors of p-group separators of Fig. 4 according to some embodiments of the present disclosure; Fig. 7 a perspective view of the battery module assembly of Fig. 5 shows after insertion of hexagonal p-group separators according to some embodiments of the present disclosure; Fig. 8 a partial view of the battery module assembly of Fig. 7 according to some embodiments of the present disclosure; Fig. 9 a perspective view of the battery module assembly from both of the Fig. 6 and Fig. 7 shows after insertion of a plurality of battery cells according to some embodiments of the present disclosure; Fig. 10 a perspective partial view of a bottom side of the battery module of Fig. 9 according to some embodiments of the present disclosure; Fig. 11 a top view of the battery module assembly of Fig. 6 shows after insertion of a plurality of battery cells according to some embodiments of the present disclosure; Fig. 12 a plan view of the battery module assembly of Fig. 5 shows after insertion of wavy p-group separators and a plurality of battery cells according to some embodiments of the present disclosure; Fig. 13 is a perspective view of a battery module consisting of two of the battery module assemblies of Fig. 9 coupled to opposite sides of a cold plate, according to some embodiments of the present disclosure; Fig. 14A is a partial perspective view of a front side of the battery module of Fig. 13 shows after installation of components on the front of the battery module according to some embodiments of the present disclosure; Fig. 14B is a partial perspective view of a rear side of the battery module of Fig. 13 shows after installation of components on the back of the battery module according to some embodiments of the present disclosure; and Fig. 15 shows a flowchart of an illustrative method 1500 for assembling the battery module described above, according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0032] With an approach such as Fig. 1, a first end 105 of each of a plurality of battery cells 103 may be inserted into and coupled to a respective recess on a first side of a carrier layer 101 of a battery module 100. The first end 105 (e.g., a top end) may include a first electrical terminal (e.g., a center key terminal), while a second end 107 (e.g., a bottom end) of each of the plurality of battery cells 103 may include a second electrical terminal. The second electrical terminal may be formed by the second end 107, a side of each battery cell 103, and a portion of the first end 105. After the plurality of battery cells 103 are coupled to the carrier layer 101, the sidewalls 109 may be attached to two sides of the battery module 100 (e.g., using an adhesive). Additional side panels (not shown) may also be attached to the remaining sides of the battery module 100 (e.g.,B. also using an adhesive. A current collector assembly including at least one bus bar can be coupled to a second side of the carrier layer 101 and selectively connected to the plurality of battery cells 103. However, in some embodiments, it would be advantageous to reduce the number of parts required to assemble a battery module, e.g., to simplify assembly.

[0033] The Fig. 2-14B show a cell carrier, components of a battery module, and a series of steps in a process of assembling a battery module including the cell carrier, such as the battery module of Fig. 9, Fig. 11, Fig. 12, Fig. 13, Fig. 14A and Fig. 14B, according to some embodiments of the present disclosure.

[0034] Fig. Figure 2 shows a perspective view of a cell carrier 201 of a battery module assembly according to some embodiments of the present disclosure. As shown, the cell carrier 201 includes a base 203 (e.g., a multi-sided base) having a plurality of through-holes 205 extending from a top surface of the base 203 to a bottom surface of the base 203. As explained in more detail below, each of the through-holes 205 includes an inner sidewall 805 configured to be disposed around and retain a lower portion of a battery cell (e.g., to interconnect a plurality of battery cells).

[0035] As shown, the cell carrier 201 further includes: a front wall 207 (e.g., a third sidewall) formed along a front edge of the base 203; a rear wall 209 (e.g., a fourth sidewall) opposite the front wall 207 and formed along a rear edge of the base 203; and first and second sidewalls 211a and 211b opposite each other and formed along respective side edges of the base 203 (e.g., a five-sided box). Although the terms "front wall" and "rear wall" are used herein, it should be understood that the battery module may not have a front or rear side. The cell carrier 201 may be formed as a single piece. That is, the front wall 207, the rear wall 209, and the first and second side walls 211a and 211b may be formed integrally with the base 203 (e.g., by injection molding, three-dimensional printing, or any other suitable manufacturing process).In some embodiments, the cell carrier 201 may be formed from plastic materials, a composite material including plastic, any other suitable material, or any combination thereof. As shown, the base 203 may be substantially rectangular (e.g., a rectangular base). As used herein, "rectangular" includes shapes with four sides of equal length. However, this is only an example, and the base 203 may have any suitable multi-sided shape (e.g., triangular, hexagonal, heptagonal, circular, etc.) depending on the requirements of the battery module. Any or a combination of the first and second sidewalls 211a and 211b, the front wall 207, and the rear wall 209 may be referred to herein as one or more walls or one or more sidewalls.

[0036] As shown, the first sidewall 211a may include a first plurality of latches 213a, 213b...213n (collectively referred to as first latches 213) spaced apart along the inner surface of the first sidewall 211a (e.g., along the longitudinal direction of the first sidewall 211a). The second sidewall 211b may also include a second plurality of latches 214a, 214b...214n (collectively referred to as second latches 214) spaced apart along the inner surface of the second sidewall 211b (e.g., along the longitudinal direction of the second sidewall 211b). In some embodiments, the spacing between adjacent ones of the latches (213, 214) along each sidewall (211a, 211b) may correspond to the spacing and size of the through-holes 205 along each sidewall (211a, 211b). That is, as shown, one latch (213, 214) may be centered between each pair of through-holes 205.However, this is only an example, and the number of locks (213, 214) along each sidewall can be reduced depending on the requirements of the battery module (e.g., a lock can be arranged between every other pair of through-holes or only between parallel groups of battery cells). Additional details of the cell carrier 201 are described below with reference to, for example, FIG. Fig. 3A, Fig. 3B and Fig. 3C described.

[0037] Fig. 3A shows a top view of the cell carrier 201 of Fig. 2 according to some embodiments of the present disclosure. As shown, each of the plurality of through-holes 205 in the base 203 may be circular (e.g., including a cylindrically shaped inner sidewall 805 corresponding to the cylindrical sidewalls of the battery cells to be inserted into each of the plurality of through-holes 205) and may be arranged in a close-hex pack configuration (e.g., a predetermined pattern) as illustrated. However, it should be understood that the shape and arrangement of the through-holes 205 may be changed to any suitable shape and arrangement based on the shape and arrangement of the battery cells to be inserted into the through-holes 205.

[0038] In some embodiments, the cell carrier 201 may include positioning holes 301a and 301b for aligning the cell carrier 201 with other components of the battery module, such as a cold plate and a second cell carrier, as explained in more detail below. In some embodiments, the cell carrier 201 may also include positioning holes 303a, 303b, and 303c on a top surface of the front wall 207 for aligning a first end of a current collector assembly (e.g., including at least one bus bar connecting battery cells of the battery module). In some embodiments, the cell carrier 201 may also include positioning slots 305a, 305b, and 305c on a top surface of the rear wall 209 for aligning a second end of the current collector assembly.In some embodiments, the positioning holes 303 and 305 may be used to align any suitable components to be mounted to the battery module.

[0039] Fig. Figure 3B shows an elevation view of the outer surface of the front wall 207 of the cell carrier 201 of Fig. 2 according to some embodiments of the present disclosure. Fig. Figure 3C shows an elevation view of the outer surface of the rear wall 209 of the cell carrier 201 of Fig. 2 according to some embodiments of the present disclosure. In some embodiments, the front wall 207 may be identical to the rear wall 209. However, in some embodiments, if different components are to be mounted on the front wall 207 and the rear wall 209 (e.g., as described below with reference to Fig. 14A and Fig. 14B), it may be advantageous if the front wall 207 and the rear wall 209 are individually configured to mount respective components. For example, as in Fig. 3B, the front wall 207 may include: the pocket 307 configured to house a thermistor (e.g., thermistor 1401 of Fig. 14A) to the battery module; front busbar supports 309a and 309b configured to support at least one busbar (e.g., busbar 1403a or busbar 1403b of Fig. 14A) to the battery module; and insulation clip holders 311a, 311b, 311c, 311d, 311e and 311f configured to hold an insulation clip (e.g., insulation clip 1405 of Fig. 14A) to the battery module. As shown, the pocket 307, the front busbar supports 309a and 309b, and the insulation clip supports 311a, 311b, 311c, 311d, 311e, and 311f may be arranged in a pattern (e.g., a first pattern). As shown in Fig. 3C, the backplane 209 may include only rear bus bar supports 309c and 309d (e.g., arranged in a second pattern) configured to support a serial bus bar (e.g., serial bus bar 1407 of Fig. 14B) to the battery module. However, these are merely examples, and each of the front wall 207 and the rear wall 209 may be configured with any suitable arrangement or number of mounting features depending on the requirements of the battery module. Any or a combination of the pocket 307, the front busbar supports 309a and 309b, and the insulation clip supports 311a, 311b, 311c, 311d, 311e, and 311f may be referred to herein as a first plurality of supports. Any or a combination of the rear busbar supports 309a and 309d may be referred to herein as a second plurality of supports.

[0040] Fig. 4 shows a perspective view of the first and second edge support structures 401a and 401b and first and second p-group separators 405a and 405b (e.g., a plurality of p-group separators) of a battery module assembly according to some embodiments of the present disclosure. As described below with reference to Fig. 11, each of the first and second edge support structures 401a and 401b includes a plurality of battery support segments 403 configured to support battery cells arranged along edges of the battery module. For example, the first edge support structure 401a, which is shown, for example, in the Fig. 5, Fig. 6, Fig. 8 and Fig. 11, shown in more detail, may be configured to be attached to the latches 213 of the first sidewall 211a and to support battery cells adjacent to the first sidewall 211a, while the second edge support structure 401b may be configured to be attached to the latches 214 of the second sidewall 211b and to support the battery cells adjacent to the second sidewall 211b.

[0041] The first and second p-group separators 405a and 405b (e.g., insulators) may also be configured to be attached to certain ones of the latches 213 and 214. The first and second p-group separators 405a and 405b may provide additional support for battery cells in the battery module and separate different parallel groups of battery cells from each other (e.g., at different operating voltages), as described with reference to Fig. 11. As shown, the first p-group separator 405a may include a first plurality of y-shaped connectors 407a, 407b, and 407c (collectively, first y-shaped connectors 407) disposed at a first end and a second plurality of y-shaped connectors 409a, 409b, and 409c (collectively, second y-shaped connectors 409) disposed at a second end opposite the first end. As explained in more detail below, the first and second y-shaped connectors 407 and 409 (e.g., having a flared y-design) are configured to attach to latches of the first and second latches 213 and 214.The first p-group separator 405a further includes a first plurality of segments 411a, 411b, and 411c (collectively, first segments 411) extending from the first end to the second end of the first p-group separator 405a, and a second plurality of segments 413a, 413b, 413c, 413d, and 413e (collectively, second segments 413) extending in a direction substantially perpendicular to the first segments 411 and interconnecting the first segments 411 (e.g., lead p-group separators). In some embodiments, the first p-group separator 405a may include a positioning protrusion 415a for aligning other components to be mounted to the battery module (e.g., a current collector assembly).

[0042] In some embodiments, certain of the first and second segments 411 and 413 may be omitted depending on the requirements of the battery module. For example, Fig. 12 shows an embodiment that includes only segments between parallel groups of battery cells. In addition, p-group separators may have other configurations (e.g., like those shown in Fig. 7). In some embodiments, the second p-group separator 405b may be identical to the first p-group separator. However, in some embodiments, the second p-group separator 405b may be mounted to the battery module in a different orientation than the first p-group separator 405a. For example, as shown, the second p-group separator 405b may be rotated 180 degrees relative to the first p-group separator 405a such that the first end of the first p-group separator 405a is disposed on the same side as the second end of the second p-group separator 405b.

[0043] The first and second p-group separators 405a and 405b (as well as any of the other p-group separators described below) may comprise a rigid material that provides additional support to the battery module. For example, the first and second p-group separators 405a and 405b may be made of a plastic material (e.g., formed by injection molding), a meta-aramid fiber material (e.g., NOMEX®), or any other suitable material.

[0044] Fig. 5 shows a perspective view of the battery module assembly of Fig. 2 after inserting the edge support structures 401a and 401b of Fig. 4 according to some embodiments of the present disclosure. As shown, the edge support structure 401a may be connected (e.g., slidably connected) to the latches 213 on the inner surface of the first sidewall 211a, as described with respect to Fig. 8. Similarly, the edge support structure 401b may be connected (e.g., slidably connected) to the latches 214 on the inner surface of the second sidewall 211b.

[0045] Fig. 6 shows a perspective view of the battery module assembly of Fig. 5 after inserting the p-group separators 405a and 405b of Fig. 4 according to some embodiments of the present disclosure. As shown, the first Y-shaped connectors 407 (e.g., at a first end) of the first p-group separator 405a may be connected (e.g., slidably connected) to certain latches from the latches 213 of the first sidewall 211a, while the second Y-shaped connectors 409 (e.g., at a second end opposite the first end) of the first p-group separator 405b may be connected (e.g., slidably connected) to certain latches from the latches 214 of the second sidewall 211b. As shown, the second p-group separator 405b may be connected in an opposite orientation to the first p-group separator 405a.For example, a second end of the second p-group separator 405b may be connected to certain latches from the latches 213 of the first sidewall 211a, while a first end of the second p-group separator 405b may be connected to certain latches from the latches 214 of the second sidewall 211b. However, this is only an example, and the first and second p-group separators 405a and 405b may also be connected in the same orientation depending on the configuration of the battery module.

[0046] Fig. Figure 7 shows a perspective view of the battery module assembly of Fig. 5 after insertion of the hexagonal p-group separators 701a, 701b, 701c, and 701d according to some embodiments of the present disclosure. The p-group separators 701a, 701b, 701c, and 701d (collectively referred to as p-group separators 701) may be used instead of one or more of the p-group separators 405a and 405b of FIG. 10, depending on the requirements of the battery module. Fig. 6. As shown, each of the p-group separators 701 includes a plurality of hexagonal cells 703 arranged in a pattern corresponding to the arrangement of the plurality of through-holes 205 as described above with reference to Fig. 3A. That is, the hexagonal cells 703 may form one or more honeycomb structures corresponding to the arrangement of the plurality of battery cells or groups of the plurality of battery cells.

[0047] Fig. Figure 8 shows a partial view of the battery module assembly of Fig. 7 according to some embodiments of the present disclosure. In particular, Fig. 8 shows an example of the configuration of the latches 213 and how the first edge support structure 401a and the first hexagonal p-group separator 701a are connected to the latches 213. As shown, each of the latches 213 may include a pair of protrusions (e.g., a first protrusion 801a and a second protrusion 801b) extending from the inner surface of the first sidewall 211a. The first and second protrusions 801a and 801b may be angled relative to each other, forming a trapezoidal space 801c between the first and second protrusions 801a and 801b. The height of the trapezoidal space 801c may be high enough to accommodate both the first edge support structure 401a and the first hexagonal p-group separator.

[0048] As shown, the first edge support structure 401a includes a plurality of Y-shaped connectors 402 that correspond to the trapezoidal space 801c of each of the latches 213. When the Y-shaped connectors 402 are inserted into the trapezoidal space 801c of each of the latches 213 (e.g., from a top surface of the latches 213), the latches 213 can hold the first edge support structure 401a in position. That is, the Y-shaped connectors 402 can be slidably connected to each of the latches 213 to form a sliding connection (e.g., a sliding dovetail connection). In some embodiments, the first edge support structure 401a can include one Y-shaped connector 402 for each of the latches 213. In other embodiments, certain of the Y-shaped connectors 402 can be omitted. For example, as shown, an end portion of the first edge support structure 401a may not include a y-shaped connector 402.As shown, the battery support segments 403 may conform to the shape of the sidewall of a cylindrical battery cell. The second edge support structure 401b may be configured in the same manner as the first edge support structure 401a. Although a y-space is illustrated, it should be understood that the protrusions may form any suitable space that holds the components in place during assembly of the battery module (e.g., a sliding joint).

[0049] The first hexagonal p-group separator 701a also includes a plurality of y-shaped connectors 803a, 803b, 803c, and 803d (collectively referred to as y-shaped connectors 803) at a first end. The first hexagonal p-group separator 701a also includes the same y-shaped connectors at a second end opposite the first end. As shown, the shape of the y-shaped connectors 803 also corresponds to the trapezoidal space 801c of each of the latches 213, so that when the y-shaped connectors 803 are inserted into the latches 213 (i.e., from a top surface of the latches 213), the latches 213 can hold the first hexagonal p-group separator 701a in position. As shown, the first hexagonal p-group separator 701a may be inserted into the latches 213 after the first edge support structure 401a and may rest on a top surface of the first edge support structure 401a.However, this is only an example, and the first hexagonal p-group separator 701a may be inserted in front of the first edge support structure 401a depending on the requirements of the battery module. In one embodiment, the first edge support structure 401a may be integrated into the first sidewall 211a.

[0050] Although only the first edge support structure 401a and the first hexagonal p-group separator 701a are shown, it is understood that the second edge support structure 401b and other p-group separators (e.g., 701b, 701c, and 701d) may be used in a similar manner. Furthermore, it is understood that the p-group separators 405a and 405b of Fig. 6 can be connected to the latches 213 (and the latches 214) in a similar manner. Although the Y-shaped connectors 402 and 803 are shown as male portions of a sliding connection, while the latches 213 are shown as female portions of the sliding connection, it should be understood that in some embodiments the portions may be configured oppositely. In some embodiments, the sliding connections may be permanently bonded by an adhesive after the battery cells are inserted into the battery module.

[0051] After the edge support structures 401 and the hexagonal p-group separators 701 have been inserted into the cell carrier 201, a lower portion of each of a plurality of battery cells (e.g., battery cells 103) can be inserted into each of the through holes 205, as shown in Fig. 9 and Fig. 10. An inner sidewall 805 of each of the through-holes 205 conforms to the shape of each of the battery cells (e.g., cylindrical) such that each inner sidewall 805 is disposed around and supports a lower portion of a battery cell.

[0052] Fig. Figure 9 shows a perspective view of the battery module assembly from both of the Fig. 6 and Fig. 7 after insertion of a plurality of battery cells 103 according to some embodiments of the present disclosure. As described above, each of the plurality of battery cells 103 may have a first end 105 including a first electrical terminal (e.g., a center button terminal) and a second end 107 including a second electrical terminal (e.g., a bezel terminal). Each of the plurality of battery cells 103 may also include one or more openings near the first end 105. After the plurality of battery cells 103 are inserted into the cell carrier 201, an adhesive may be applied to an area where the battery cells 103 intersect the through-holes 205 (e.g., to a sidewall of each of the battery cells 103 and a top surface of the base 203 around each of the through-holes 205).The adhesive may be a wicking or self-absorbing adhesive that flows into the area between the inner sidewall 805 of each of the through-holes 205 and a sidewall of a respective battery cell 103 (e.g., through capillary action) before curing. In some embodiments, the adhesive is a fast-drying adhesive (e.g., three minutes). The adhesive may also be applied to the latches 213 and 214 and the edge support structures 401 and the p-group separators 405 (or the hexagonal p-group separators 701) to attach the edge support structure 401 and the p-group separators 405 (or the hexagonal p-group separators 701) to the cell carrier 201.Because the adhesive is applied to the components of the battery module after the edge support structures 401, the p-group separators 405 (or the hexagonal p-group separator 701), and the plurality of battery cells 103 have been arranged in the cell carrier 201, the tolerance requirements for the battery module can be relaxed and the assembly of the battery module can be improved. Furthermore, because the venting portions of each of the battery cells 103 are not enclosed by the through-holes 205, the venting of the battery cells 103 can be improved (e.g., during thermal events). In some embodiments, depending on the requirements of the battery module (e.g., the number of battery cells), battery cells 103 can be omitted at certain battery cell positions (e.g., 901a and 901b).

[0053] Fig. 10 shows a partial perspective view of a bottom side of the battery module of Fig. 9 according to some embodiments of the present disclosure. As shown, the second end 107 of each of the plurality of battery cells 103 may extend from a bottom surface of the base 203 by a distance (e.g., distance "h") that allows the second end 107 of each of the plurality of battery cells 103 to be attached to a cold plate, as explained in more detail below. That is, the interior surface (e.g., the surface shown in Fig. 8) of each of the through-holes 205 is disposed around a bottom portion 1001 (e.g., on one half of the battery cell 103 opposite the end having a center key terminal) of a respective battery cell 103. In some embodiments, the bottom portion 1001 may be 30% or less of the total length of each of the plurality of battery cells 103. Although assembly of the battery module is described as inserting the second ends 107 of each of the plurality of battery cells 103 into the respective through-holes 205 from a top surface of the battery module (e.g., the side of the base 203, including the front wall 207, the back wall 209, and the side walls 211), in some embodiments, the first end 105 of each of the battery cells 103 may be inserted into the respective through-holes 205 from a bottom surface of the battery module.In this example, the battery module assembly tool may include tools to hold the edge support structures 401 and the p-group separators 405 (or the hexagonal p-group separators 701) in position before the battery module is turned over to apply adhesive to each of these components.

[0054] Fig. 11 shows a top view of the battery module assembly of Fig. 6 after insertion of a plurality of battery cells 103 according to some embodiments of the present disclosure. As shown, the plurality of battery cells 103 may include parallel groups of battery cells 103 with different operating voltages (e.g., parallel groups 1101a, 1101b, 1101c, 1101d, and 1101e, collectively referred to as parallel groups 1101). The parallel groups 1101 may be separated from each other by segments (e.g., 1103a, 1103b, 1103c, 1103d) of the p-group separators 405. In some embodiments, it may be advantageous to include a p-group separator that includes only a structure for separating the parallel groups 1101 from each other, as shown in Fig. 12. As shown, the battery cells 103 at battery cell positions 1105a and 1105b may be omitted depending on the requirements of the battery module. As shown, the edge support structure 401a may support battery cells 103 adjacent to the first sidewall 211a, while the edge support structure 401b may support battery cells 103 adjacent to the second sidewall 211b.

[0055] Fig. 12 shows a top view of the battery module assembly of Fig. 5 after insertion of undulating p-group separators 1201a, 1201b, 1201c, and 1201d (collectively referred to as undulating p-group separators 1201) and a plurality of battery cells 103 according to some embodiments of the present disclosure. As described above, in some embodiments, it may be advantageous to include a p-group separator that sandwiches only one segment between adjacent parallel groups 1101 of battery cells 103 (e.g., to reduce costs or manufacturing tolerance requirements). In this case, as shown, a undulating p-group separator 1201 may be sandwiched between adjacent parallel groups 1101. Although only certain implementations of p-group separators are shown, it should be understood that the p-group separators may be configured differently depending on the requirements of the battery module.

[0056] Fig. Figure 13 shows a perspective view of a battery module consisting of two of the battery module assemblies of Fig. 9 coupled to opposite sides of a cooling plate 1301, according to some embodiments of the present disclosure. As shown, two of the battery module assemblies of Fig. 9 (e.g., including the cell carriers 201a and 201b) are coupled to opposite sides of the cooling plate 1301. In particular, the cooling plate 1301 is coupled to the exposed ends 107 of the plurality of battery cells 103 by a thermal compound. As shown, the cooling plate 1301 may include at least one positioning hole 1303 for aligning the cooling plate 1301 with the cell carriers 201a and 201b during assembly (e.g., also using the methods described above with respect to Fig. 3A discussed positioning holes 301a and 301b).

[0057] Fig. 14A shows a partial perspective view of a front side of the battery module of Fig. 13 after installation of components on the front of the battery module according to some embodiments of the present disclosure. As shown, a thermistor 1401 may be installed in the Fig. 3B. In some embodiments, the thermistor 1401 is mounted in the thermistor pocket 307 of only one of the cell carriers (e.g., 201a). In other embodiments, a thermistor may be mounted in the thermistor pocket of each of the cell carriers (e.g., 201a and 201b of Fig. 13). In some embodiments, a busbar (1403a and 1403b) may be mounted on each of the cell carriers 201a and 201b by the front busbar supports 309a and 309b of Fig. 3B. In some embodiments, an insulating clamp 1405 (e.g., an ISO clamp) may be mounted to one of the cell carriers (e.g., 201a) by the insulating clamp mounts 311, as described above with reference to, for example, Fig. 3B. The insulation clip 1405 can provide attachment features for certain battery module components (e.g., a module-mounted circuit board and the cable management of the thermistor harness) and can provide insulation for certain electrical components. It should be understood that other suitable components can be mounted to the front of the battery module depending on the requirements of the battery module.

[0058] Fig. 14B shows a partial perspective view of a back side of the battery module of Fig. 13 after installation of components on the rear of the battery module according to some embodiments of the present disclosure. As shown, a serial bus bar 1407 (e.g., electrically connecting the battery cells of the two battery module assemblies) can be connected to the rear bus bar supports 309c and 309d of Fig. 3C can be mounted on the rear of the battery module. It is understood that other suitable components can be mounted on the rear of the battery module depending on the requirements of the battery module.

[0059] Fig. 15 shows a flowchart of an illustrative method 1500 for assembling the battery module described above, according to some embodiments of the present disclosure.

[0060] In step 1501, a one-piece cell carrier is provided. The one-piece cell carrier may be the one-piece cell carrier 201 (e.g., as shown in Fig. 2 illustrates).

[0061] In step 1503, edge support structures are provided on each inner side of the opposing sidewalls of the one-piece cell carrier and attached to latches. The edge support structures may be edge support structure 401a attached to latches 213 on an inner side of first sidewall 211a and end support structure 401b attached to latches 214 on an inner side of second sidewall 211b, as described above with reference to, for example, FIG. Fig. 5 described.

[0062] In step 1505, at least one p-group separator is provided and attached to the latches on the inner sides of the opposing sidewalls. The at least one p-group separator may be any of the p-group separators 405, the hexagonal p-group separators 701, and the wave-shaped p-group separators 1201, as described above with reference to, for example, one of the Fig. 6, Fig. 7 and Fig. 12 described.

[0063] In step 1507, each of a plurality of battery cells is provided and inserted into respective through-holes of a base of the one-piece cell carrier such that an inner side wall of each through-hole is arranged around and holds a lower portion of the inserted battery cell. The battery cells may be the battery cells 103, which are inserted into the respective through-holes 205 of the base 203 such that the inner side wall 805 of each through-hole 205 is arranged around and holds the lower portion of the inserted battery cell 103, as described above with reference to, for example, the Fig. 3A, Fig. 8, Fig. 9 and Fig. 10. In some embodiments, step 1507 may be performed before step 1505 or step 1503.

[0064] In step 1509, adhesive is provided and applied to at least one of the plurality of battery cells and the base such that the adhesive bonds each inner sidewall to the lower portion of the inserted battery cell. The adhesive may be the adhesive described above with reference to, for example, Fig. 9 and Fig. 10. In some embodiments, step 1509 may be performed before step 1507.

[0065] In step 1511, adhesive is provided and applied to at least one of the latches, the edge support structures, and the at least one p-group separator, such that the adhesive bonds the edge support structures and the at least one p-group separator to the respective sidewalls. The adhesive may be the adhesive described above with reference to, for example, Fig. 9. In some embodiments, step 1511 is performed before step 1509 or 1507.

[0066] In step 1513, the applied adhesive is cured. The adhesive may be a fast-drying adhesive that cures by setting during the curing time (e.g., three minutes), as described above with reference to Fig. 9. In some embodiments, the adhesive may be a UV-curing adhesive or a combination of a UV-curing adhesive and a fast-drying or slow-drying adhesive, and UV light is used to cure the UV-curing adhesive so that subsequent assembly steps can be performed without waiting.

[0067] In step 1515, a cooling plate is provided and attached to the bottom end of each of the plurality of battery cells. The cooling plate may be the cooling plate 1301 attached to the bottom end of each of the plurality of battery cells 103, as described above with reference to, for example, FIG. Fig.13. In some embodiments, steps 1501-1513 are repeated, and the resulting assembly is attached to the opposite side of the cold plate to form the battery module.

[0068] The foregoing is merely illustrative of the principles of this disclosure, and various modifications may be made by those skilled in the art without departing from the scope of this disclosure. The above-described embodiments are presented for purposes of illustration and not limitation. This disclosure may take many forms other than those expressly described herein. Accordingly, it is understood that this disclosure is not limited to the explicitly disclosed methods, systems, and devices, but is intended to include variations and modifications thereof that are within the scope of the following claims.

Claims

[1] Cell carrier (201) for a battery module (100), the cell carrier comprising: a multi-sided rectangular base (203) comprising: a plurality of through-holes (205) arranged in a predetermined pattern, each through-hole including an inner sidewall (805) configured to hold one of a plurality of battery cells (103); and Side walls (211a, 211b), each of the side walls (211a, 211b) comprising a plurality of locks (213, 214) formed integrally along an inner surface of the respective side wall and spaced apart from one another in a direction parallel to the respective side edge, wherein each of the plurality of locks (213, 214) comprises a pair of projections extending from the inner surface and angled toward each other to form part of a sliding connection. [2] Cell carrier (201) according to claim 1, wherein: the inner side wall (805) is arranged around a lower portion of the one battery cell (103); and the rectangular base (203) and the side walls (211a, 211b) are integrally formed as a single part. [3] The cell carrier of claim 1, wherein each of the plurality of locks is configured to receive a y-shaped connector of a p-group separator or an edge support structure, the y-shaped connector being configured to slide between respective pairs of projections to form the sliding connection. [4] Cell carrier (201) according to claim 2, wherein: the multi-sided rectangular base (203) further comprises: a front wall (207) formed along a front edge of the multi-sided rectangular base (203); a rear wall (209) opposite the front wall (207) and formed along a rear edge of the rectangular base (203); and the rectangular base (203), the side walls (211a, 211b), the front wall (207) and the rear wall (209) are integrally formed as the single part. [5] The cell carrier (201) of claim 1, wherein the multi-sided rectangular base (203) further comprises: a front wall (207) comprising a first plurality of brackets (309a, 309b, 311) arranged in a first pattern, wherein the first plurality of brackets (309a, 309b, 311) are configured to attach a first component (1403a, 1403b, 1405) to the front wall (207); and a rear wall (209) comprising a second plurality of brackets (309c, 309d) arranged in a second pattern, the second plurality of brackets (309c, 309d) being configured to attach a second component (1407) to the rear wall (209), and wherein the first pattern differs from the second pattern and the first component (1403a, 1403b, 1405) differs from the second component (1407). [6] Cell carrier (201) according to claim 1, wherein the cell carrier (201) comprises a plastic material and is formed as a single part by injection molding. [7] Battery module (100), comprising: a one-piece cell carrier (201) configured to interconnect a plurality of battery cells (103), the one-piece cell carrier (201) comprising: a rectangular base (203) comprising a plurality of through-holes (205), each comprising an inner sidewall (805) configured to be disposed around a lower portion of one of the plurality of battery cells (103); and one or more walls (211a, 211b, 207, 209) formed integrally with the base, each along a respective edge of the base, wherein the one or more walls (211a, 211b, 207, 209) comprise: a first side wall (211a) formed along a first edge of the base (203), the first side wall (211a) comprising a first plurality of locks (213) integrally formed along an inner surface of the first side wall (211a) and spaced apart from each other in a direction along the first edge of the base (203); and a second side wall (211b) opposite the first side wall (211a) and formed along a second edge of the base (203), the second side wall (211b) comprising a second plurality of locks (214) integrally formed along an inner surface of the second side wall and spaced apart from each other in a direction along the second edge of the base, wherein each of the first and second plurality of locks (213, 214) comprises a pair of projections extending from the inner surface of the respective side wall and angled toward each other to form part of a sliding connection. [8] The battery module (100) of claim 7, further comprising a first edge support structure (401a) and a second edge support structure (401b), wherein: the first edge support structure (401a) is configured to be attached to the first plurality of latches (213) of the first side wall (211a) and to support first battery cells of the plurality of battery cells (103) adjacent to the first side wall (211a); and the second edge support structure (401b) is configured to be attached to the second plurality of latches (214) of the second side wall (211b) and to support second battery cells of the plurality of battery cells (103) adjacent to the second side wall (211b). [9] The battery module (100) of claim 7, further comprising a plurality of p-group separators (405a, 405b), wherein: each of the plurality of p-group separators (405a, 405) comprises at least one segment (211) configured to be arranged in a free space between adjacent parallel groups of the plurality of battery cells (103); and each of the plurality of p-group separators (405a, 405b) comprises a first connector (407) arranged at a first end of the p-group separator (405a, 405b) and configured to be attached to one of the first plurality of latches (213), and a second connector (409) arranged at a second end of the p-group separator (405a, 405b) and configured to be attached to one of the second plurality of latches (214). [10] Battery module (100) according to claim 9, wherein: each of the first connectors comprises a first Y-shaped connector (407) configured to slide between a pair of projections of a lock of the first plurality of locks to form the corresponding sliding connection; and each of the second connectors comprises a second Y-shaped connector configured to slide between a pair of projections of a lock of the second plurality of locks to form the corresponding sliding connection. [11] The battery module (100) of claim 7, further comprising a bus bar (1403a, 1403b) and an insulating clamp (1405), wherein: the one or more walls further comprise: a third side wall (207) formed along a third edge of the base (203), the third side wall (207) comprising an insulation clip holder (311); a fourth side wall (209) opposite the third side wall (207) and formed along a fourth edge of the base (203), the fourth side wall comprising a busbar support (309a, 309b); and the insulating clamp (1405) is mounted on the insulating clamp holder (311) and the busbar (1403a, 1403b) is mounted on the busbar holder (309a, 309b). [12] The battery module (100) of claim 11, further comprising a thermistor (1401), wherein: the third side wall (207) includes a thermistor pocket (307) integrally formed therein; and the thermistor (1401) is mounted in the thermistor pocket (307). [13] The battery module (100) of claim 7, further comprising the plurality of battery cells (103), wherein: each of the plurality of battery cells (103) comprises a cylindrical sidewall; and each of the inner sidewalls (805) comprises a cylindrical inner sidewall corresponding to the cylindrical sidewalls of the plurality of battery cells (103). [14] The battery module (100) of claim 7, further comprising a cooling plate (1301), wherein the cooling plate (1301) is attached to a bottom surface of each of the plurality of battery cells (103). [15] Battery module (100) according to claim 7, wherein the one-piece cell carrier (201) comprises a plastic material and is formed as a single part by injection molding. [16] A method (1500) for assembling a battery module (100), the method comprising: Providing (1501) a one-piece cell carrier (201), a plurality of battery cells (103), and an adhesive, the one-piece cell carrier (201) comprising a rectangular base (203) comprising a first side, a second side opposite the first side, and a plurality of through-holes (205) arranged in a predetermined pattern, each through-hole (205) extending from the first side to the second side and having an inner sidewall (805) configured to be disposed around and retain a lower portion of one of the plurality of battery cells (103); Inserting (1507) each of the plurality of battery cells (103) into a respective through-hole (205) such that an upper end (105) of each of the plurality of battery cells (103) extends from the first side and a lower end (107) of each of the plurality of battery cells (103) extends from the second side; selectively applying (1509) adhesive to at least one of the plurality of battery cells and the rectangular base (203) such that the adhesive bonds each inner sidewall (805) to a respective lower portion of one of the plurality of battery cells, and Curing (1513) of the adhesive. [17] The method (1500) of claim 16, wherein the one-piece cell carrier (201) further comprises a first side wall (211a) formed integrally with the rectangular base (203) along a first edge of the rectangular base (203), and a second side wall (211b) opposite the first side wall (211a) and formed integrally with the rectangular base (203) along a second edge of the rectangular base (203), and wherein the method further comprises: Providing (1503) a first edge support structure (401a) configured to support battery cells (103) along the first edge and a second edge support structure (401b) configured to support battery cells (103) along the second edge; and before inserting each of the plurality of battery cells (103) into a respective through-hole (205), Attaching the first edge support structure (401a) to an inner side of the first side wall (211a), and Attaching the second edge support structure (401b) to an inner side of the second side wall (211b). [18] The method of claim 17, further comprising: Providing (1505) a plurality of p-group separators (405a, 405b), each comprising at least one segment (411) configured to be disposed in a free space between adjacent parallel groups of battery cells (103); after attaching the first edge support structure (401a) and the second edge support structure (401b) and before inserting each of the plurality of battery cells (203) into a respective through hole (205), Attaching a first end of each of the plurality of p-group separators (405a, 405b) to the inside of the first sidewall (211a); and Attaching a second end, opposite the first end, of each of the plurality of p-group separators (405a, 405b) to the inner side of the second sidewall (211b). [19] The method (1500) of claim 18, further comprising: Providing (1515) a cooling plate (1301); and Attaching, after inserting each of the plurality of battery cells (103) into a respective through-hole (205), the cooling plate (1301) to lower ends (107) of each of the plurality of battery cells (103).

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