BATTERY MODULE HOUSING WITH PRESSED-ON CONNECTIONS FOR A VEHICLE-MOUNTED RECHARGEABLE ENERGY STORAGE SYSTEM

Abstract

A battery module housing comprises a bottom wall, a first side wall with a first connecting element, a second side wall with a second connecting element, and a connecting wall extending between the first and second side walls. The connecting wall includes a first side edge with a first recess aligned with the first connecting element and a second edge with a second recess aligned with the second connecting element. The first recess press-fits the first connecting element, and the second recess press-fits the second connecting element to join the connecting wall to the first and second side walls.

Description

INTRODUCTION

[0001] The present invention relates to a battery module housing according to the preamble of claim 1, as is known from CN 2 18 182 318 U. Further prior art can be found in DE 10 2012 221 503 A1.

[0002] Rechargeable battery systems often include multiple interconnected battery cells arranged in a module housing to form a battery module. Multiple battery modules are interconnected and arranged in a housing to form a battery pack. The battery pack may be used, for example, to provide motive power to a vehicle, such as an automobile. In such an environment, the battery pack is connected to a load, such as a drive motor, and a charging port that can be connected to an electrical power source. The battery pack discharges into the drive motor to provide power to the vehicle and is charged via the charging port.

[0003] Each battery module is designed for a specific module housing and to accommodate a specific number and size of battery cells. Mechanical fasteners are used to assemble the module housings. The use of mechanical fasteners imposes design and size constraints on the module housing. This means that the module housing must not only be designed to accommodate the battery cells, but also to allow access to the tools needed to manipulate the mechanical fasteners. Accordingly, it is desirable to provide a system for connecting module housing components that eliminates the need for tool access to the fasteners in order to reduce module size. SUMMARY

[0004] According to the invention, a battery module housing is presented which is characterized by the features of claim 1.

[0005] In addition to one or more of the features described herein, the first connecting element comprises a head portion and a shaft portion extending from the head portion, the shaft portion comprising a plurality of gripping elements that engage the connecting wall in the first recess.

[0006] In addition to one or more of the features described herein, the first sidewall comprises a first surface portion and a second surface portion opposite the first surface portion, the first surface portion comprising a recess extending around the first opening, the head portion of the first connecting element being received in the recess.

[0007] In addition to one or more of the features described herein, the second side wall comprises a second opening, wherein the second connecting element extends through the second opening into the second recess formed in the connecting wall.

[0008] In addition to one or more of the features described herein, the second connecting element comprises a central portion configured to be received by the second opening, a first shank portion extending from the central portion in a first direction into the second recess of the connecting wall, and a second shank portion extending from the central portion in a second direction opposite the first direction.

[0009] In addition to one or more of the features described herein, the first shaft portion comprises a first plurality of gripping elements that engage the connecting wall in the second recess, and the second shaft portion comprises a second plurality of gripping elements.

[0010] In addition to one or more of the features described herein, the second sidewall includes a first surface portion connected to the connecting element via the first shaft portion and a second surface portion connected to another connecting element via the second shaft portion.

[0011] In addition to one or more of the features described herein, the first sidewall comprises a first sidewall member, a second sidewall member connected to the first sidewall member, and a cooling element extending between and disposed in heat exchange contact with the first sidewall member and the second sidewall member.

[0012] In addition to one or more of the features described herein, the bottom wall includes a cooling channel extending substantially parallel to each of the first and second side walls.

[0013] A vehicle according to one non-limiting example comprises a body having a passenger compartment, an electric drive motor arranged in the body, and a battery pack having a battery module housing according to claim 1.

[0014] In addition to one or more of the features described herein, the first connecting element comprises a head portion and a shank portion extending from the head portion, the shank portion comprising a plurality of gripping elements that engage the connecting wall in the first recess.

[0015] In addition to one or more of the features described herein, the first sidewall comprises a first surface portion and a second surface portion opposite the first surface portion, the first surface portion comprising a recess extending around the first opening, the head portion of the first connecting element being received in the recess.

[0016] In addition to one or more of the features described herein, the second side wall comprises a second opening, wherein the second connecting element extends through the second opening into the second recess formed in the connecting wall.

[0017] In addition to one or more of the features described herein, the second connecting element comprises a central portion configured to be received by the second opening, a first shank portion extending from the central portion in a first direction into the second recess of the connecting wall, and a second shank portion extending from the central portion in a second direction opposite the first direction.

[0018] In addition to one or more of the features described herein, the first shaft portion comprises a first plurality of gripping elements that engage the connecting wall in the second recess, and the second shaft portion comprises a second plurality of gripping elements.

[0019] In addition to one or more of the features described herein, the second sidewall includes a first surface portion connected to the connecting element via the first shaft portion and a second surface portion connected to another connecting element via the second shaft portion.

[0020] In addition to one or more of the features described herein, the first sidewall comprises a first sidewall member, a second sidewall member connected to the first sidewall member, and a cooling element extending between and disposed in heat exchange contact with the first sidewall member and the second sidewall member.

[0021] In addition to one or more of the features described herein, the bottom wall includes a cooling channel extending substantially parallel to each of the first and second side walls.

[0022] The foregoing features and advantages, as well as other features and advantages of the disclosure, will be readily apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Further features, advantages and details are included by way of example only in the following detailed description, which refers to the drawings in which: Fig. 1 is a left side view of a vehicle having a battery pack including a battery module with press-fitted connections according to a non-limiting example; Fig. 2 is a partial perspective view of a battery pack including a battery module with battery modules with press-fitted connections according to a non-limiting example; Fig. 3 a partial perspective view of two battery modules of the battery group of the Fig. 2 according to a non-limiting example; Fig. 4 a disassembled view of the battery mounting system of Fig. 3 according to a non-limiting example; Fig. 5 an end view of the two battery systems of Fig. 3 according to a non-limiting example; and Fig. 6 is a plan view of a crimped connection according to a non-limiting example. DETAILED DESCRIPTION

[0024] A vehicle according to a non-limiting example is in Fig. 1, generally designated 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20 with seats 23 arranged behind a dashboard 26. A steering controller 30 is arranged between the seats 23 and the dashboard 26. The steering controller 30 is actuated to control the orientation of the steerable wheel(s). The vehicle 10 includes an electric drive motor 34 that drives one or more of the wheels 16.

[0025] A rechargeable energy storage system (RESS) or battery pack 38 is attached to the housing 12. The battery pack 38 supplies power to the electric drive motor 34. It should be noted that the arrangement of the electric drive motor 34 and the battery pack 38 in the vehicle 10 may vary. In a Fig. 2, the battery pack 38 includes a housing 46 having a bottom wall 50 and a plurality of side walls 52 defining an interior space 56 in which a battery module pack 58 formed from a plurality of battery modules 60 is disposed.

[0026] In one non-limiting example, each battery module 60 includes a plurality of battery cells 62 arranged in a row and connected by an interconnect printed circuit board (ICB) (not shown). In one non-limiting example, the battery module group 58 is composed of pairs of battery modules, as shown at 64 in Fig. 3, which is mounted in a first module housing 72 and a second module housing 74. The first module housing 72 and the second module housing 74 are connected to one another. It should be noted that the number of interconnected module housings can vary.

[0027] There now follows a reference to Fig. 4, with further reference to Fig. 3, in describing the first module housing 72 according to a non-limiting example, it is assumed that the second module housing 74 includes a similar structure. The first module housing 72 includes a bottom wall 80, a first side wall 82, a second side wall 84, and a plurality of connecting walls 86 defining a plurality of battery cell receiving zones 88. The first side wall 82 is connected to the connecting wall 86 by a first plurality of connecting elements 92, and the second side wall 84 is connected to the connecting wall 86 by a second plurality of connecting elements 94. As explained in more detail below, the first plurality of connecting elements 92 and the second plurality of connecting elements 94 are press-fitted into the connecting wall 86.

[0028] In one non-limiting example, the bottom wall 80 includes a support surface 104 beneath which is disposed a series of channels 106 extending beneath and parallel to the battery cell receiving zones 88 of the first module housing 72. The channels 106 may include a cooling channel 108 that carries cooling fluid in heat exchange relationship with the bottom wall 80 beneath the battery cells 62, as well as a first cable channel 110 and a second cable channel 112. The first cable channel 110 and the second cable channel 112 provide passage for wires (not shown) that may be used in the battery pack 38.

[0029] In one non-limiting example, the first sidewall 82 includes a first sidewall member 116 connected to a second sidewall member 118. A first cooling member 122 is disposed between the first sidewall member 116 and the second sidewall member 118. The first sidewall member 116 includes a first surface portion 124, and the second sidewall member 118 includes a second surface portion 126. A first plurality of openings 130 extend through the first sidewall member 116 and the second sidewall member 118. The first plurality of openings 130 receive corresponding ones of the first plurality of connecting members 92. In one non-limiting example, an annular recess, as shown at 134 on the first sidewall member 116 of the second module housing 74, is formed on the first surface portion 124 around each opening 130.

[0030] Similarly, the second sidewall 84 includes a first sidewall member 136 connected to a second sidewall member 138. A second cooling member 139 is disposed between the first sidewall member 136 and the second sidewall member 138. The first sidewall member 136 includes a first surface portion 140, and the second sidewall member 138 includes a second surface portion 142. A second plurality of openings 146 extend through the first sidewall member 136 and the second sidewall member 138. The second plurality of openings 146 receive a second plurality of connecting members 94, as will be explained in more detail herein.

[0031] Referring to Fig. 5 and with further reference to Fig. 4, each connecting wall 86 includes a first side edge 150 connected to the first side wall 82, and a second side edge 152 connected to the second side wall 84. The first side edge 150 includes a first plurality of recesses 154 that correspond to, i.e., are aligned with, the first plurality of openings 130. The second side edge 152 includes a second plurality of recesses 156 ( Fig. 4) that correspond to, i.e., are aligned with, a second plurality of openings 146. As explained in more detail herein, the first plurality of connecting elements 92 extend through corresponding openings 130 and are pressed into corresponding recesses 154 in the first side edge 150, and the second plurality of connecting elements 94 extend through corresponding openings 146 and are pressed into corresponding recesses 156 in the second side edge 152.

[0032] In one non-limiting example, each of the first plurality of connecting elements 92 includes a head portion 170 and a shaft portion 172, as shown in Fig. 4. The shaft portion 172 includes a plurality of gripping elements 178, which may take the form of raised ribs, teeth, or the like. Each of the first plurality of connecting elements 92 extends through each of the plurality of openings 130, with the head portion 170 fitting into the annular recess 134. Each shaft portion 172 merges into the connecting wall 86, and the gripping elements 178 engage the walls (not separately labeled) that form the corresponding one of the first plurality of recesses 154. In this way, the first side wall 82 is secured to the connecting walls 86.

[0033] In one non-limiting example, each of the second plurality of connecting elements 94 provides a connection between the second side wall 84 and one of the connecting walls of the first module housing 72 and one of the connecting walls 86 of the second module housing 74. That is, the second plurality of connecting elements 94 engage two different connecting walls 86. For this purpose, each of the second plurality of connecting elements 94 comprises, as shown in Fig. 6 shows a central portion 188, a first shaft portion 190 and a second shaft portion 192.

[0034] In one non-limiting example, the first shaft portion 190 extends from the central portion 188 in a first direction and includes a first plurality of gripping elements 194, and the second shaft portion 192 extends from the central portion 188 in a second direction, opposite the first direction, and includes a second plurality of gripping elements 196. The first shaft portion 190 of each of the second plurality of connecting elements 94 extends from the corresponding openings 146 into the connecting wall 86, with the first plurality of gripping elements 194 engaging the walls (not separately labeled) that form the corresponding one of the second plurality of recesses 156.

[0035] The second shaft portion 192 of each of the second plurality of connecting elements 94 extends from corresponding openings 146 in an adjacent connecting wall 86. The second plurality of gripping elements 196 engage walls (not separately labeled) that define the corresponding one of the first plurality of recesses 154 of the adjacent connecting wall 86. With this construction, the battery module assembly 58 can be easily reconfigured to accommodate different battery designs, the size of the battery cell receiving zone, different battery cell configurations, sizes, and the like, without requiring a new housing. Thus, this non-limiting example not only increases design options and flexibility but also reduces manufacturing costs.

Claims

[1] Battery module housing (72), comprising: a floor wall (80); a first side wall (82) with a first connecting element (92); a second side wall (84) with a second connecting element (94); a connecting wall (86) extending between the first side wall (82) and the second side wall (84), the connecting wall (86) comprising a first side edge (150) having a first recess (154) aligned with the first connecting element (92) and a second edge (152) having a second recess (156) aligned with the second connecting element (94), the first recess (154) compressively receiving the first connecting element (92) and the second recess (156) compressively receiving the second connecting element (94) to connect the connecting wall (86) to each of the first side wall (82) and the second side wall (84); characterized by , that the first side wall (82) comprises a first opening (130) and the first connecting element (92) extends through the first opening (130) into the first recess (154) formed in the connecting wall (86). [2] The battery module housing (72) of claim 1, wherein the first connecting member (92) comprises a head portion (170) and a shaft portion (172) extending from the head portion (170), the shaft portion (172) comprising a plurality of gripping members (178) engaging the connecting wall (86) in the first recess (154). [3] The battery module housing (72) of claim 2, wherein the first sidewall (82) comprises a first surface portion (124) and a second surface portion (126) opposite the first surface portion (124), the first surface portion (124) comprising a recess (134) extending around the first opening (130), the head portion of the first connecting member (92) being received in the recess (134). [4] Battery module housing (72) according to claim 1, wherein the second side wall (84) comprises a second opening (146) and the second connecting element (94) extends through the second opening (146) into the second recess (156) formed in the connecting wall (86). [5] The battery module housing (72) of claim 4, wherein the second connecting member (94) comprises a central portion (188) configured to be received by the second opening (146), a first shaft portion (190) extending from the central portion (188) in a first direction into the second recess (156) of the connecting wall (86), and a second shaft portion (192) extending from the central portion (188) in a second direction opposite the first direction. [6] The battery module housing (72) of claim 5, wherein the first shaft portion (190) comprises a first plurality of gripping elements (194) engaging the connecting wall (86) in the second recess (156), and the second shaft portion (192) comprises a second plurality of gripping elements (196). [7] The battery module housing (72) of claim 6, wherein the second side wall (84) comprises a first surface portion (140) connected to the connecting element by the first shaft portion (190) and a second surface portion (142) connected to another connecting element by the second shaft portion (192). [8] Battery module housing (72) according to claim 1, wherein the first side wall (82) comprises a first side wall element (116), a second side wall element (118) connected to the first side wall element (116), and a cooling element (122) extending between the first side wall element (116) and the second side wall element (118) and arranged in heat exchange contact therewith, and wherein the bottom wall (80) includes a cooling channel (108) extending substantially parallel to each of the first and second side walls (84). [9] Vehicle (10) comprising: a body (12) with a passenger compartment (20); an electric drive motor (34) arranged in the body (12); and a battery group (38) with a battery module housing (72) according to claim 1.

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