Vehicle battery

Abstract

Vehicle battery comprising a housing which includes: - a lower compartment housing a first group of battery modules, - an upper compartment housing a second group of battery modules and a battery module control system, the upper and lower compartments being separated by a plate (5), referred to as the upper plate, carrying the second group of modules, the upper plate (5) having a through opening (55) allowing the passage of an electrical connection element (6) which extends from the lower compartment to the upper compartment and which is arranged to connect at least one module of the lower compartment and the control system. Figure for abbreviation: Figure 4c

Description

Title of the invention: Vehicle battery

[0001] The invention relates to a vehicle battery, in particular a battery comprising modules distributed over two stages.

[0002] A vehicle battery, particularly for an electric, hybrid, or hydrogen vehicle, generally comprises a casing housing a plurality of modules, each containing battery cells that supply electrical energy through electrochemical reactions. The energy supplied powers electrical components, for example, an electric motor, an internal combustion engine for starting, a battery control unit, electrical accessories, and / or components for maintaining the stability of the electrical system under various vehicle operating conditions.

[0003] It is known to provide batteries comprising battery cells distributed over two stages, particularly for the purpose of obtaining a high-energy-power and compact battery. Generally, for such an arrangement, two cell control systems are provided, one to control the first stage and the other the second stage. However, providing two control systems can be expensive and can also considerably increase the weight of the battery, which is undesirable for a battery intended for use in a vehicle. Moreover, the presence of two control systems can generate considerable heat that could impair the proper functioning of the battery cells. It is also known to provide a single control system for managing both stages.However, assembling electrical connections tends to be complex, particularly because these connections require long and bulky cables that must be arranged in a confined space. Furthermore, since electrical assembly is often done manually by an operator, handling such cables in a limited space is more complicated, especially when handling cables in a high-voltage battery environment, which requires certain safety precautions, such as the use of thick gloves.

[0004] The invention aims in particular to simplify the assembly of electrical elements in a battery in which the modules are distributed over two stages, while ensuring the safety of operators.

[0005] To this end, the invention relates to a vehicle battery comprising a casing which includes: - a lower compartment housing a first group of battery modules, - an upper compartment housing a second group of battery modules and a battery module control system, the upper compartment and the lower compartment being separated by a plate, called upper plate, carrying the second group of modules, battery in which, the upper plate has a through opening allowing the passage of an electrical connection element which extends from the lower compartment to the upper compartment and which is arranged to connect at least one module of the lower compartment and the control system.

[0006] The invention therefore proposes a plate separating the two compartments and having at least one through-hole through which an electrical connection element extends. Thus, the electrical connection element creates a shortcut for connecting a module from the lower compartment to the control system. Consequently, unlike the prior art, this configuration eliminates the need for long cables to connect the modules on the lower level. This makes the electrical connections of the modules less complex and safer for operators.Indeed, for example, during battery assembly, an operator can first assemble the lower compartment, then assemble the control system in the upper compartment, and finally, to connect the lower modules to the control system, simply use the shortcut created by the through-hole instead of handling long cables in the confined space of the battery casing. Such a shortcut also proves advantageous during maintenance procedures, as the handling and time spent handling long cables in a high-voltage battery environment by the operator is limited.

[0007] It is understood that the battery comprises two stages, with the lower compartment forming the first stage and the upper compartment forming the second stage. Preferably, the two compartments are stacked one on top of the other in the vertical direction of the vehicle. Preferably, the battery comprises a single module control system, namely the system located in the upper compartment. Again preferably, the control system comprises a plurality of components for managing the modules, such as an electronic board for controlling the modules (for example, a board called a BMS for "battery management system") and also electrical cables for connecting to the modules.

[0008] The battery may further include one or more of the following optional features, taken alone or in combination:

[0009] - The electrical connection element is fixed to a plate of the compartment lower, called lower plate, the electrical connection element extending from the lower compartment to the upper compartment through the opening.

[0010] Thus, the electrical connection element forms a kind of tower which will allow the electrical cable(s) arranged between the lower compartment module and the control system to be shortened.

[0011] Preferably, the electrical connection element is fixed by screwing onto the lower plate. More particularly, the electrical connection element has a hole into which a threaded stud carried by the lower plate is inserted, the stud being fixed in the hole by means of a nut attached to the electrical connection element.

[0012] - The electrical connection element includes a housing for receiving a connector suitable for connecting together an electrical cable connected to a module in the lower compartment and an electrical cable connected to the control system.

[0013] The term "electrical cable" refers to both low-voltage and high-voltage cables. "High-voltage cable" refers to a cable designed to carry high levels of electrical voltage, for example, voltages above 60V. Such cables are generally in the form of a strip, for example, a busbar. "Low-voltage cable" refers to a cable designed to carry relatively low voltage levels, lower than those of high-voltage cables, for example, voltages below 60V. Such cables are generally in the form of small-section electrical wires, for example, single wires or pairs or bundles of such wires.

[0014] Preferably, the connector is snapped into the housing. Preferably also, the housing includes a guide rail for the connector allowing the connector to be slid into place, for example from the top of the electrical connection element.

[0015] - The housing for the connector is located in an upper part of the element electrical connection, this part being arranged in the upper compartment protruding from the opening.

[0016] Thus, the electrical connection element allows the connection of the lower compartment module to be relocated to the upper compartment, bringing it closer to the control system and / or an area accessible to an operator, for example, during battery installation or maintenance. Consequently, during battery electronics installation or repair, the connection for the lower-stage modules is directly accessible at the control system level and does not require any additional tools or steps to access the lower compartment modules.

[0017] - The electrical connection element is arranged to connect at least two modules of the lower compartment to the control system.

[0018] Thus, it is not necessary to provide a through-hole and an electrical connection element for each module in the lower compartment. Furthermore, if a connector is present in the electrical connection element, it is possible to relocate the electrical connection of at least two modules, which simplifies battery assembly while reducing the number of parts required.

[0019] - The electrical connection element has a trapezoidal shape with a wider lower base, fixed in the lower compartment, and an opposite, narrower top, arranged in the upper compartment.

[0020] Thanks to its trapezoidal shape, only a small opening is required to allow the top of the electrical connection element to pass through, thus increasing the available area on the top plate for receiving the modules of the upper compartment and / or the control system. Furthermore, the wider base facilitates the seating of the electrical connection element on the bottom plate. In addition, the trapezoidal shape simplifies battery assembly. Preferably, if the electrical connection element has a connector, the top of the trapezoidal shape houses the connector.

[0021] - The electrical connection element comprises, in addition to an electrical connection between the lower compartment module and the control system, at least one so-called "busbar" extending across the opening to connect a lower compartment module to an upper compartment module.

[0022] Thus, the through opening not only allows an electrical connection to be established between a module in the lower compartment and the control system, but also allows an electrical connection to be established between the modules in the lower compartment and the modules in the upper compartment, in particular to facilitate the series connection of the modules to increase the battery voltage.

[0023] - The upper plate carrying the second group of modules and the system of control is a cooling plate, including a channel for the flow of a cooling fluid.

[0024] The through-hole is formed in this cooling plate. This plate therefore has a dual advantage: firstly, it allows the battery components to be cooled, and secondly, it facilitates the installation of electrical connections within the battery. Advantageously, the plate carrying the first module group in the lower compartment also serves as a cooling plate.

[0025] - The upper plate includes a first area dedicated to receiving the second group of modules, and a second dedicated area for receiving the control system, the through opening being formed in the vicinity of the junction between the two areas, preferably in the second area of ​​the plate.

[0026] By providing two distinct zones, the electronics can be separated from the module control system, thus preventing hot gases from the modules from damaging the control system. The fact that the opening is located near the junction of the two zones, closer to the control system's receiving zone, allows for some additional space to facilitate temperature regulation of the management system components, while also moving the connection of the lower modules closer to the control system. Preferably, the two zones are delimited by a lip projecting from the top plate.

[0027] - The through opening made in the upper plate is an opening of closed contour.

[0028] The electrical connection of the lower modules can thus be moved to an interior area of ​​the upper plate, and not to the edges of the upper plate, which makes it possible to shorten the electrical wiring or its location on the upper or lower plate.

[0029] - The electrical connection element is a plastic part, preferably molded by injection.

[0030] By providing a plastic part, production costs are reduced, and the weight of the battery is not highly affected.

[0031] - The electrical connection element includes cable attachment elements electrical, for example for attaching an electrical cable connected to the module in the lower compartment and / or an electrical cable connected to the control system.

[0032] Thus, not only can the electrical connection element receive a connector linking two cables together, as seen above, but alternatively or in combination, it can include cable attachment elements, allowing the cable to be attached to the electrical connection element, thereby securing and positioning it on the electrical connection element. For example, the attachment element is a hook or clip shape into which the electrical cable is inserted, or a groove or notch into which the cable is pinched.

[0033] - The first group of modules comprises four modules and the second group of The module comprises four modules. Preferably, each module delivers a voltage of 48v (volts), so that the battery delivers, through the eight modules in series, a voltage of around 400v.

[0034] The invention also relates to a vehicle comprising a battery as described above. By "vehicle" is meant any vehicle, whether land-based such as a motor vehicle (car, motorcycle, truck, bus, train, machine, in particular construction equipment, etc.), marine such as a ship, aerial such as an aircraft or amphibious such as a submarine. Brief description of the figures

[0035] The invention will be better understood upon reading the following description, given solely by way of example and made with reference to the accompanying drawings in which:

[0036] [Fig-1] is a perspective view of the interior of a battery according to the invention.

[0037] [Fig.2] is an exploded view of part of the battery of [Fig.1].

[0038] [Fig.3] is a set of views (figures 3a and 3b) of the battery housing frame of the [Fig.1], isolated from the other elements, with a top view and a bottom view.

[0039] [Fig.4] is a set of views (figures 4a, 4b and 4c) according to which figure 4a is a side view of the inside of the lower compartment of the battery of [Fig.1], figure 4b is an enlarged representation of an electrical connection element of figure 4a, and figure 4c is a top view, from the upper compartment, of the top of the electrical connection element of figure 4b.

[0040] [Fig.5] is a top view, from the upper compartment, of part of the battery of [Fig.1], at a different angle from Figure 4a. Detailed description

[0041] Figures 1 and 2 show a battery 1, specifically adapted for use in a vehicle. More particularly, [Fig. 1] illustrates the battery 1 in an assembled form, without its cover so as to show its interior, and [Fig. 2] shows a portion of the battery in an exploded view to illustrate the assembly of the lower compartment and the battery casing. Certain elements have been omitted from [Fig. 2] to simplify the representation.

[0042] The battery 1 includes a housing 10 forming a receiving compartment for a plurality of battery modules 21, 31.

[0043] In particular, the modules 21, 31 are distributed over two levels: a lower level visible in [Fig. 2] and an upper level visible in [Fig. 1]. More precisely, the housing 10 comprises a lower compartment 2 housing a first group of modules 21 and an upper compartment 3 housing a second group of modules 31. Preferably, the lower compartment 2 and upper compartment 3 are stacked one above the other in a vertical direction Z.

[0044] In the example presented here, which will be described in more detail below, the battery 1 comprises eight battery modules 21, 31, arranged in four modules 21 in the lower compartment 2 and four modules 31 in the upper compartment 3. Advantageously, each module 21, 31 is capable of supplying 48V (volts) of energy by stacking prismatic battery cells, so that the total voltage of the battery 1 reaches approximately 400V by connecting the modules in series. Of course, the invention is not limited to this example; it is possible to use different numbers of modules depending on the desired voltage.

[0045] As shown in [Fig. 1], the upper compartment 3 is also configured to house a control system 32 for managing the modules, which includes all or part of the battery electronics. In particular, the upper compartment 3 comprises a first zone 310 for receiving the second group of modules 31, and a second zone 320 dedicated to receiving the control system 32. This control system 32 includes a management system for the modules 21, 31, more precisely BMSs (for "Battery Management System") which are configured to control the operation of the modules 21, 31, notably with a so-called master BMS 321 which controls so-called slave BMSs 322. Preferably, a slave BMS 322 is provided for each module 21, 31; therefore, the example shown in [Fig. 1] includes eight slave BMSs 322.Furthermore, the control system 32 includes a junction box 33, configured to form a connection interface between the vehicle's electrical components and the battery cells. More specifically, the junction box 33 forms an interface between the electrical components and the master BMS 321. The control system 32 has a number of other functions not detailed here.

[0046] With reference to [Fig.2], the housing 10 comprises a frame 11 having an upper outer wall 12 and a lower outer wall 13, which respectively delimit the upper compartment 3 and the lower compartment 2. In particular, the first group of modules 21 is mounted on a plate, referred to as the lower plate 4. The frame 11 is intended to be mounted on this lower plate 4, as illustrated by the arrows, to enclose the first group of modules 21.

[0047] Furthermore, the frame 11 carries a plate, referred to as the top plate 5, on which the second group of modules 31 and the control system 32 are mounted. Advantageously, the top plate 5 includes a lip 51 ([Fig. 1]) projecting from the top plate 5 so as to delimit the first 310 and second 320 zones, and thus delimit the space occupied by the second group of modules 31 and the control system 32. Preferably, this lip 51 corresponds to a fixing lip for the modules 31. The top plate 5 is arranged so as to separate the upper compartment 3 from the lower compartment 2.

[0048] The upper plate 5 is visible in Figure 3a. This Figure 3a represents the frame 11 of the housing 10 of the battery 1. Here, the modules 21, 31 and the control system 32 have been omitted to improve the visibility of the upper plate 5. Figure 3b is a view from below of the frame 11 of Figure 3a.

[0049] Advantageously, the upper plate 5 is a cooling plate. This upper plate 5 includes a cooling channel 52, advantageously formed in a serpentine or branching configuration, for the passage of a cooling fluid. Even more advantageously, the lower plate 4 is also a cooling plate, including in particular a channel for the passage of the cooling fluid.

[0050] In Figure 3a, the upper plate 5 has two through-holes 55. The invention is not limited to two openings 55; the upper plate 5 has at least one opening 55, and it may have more than two. Preferably, the openings 55 are formed near the junction between the two zones 310 and 320. Again, preferably, and as shown in Figure 3a, the openings 55 are formed in the second zone 320 of the upper compartment 3. The following description focuses on a single opening 55 for the sake of clarity; of course, the features presented apply to both openings 55. As can be seen in the figures, the through-hole 55 is a closed-contour opening; it is formed inside the plate 5 and not at its periphery. This is a way of further shortening the electrical cables.

[0051] The opening 55 allows the passage of an electrical connection element 6, which is shown in Figures 4a to 4c. The electrical connection element 6 extends from the lower compartment 2 to the upper compartment 3. In particular, the electrical connection element 6 is arranged to connect at least one module 21 of the lower compartment 2 and the control system 32. This arrangement is further described in the following paragraphs.

[0052] With reference to Figures 4a to 4c, the electrical connection element 6 has a trapezoidal shape. Of course, it is possible to consider an electrical connection element 6 in a shape other than that described here. The electrical connection element 6 is fixed to the lower plate 4, for example by screwing. As can be seen in Figures 4a and 4b, the electrical connection element 6 includes positioning holes 61, a threaded stud 611 being able to be inserted into each hole 61. Preferably, the stud 611 is fixed in the hole 61 by means of a nut 612 attached to the electrical connection element 6.

[0053] Furthermore, the electrical connection element 6 extends from the lower compartment 2 to the upper compartment 3 through the opening 55, as seen in Figure 4c.

[0054] In particular, in the case where the electrical connection element 6 has a trapezoidal shape, the electrical connection element 6 comprises a lower base 63, wider, fixed in the lower compartment 2 and a top 65, opposite less wide, disposed in the upper compartment 3. Thus the electrical connection element 6, more precisely the base 63, is fixed on the lower plate 4 and the top 65 passes through one of the openings 55 and protrudes from this opening 55 to be arranged in the upper compartment 3.

[0055] Preferably, the top 65 has a housing 67 configured to receive a connector 7, preferably by snap-fitting. Advantageously, the housing 67 includes a guide rail for the connector 7 to allow the connector 7 to be slid into place from the top 65. Alternatively or in combination, the position of the connector 7 in the housing 67 can be fixed by screwing.

[0056] The connector 7 is advantageously configured to establish the electrical connection between a module 21 of the lower compartment 2 and the control system 32. In particular, the connector 7 allows for the connection of an electrical cable 82 connected to a module 21 of the lower compartment 2 and an electrical cable 84 connected to the control system 32. Indeed, the connector 7 has two opposing ends, respectively lower and upper; the lower end has a lower port 72 connected to the electrical cable 82 from the module 21 of the lower compartment 2, and the upper end has an upper port 74 for the connection of the cable 84 to the control system 32. Thus, the connector 7 allows the electrical connection between the module 21 of the lower compartment 2 and the control system 32, which is located in the upper compartment 3.Advantageously, this connection is shortened by the through opening 55, which allows the passage of the electrical connection element 6. As shown in Figure 4c, the top 65 opens into the upper compartment 3 so that the connector 7 is positioned in the upper compartment 3. Thus, the connection of the lower module 21 is moved from the lower compartment 2 to the upper compartment 3, bringing the connection as close as possible to the control system 32. Consequently, during battery 1 installation or maintenance procedures, the operator's work is simplified. For example, during installation, the operator will have already mounted the modules 21 in the lower compartment 2, and when the upper compartment 3 needs to be installed, unlike in the prior art, it is not necessary to select specific cables in advance or use additional tools to bring the cables closer together.Thanks to the invention, it is only necessary for the user to assemble the upper compartment 3 and connect the cable 84 connected to the control system 32 to the upper port 74 of the connector 7 to establish the connection between the control system 32 and the module 21 of the lower compartment 2. In addition to the connector 7, the electrical connection element 6 may include attachment elements for one or more electrical cables, for example in the form of a groove at the location 62 of the electrical connection element 6 (Figure 4a), allowing the cable to be fixed by pinching.

[0057] Furthermore, the electrical connection element 6 is arranged to connect at least two modules 21 of the lower compartment 2 to the control system 32. For a Battery 1 as shown in [Fig. 1], i.e., comprising four modules 21 in the lower compartment 2 and four modules 31 in the upper compartment 3, the electrical connection element 6 with two connectors 7 is all the more advantageous, as it requires fewer through-holes 55, particularly in the cooling plate. In this case, the electrical connection element 6 has two opposite faces, each bearing a connector 7 to allow the connection between at least two modules 21 in the lower compartment 2 and the control system 32. Of course, it is possible to consider a single connector 7 with multiple ports to allow the connection of several modules 21 with the connection system 32.

[0058] Advantageously, the electrical connection element 6 described above is a plastic part, preferably injection-molded. This makes it easy to provide an electrical connection element 6 with a desired shape, reduces production costs, and does not significantly affect the battery weight.

[0059] Figure 5 is a "bird's-eye" view, i.e., a top view of the battery, in particular, above the through-hole 55, which is angularly offset to show the modules 21 of the lower compartment 2. In this Figure 5, the battery 1 includes a busbar 86 which extends through the opening 55 to connect a module 31 of the upper compartment 3 to a module 21 of the lower compartment 2. The through-hole 55 therefore also allows the modules 31 of the upper compartment 3 to be connected to the modules 21 of the lower compartment 2, in particular for connecting modules 21 and 31 in series. Consequently, the electrical connection between modules 21 and 31 is also shortened.

[0060] The invention is not limited to the embodiments shown, and other embodiments will be obvious to those skilled in the art. In particular, it is possible to omit the connector mounted on the electrical connection element and instead provide a suitable housing for the passage of an electrical cable connecting at least one module of the lower compartment to the control system. List of references

[0061] 1: battery 2: lower compartment 3: upper compartment 4: lower plate 5: top plate 6: electrical connection element 7: connector 10: case 11: Case frame 10 12: upper outer wall 13: lower outer wall 21: first group of modules 31: second group of modules 32: Control system 51: edge 52: Cooling channel 55: through opening 61: Positioning holes 62: location

[0062] 63: base 65: summit 67: housing 72: lower port 74: upper port 82: electrical cable connected to a module 21 of the lower compartment 2 84: electrical cable connected to control system 32 86: busbar 310: first zone for receiving the second group of modules 31 320: second zone dedicated to the control system 32 321: Master BMS 322: BMS slaves 611: threaded stud 612: nut.

Claims

Demands

1. Battery (1) for a vehicle comprising a housing (10) which includes: - a lower compartment (2) housing a first group of battery modules (21), - an upper compartment (3) housing a second group of battery modules (31) and a battery module control system (32), the upper compartment (3) and the lower compartment (2) being separated by a plate (5), referred to as the upper plate, carrying the second group of modules (31), characterized in that the upper plate (5) has a through opening (55) allowing the passage of an electrical connection element (6) which extends from the lower compartment (2) to the upper compartment (3) and which is arranged to connect at least one module (21) of the lower compartment (2) and the control system (32).

2. Battery (1) according to the preceding claim, wherein the electrical connection element (6) is fixed on a plate (4) of the lower compartment (2), referred to as the lower plate, the electrical connection element (6) extending from the lower compartment (2) to the upper compartment (3) through the opening (55).

3. Battery (1) according to any one of the preceding claims, wherein the electrical connection element (6) has a housing (67) receiving a connector (7) adapted to connect together an electrical cable (82) connected to a module (21) of the lower compartment and an electrical cable (84) connected to the control system (32).

4. Battery (1) according to the preceding claim, wherein the housing (67) for the connector (7) is located in an upper part of the electrical connection element (6), this part being arranged in the upper compartment (3) by projecting from the opening (55).

5. Battery (1) according to any one of the preceding claims, wherein the electrical connection element (6) is arranged to connect at least two modules (21) of the lower compartment (2) to the control system (32).

6. Battery (1) according to any one of the preceding claims, wherein the electrical connection element (6) has a trapezoidal shape with a lower base (63) wide, fixed in the lower compartment (2), and an opposite, less wide vertex (65) arranged in the upper compartment (3).

7. Battery (1) according to any one of the preceding claims, wherein the electrical connection element (6) comprises, in addition to an electrical connection between the module (21) of the lower compartment (2) and the control system (32), at least one so-called “busbar” (86) extending through the opening (55) to connect a module (21) of the lower compartment (2) to a module (31) of the upper compartment.

8. Battery (1) according to any one of the preceding claims, wherein the upper plate (5) carrying the second group of modules (31) and the control system (32) is a cooling plate, comprising a channel (52) for the flow of a cooling fluid.

9. Battery (1) according to any one of the preceding claims, wherein the upper plate (5) comprises a first zone (310) dedicated for receiving the second group of modules (31), and a second zone (320) dedicated for receiving the control system (32), the through opening (55) being formed in the vicinity of the junction between the two zones, preferably in the second zone (320) of the plate (5).

10. Battery (1) according to any one of the preceding claims, wherein the through opening (55) made in the upper plate (5) is a closed contour opening.

11. Battery (1) according to any one of the preceding claims, wherein the electrical connection element (6) is a plastic part, preferably injection molded.

12. Battery according to any one of the preceding claims, wherein the electrical connection element (6) comprises attachment elements for an electrical cable.

13. Battery (1) according to any one of the preceding claims, wherein the first group of modules (21) comprises four modules and the second group of modules (31) comprises four modules.

14. Vehicle comprising a battery (1) according to any one of the preceding claims.

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