Connecting board frame for a battery module

Abstract

A connecting board frame for a battery module having at least one first battery cell with a positive terminal and a negative terminal comprises a first frame element defining a first slot aligned with the positive terminal of the first battery cell, a second frame element connected to the first frame element, wherein the second frame element defines a second slot aligned with the negative terminal of the first battery cell, and a puzzle connection defined by the connection of the first frame element and the second frame element, the puzzle connection between the first slot and the second slot passing over the series connections between the battery cells.

Description

INITIATIONThe present disclosure relates to an interconnect board (ICB) frame. Interconnect Board) for a battery module. More particularly, the present disclosure relates to an ICB frame having frame members connected together at a puzzle connection between a series connection of battery cells within the battery module.In electric and hybrid vehicles, a high-voltage electric battery system is used that includes a series of battery cells that are generally combined as a plurality of battery modules in a battery pack. The battery pack is often located under the body in the middle between the front and rear wheels. These electric and hybrid vehicles generally require a plurality of battery modules in order to meet the power and energy requirements of the vehicle. Power and / or range requirements may result in the battery modules becoming longer to allow sufficient battery cells to be housed to meet these requirements. This in turn leads to components within the battery module, such as e.g. circuit board frames, which are used for fastening and supporting the busbars connected to the battery cells, having a greater length. A greater length of the board frames can lead to assembly, shipping and manufacturing problems.Therefore, there is a need in the art for improved circuit board frames suitable for all battery module sizes.SUMMARYA connection board frame for a battery module is provided. The battery module comprises at least one first battery cell having a positive pole and a negative pole. The connector board frame includes a first frame member defining a first slot aligned with the positive pole of the first battery cell, a second frame member connected to the first frame member, the second frame member defining a second slot aligned with the negative pole of the first battery cell, and a puzzle connection defined by the connection of the first frame member and the second frame member, the puzzle connection extending between the first slot and the second slot.In one aspect, a holding device is arranged on the first frame element and the second frame element, wherein the holding device fixes the first frame element to the second frame element in all directions.In another aspect, the retaining device includes a snap connection connected to the first frame member and a hole disposed in the second frame member, the snap connection disposed in the hole.In another aspect, the connector board frame has a length and a width, and the puzzle connection extends across the width.In another aspect, the puzzle piece includes a first transverse portion connected to a longitudinal portion connected to a second transverse portion, the first transverse portion being adjacent the first slot, the second transverse portion being adjacent the second slot, and the longitudinal portion being disposed between the first slot and the second slot.According to a further aspect, the longitudinal section runs perpendicular to the first transverse section and second transverse section.In another aspect, the puzzle connection is separate from the first and second slots.In another aspect, the first slot has a first window extending therethrough and the second slot has a second window extending therethrough.In another aspect, the first slot is offset from the second slot along a width.In another embodiment, a battery module is provided. The battery module includes a first battery cell having a positive pole and a negative pole, an interconnect board (ICB) frame disposed on the first battery cell, the ICB frame including a first frame member defining a first slot aligned with the positive pole of the first battery cell, a second frame member connected to the first frame member, the second frame member defining a second slot aligned with the negative pole of the first battery cell, and a puzzle connection defined by the connection of the first frame member and the second frame member, the puzzle connection extending between the first slot and the second slot.In one aspect, a plurality of busbars are arranged in the first or second slot.In another aspect, the first slot has a first window extending therethrough and the second slot has a second window extending therethrough, and the bus bars are connected to the positive pole and the negative pole through the first window and the second window.In a further aspect, a holding device is arranged on the first frame element and the second frame element, wherein the holding device fixes the first frame element to the second frame element in all directions.In another aspect, the retaining device comprises a snap connection connected to one of the first and second frame elements and a hole arranged in the other of the two frame elements, wherein the snap connection is arranged in the hole.In another aspect, the puzzle piece includes a first transverse portion connected to a longitudinal portion connected to a second transverse portion, the first transverse portion being adjacent the first slot, the second transverse portion being adjacent the second slot, and the longitudinal portion being disposed between the first slot and the second slot.In a further aspect, the longitudinal section runs perpendicular to the first transverse section and second transverse section.In another embodiment, a battery module for a vehicle is provided. The battery module includes a plurality of battery cells, a plurality of bus bars connected to the plurality of battery cells, the battery cells being connected in series by the plurality of bus bars, an interconnect board (ICB) frame disposed between the plurality of battery cells and the plurality of bus bars, the ICB frame including a first frame member defining a plurality of first slots aligned with positive poles or negative poles of the plurality of battery cells, a second frame member connected to the first frame member, the second frame member defining a plurality of second slots aligned with the positive poles or negative poles of the plurality of battery cells, and the first frame being connected to the second frame member via one of the series connections between the plurality of battery cells.In one aspect, the plurality of first slots and the plurality of second slots are each arranged in two rows along a length of the ICB frame.In a further aspect, a holding device is arranged on the first frame element and the second frame element, wherein the holding device fixes the first frame element to the second frame element in all directions.In another aspect, the retaining device includes a snap connection connected to one of the first and second frame members and a hole disposed in the other of the first frame member and the second frame member, the snap connection being disposed in the hole.Further areas of application will become apparent from the present description. The specification and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGSThe drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. FIG. 1 is a schematic view of an exemplary motor vehicle having a battery pack and a connector board frame according to the principles of the present disclosure; FIG. 2 is an exploded perspective view of a battery module within the battery pack with the connector board frame; FIG. 3 is a plan view of the connector board frame; FIG. 4 is an enlarged plan view of a part of the connection board frame; FIG. 5 is a perspective view of an end of a first frame member of the connector board frame; FIG. 6 is a perspective view of an end of a second frame member of the connection board frame; FIG. 7A is a cross-sectional view of the connector board frame taken in the direction of arrows 7A-7A of FIG. 4 ; FIG. 7B is a cross-sectional view of the connector board frame taken in the direction of arrows 7B- 7B of FIG. 4 ; and FIG. 7C is a cross-sectional view of the connector board frame taken in the direction of arrows 7C-7C of FIG. 4.DETAILED DESCRIPTIONThe following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or its use.Referring to FIG. 1, a battery pack 10 is shown having a connector board frame, discussed in more detail below, in accordance with the principles of the present disclosure. The battery pack 10 is illustrated with an example vehicle 12. The vehicle 12 is preferably an electric or hybrid vehicle having wheels 14 driven by electric motors / inverters 16. The electric motors / inverters 16 are supplied with driving power from the battery pack 10. Although the vehicle 12 is shown as a passenger car, the battery pack 10 may be used in various other types of vehicles. The battery pack 10 may be used in watercraft such as boats, or aircraft such as drones or passenger aircraft, for example. Moreover, the battery pack 10 may be used as a stationary power source separately and independently of a vehicle. The battery pack 10 typically includes a battery carrier 18 connected to the vehicle 12. The battery carrier 18 structurally supports one or a plurality of battery modules 20. The battery pack 10 may further include an unillustrated battery thermal management system and battery management system.In FIG. 2, the battery module 20 generally includes a plurality of battery cells 22, a plurality of bus bars 24, and a pair of connection board (ICB) frames 26.The battery module 20 is oriented to include a row of battery cells 22 extending along a length "L" and one or more rows of battery cells 22 arranged along a width "W". Although two rows of battery cells 22 are depicted with a plurality of battery cells 22 and two ICB frames 26, respectively, it should be appreciated that any number of battery cells 22, bus bars 24, and ICB frames 26 may be used in the battery module 20 without departing from the scope of the present disclosure.The battery cells 22 are lithium ion battery cells. However, all other types of battery cells 22 may be used. Moreover, the battery cells 22 may be cylindrical battery cells, prismatic can battery cells, or pouch battery cells. Generally, the battery cells 22 each include a housing 28 having a top surface 30. a positive pole 32 and a negative pole 34 are disposed on the top surface 30. The negative pole 34 is connected to an unillustrated anode current collector within the battery cell 22. The positive pole 32 is connected to a cathode current collector, not shown, within the battery cell 22.The busbars 24 are electrical conductors which serve to connect individual battery cells 22 in series or in parallel. The bus bars 24 generally each include a number of contact pads 25. In the present example, the bus bar 24 includes four contact pads 25. the bus bars 24 are laser welded (or otherwise fixedly connected) to the positive terminals 32 and negative terminals 34 of the battery cells 22 at the contact pads 25. The configuration of the bus bars 24 and the orientation of the battery cells 22 determine the series and parallel connections therebetween.FIGS. 3 and 4 show the ICB frame 26 having a plurality of bus bars 24. the ICB frame 26 is configured to fix and retain the bus bars 24 relative to the battery cells 22 during assembly. The ICB frame 26 is preferably made of a plastic. The ICB frame 26 is arranged along the length of the battery module 20 between the busbars 24 and the battery cells 22, wherein an ICB frame 26 is provided in each case for a row of battery cells 22. The ICB frame 26 generally includes a first frame member 36 that is connected to a second frame member 38 at a puzzle joint 40. Although only one puzzle connection 40 is shown, the ICB frame 26 may include more than one puzzle connection 40 (shown in dotted lines in FIG. 3 ) to divide the ICB frame 26 into a plurality of frame members. As will be described in more detail below, the location and configuration of the puzzle bond 40 enables the ICB frame 26 to be manufactured, shipped, and installed as shorter frame members or modules without requiring additional components or power rails.The first frame member 38 includes a first distal end 42 and an insert end 44 opposite the first distal end 42. the first frame member 36 also includes a plurality of first slots 46 formed therein. The first slots 46 are arranged in two rows 48, 50. The first slots 46 in each of the rows 48, 50 are offset from one another along the length of the battery module 20. Each of the first slots 46 is defined by a plurality of first windows 52 extending through the first frame member 38, as best seen in FIG. 2. The first windows 52 are each aligned with a positive pole 32 or negative pole 34 on a battery cell 22. In the present example, the first slots 46 include four windows 52. In the present example, each first slot 46 is aligned with two positive poles 32 and two negative poles 34 (shown schematically in FIG. 4 with "+" and symbols) on four battery cells 22.The first slots 46 are each sized to receive and retain a bus bar 24. Each of the first windows 52 is sized to receive a contact pad 25 of a corresponding bus bar 24. In the present example, the battery cells 22 are therefore connected in series (indicated by the dashed line "S") and in parallel (indicated by the dashed line "P").In FIG. 5, the insert end 44 of the first frame element 36 comprises two transverse edges 60, 62 and a longitudinal edge 64. Each of the edges 60, 62, and 64 includes an insert retaining member 66. the insert retaining member 66 includes a tab 68 and a snap fit connection 70 extending from the tab 68. The height "h" of the tab 68 and the snap fit connection 70 does not exceed the thickness "t" of the first frame member 36.Referring back to FIGS. 3-4, the second frame member 38 includes a second distal end 80 and a receiving end 82 opposite the second distal end 80. the second frame member 38 also includes a plurality of second slots 84 formed therein. The second slots 84 are disposed in the two rows 48, 50. The second slots 84 in each of the rows 48, 50 are offset from one another along the length of the battery module 20. Each of the second slots 84 is defined by a plurality of second windows 90 extending through the second frame member 38, as best seen in FIG. 2. The second windows 90 are each aligned with a positive terminal 32 or negative terminal 34 on a battery cell 22. In the present example, the second slots 84 include four second windows 90. In the present example, each second slot 84 is aligned with two positive poles 32 and two negative poles 34 (schematically shown in FIG. 4 with "+" and "-" symbols) on four battery cells 22.The second slots 84 are each sized to receive and retain a bus bar 24. Each of the second windows 90 is sized to receive a contact pad 25 of a corresponding bus bar 24. In the present example, the battery cells 22 are therefore connected in series (indicated by the dashed line "S") and in parallel (indicated by the dashed line "P").In FIG. 6, the receiving end 44 of the second frame element 38 comprises two transverse edges 92, 94 and a longitudinal edge 96. the transverse edges 92, 94 are arranged at right angles to the longitudinal edge 96. Each of the edges 92, 94, 96 includes a female retaining member 98. Each of the female retaining members 98 includes a housing 100 for receiving one of the tabs 68 (FIG. 5 ) and a hole 102 sized to receive one of the snap connections 70 (FIG. 5 ) of the first frame member 36. FIGS. 7A-7C illustrate the interaction of the retainers 66, 98. the retainers 66, 98 fix the first frame member 36 in all directions with the second frame member 38. Moreover, since each frame member 36, 38 includes either an insert retainer 66 or a receiving retainer 98, errors in assembly are reduced.Referring back to FIG. 4, the puzzle joint 40 is the interface between the insert end 44 of the first frame member 36 and the receiving end 82 of the second frame member 38. The puzzle piece 40 is characterized as having a first transverse portion 110, a second transverse portion 112 and a longitudinal portion 114. The first transverse section 110 and the second transverse section 112 run perpendicular to the longitudinal section 114. The first transverse portion is disposed between one of the first slots 46 and one of the second slots 84 in the same row 48. The second transverse portion 112 is disposed between one of the first slots 46 and one of the second slots 84 in the same row 50. The longitudinal portion 114 is disposed between one of the first slots 46 in one row 50 and one of the second slots 84 in the other row 48. The puzzle connection 40 thus runs via the series connections between the battery cells 22 and not via the parallel connections.The ICB frame 26 with the puzzle connection 40 and the holders 66, 98 offers many advantages, including the fact that internal connections between the busbars 24 are no longer necessary due to the puzzle connections between the parallel connections of the battery cells 22. The retaining devices 66, 98 ensure retention on all axes (i.e., directions) and thus ensure that the first frame element 36 is fastened to the second frame element 38. In addition, since the height of the holders 66, 98 is less than the thickness of the ICB frame 26, the packaging of the ICB frame 26 is not increased. The ICB frame 26 with the puzzle joint 40 reduces cycle time in the manufacturing facilities during installation, provides failsafety and sequential installation operations (i.e., the first frame member 36 cannot be joined to another first frame member 36), enables the ICB frame 26 to be accommodated as a component without loose parts, and enables long battery modules 20 (e.g., modules having a length of about fifty-four battery cells).The description of the present disclosure is merely exemplary in nature, and modifications that do not depart from the gist of the present disclosure are to be considered as being within the scope of the present disclosure.Such modifications are not to be interpreted as a departure from the spirit and scope of the present disclosure.

Claims

A connector board frame for a battery module, the battery module having at least a first battery cell having a positive pole and a negative pole, comprising: a first frame member defining a first slot aligned with the positive pole of the first battery cell; a second frame member connected to the first frame member, the second frame member defining a second slot aligned with the negative pole of the first battery cell; and a puzzle connection defined by the connection of the first frame member and the second frame member, the puzzle connection extending between the first slot and the second slot.The connector board frame according to claim 1, further comprising a holder disposed on the first frame member and the second frame member, wherein the holder fixes the first frame member to the second frame member in all directions.The connector board frame of claim 2, wherein the retaining device comprises a snap connection connected to the first frame member and a hole disposed in the second frame member, the snap connection being disposed in the hole.The connector board frame of claim 1, wherein the connector board frame has a length and a width and the puzzle connect extends across the width.The connector board frame of claim 1, wherein the puzzle piece comprises a first transverse portion connected to a longitudinal portion connected to a second transverse portion, the first transverse portion being adjacent the first slot, the second transverse portion being adjacent the second slot, and the longitudinal portion being disposed between the first slot and the second slot.The circuit board frame of claim 5, wherein the longitudinal portion is perpendicular to the first transverse portion and the second transverse portion.The connector board frame of claim 1, wherein the puzzle connection is separate from the first and second slots.The connector board frame of claim 1, wherein the first slot has a first window extending therethrough and the second slot has a second window extending therethrough.The connector board frame of claim 1, wherein the first slot is offset along a width from the second slot.A battery module comprising: a first battery cell having a positive pole and a negative pole; an interconnect board (ICB) frame disposed on the first battery cell, comprising: a first frame member defining a first slot aligned with the positive pole of the first battery cell; a second frame member connected to the first frame member, the second frame member defining a second slot aligned with the negative pole of the first battery cell; and a puzzle connection defined by the connection of the first frame member and the second frame member, the puzzle connection extending between the first slot and the second slot.

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