BATTERY MODULE FOR ELECTRIC OR HYBRID VEHICLE INCLUDING COVERS
The battery cell module with a folding lid and foam structure addresses the issues of gas backflow and thermal runaway by enhancing mechanical protection, thermal insulation, and shock absorption, ensuring gas tightness and improved cell safety.
Patent Information
- Authority / Receiving Office
- FR · FR
- Patent Type
- Applications
- Current Assignee / Owner
- STELLANTIS AUTO SAS
- Filing Date
- 2024-12-03
- Publication Date
- 2026-06-05
AI Technical Summary
Existing battery cell covers in electric or hybrid vehicles provide mechanical protection but expose connecting bars to gas backflow during thermal runaway, risking damage and short-circuiting, and lack effective thermal insulation and shock absorption.
A module architecture with a first cover including an electrical terminal, a second lid folding over the first lid, and foam between them, providing mechanical protection, thermal insulation, and shock absorption, while guiding gas flow and maintaining seal integrity under stress.
Enhances mechanical protection, reduces risk of damage and short-circuiting, improves thermal management, and ensures gas tightness and thermal insulation, contributing to cell durability and safety by preventing overheating and fire spread.
Smart Images
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Abstract
Description
Title of the invention: MODULE FOR ELECTRIC OR HYBRID VEHICLE BATTERY COMPRISING COVERS
[0001] The present invention relates to electric or hybrid vehicles in the automotive field, and more particularly to modules comprising battery cells for electric or hybrid vehicles.
[0002] Patent application KR20240112533 describes a battery cell comprising a connecting bar, a fastening means, and a cover including a gas outlet and a clipping means configured to be attached to the fastening means. In this way, the gas outlet dissipates the heat generated by the battery cell.
[0003] However, the cover is limited to providing mechanical protection for the cell. In the event of a gas release from the cell, for example when the cell undergoes thermal runaway, the connecting bar is exposed through the gas outlet to a backflow of gas which can cause damage to the cell, particularly to the connecting bar.
[0004] Thus, the objective of the present invention is to remedy this drawback by proposing a simple and easy-to-manufacture module architecture.
[0005] To achieve this objective, the invention proposes a module for an electric or hybrid vehicle battery, the module comprising at least one cell, the cell comprising an electrical terminal, the module comprising: - a first cover including the electrical terminal; - a second lid having a folded edge against the first lid so as to cover the first lid.
[0006] Such a cell thus offers additional mechanical protection to the electrical terminal, in particular because the second cover covers the first cover. This reduces the risks of damage to or short-circuiting of the cell due to the cell's environment.
[0007] Furthermore, due to the covering of the first cover by the second cover, the second cover provides thermal insulation thus protecting the electrical terminal and the cell, in particular from the risks of overheating, improving the thermal management of the cell.
[0008] Advantageously, the first cover includes a foam.
[0009] The foam deforms under stress, thus acting as a mechanical damper. In this way, the foam absorbs external vibrations and shocks, protecting the cell from damage and contributing to improved cell durability.
[0010] The foam's ability to change its conformation allows the cell's seal with respect to the electrical terminal to be adjusted according to the mechanical stress applied to the foam. When mechanical stress is applied, the foam adjusts to fill the gaps between the covers so that gas tightness and thermal insulation are maintained, even under mechanical and thermal stresses such as in the case of thermal runaway of the cell.
[0011] Advantageously, the first cover and a third cover form a rim comprising the foam.
[0012] The rim guides the gases out of the cell, thus channeling the gas flow and preventing their accumulation. The foam also ensures a seal between the cell lids while facilitating gas evacuation and protecting the connecting bar from heat rise.
[0013] Advantageously, the foam is arranged at the intersection between the first cover and the third cover.
[0014] The foam retains its integrity throughout the movements and / or deformations of the cell, the foam ensuring its thermal protection and sealing function, even under mechanical stress, thus reducing the risks of cell failure, particularly in the event of thermal runaway.
[0015] Advantageously, the module has an end comprising additional foam.
[0016] The additional foam not only provides a thermal barrier but also contributes to fire protection so that, in the event of a fire, the foam limits the spread of fire to the cell, thus improving vehicle safety. Furthermore, the foam provides a barrier against dust particles, preventing their infiltration into the cell, preserving the cell's performance and longevity by preventing wear and contamination caused by these particles.
[0017] Advantageously, the second cover is fixed to the module by at least gluing, welding, crimping or riveting.
[0018] The second cover is fixed so as to resist mechanical and thermal stresses without risk of deformation or displacement of the elements of the cell, in particular of the first cover and the second cover.
[0019] The invention also relates to a battery for an electric or hybrid vehicle, characterized in that the battery comprises: - a cell defined as previously; - a beam configured to fold down the second lid.
[0020] The invention also relates to an electric or hybrid vehicle comprising a battery defined as above.
[0021] Advantageously, the vehicle includes a base comprising the beam.
[0022] The beam is integrated into the existing structure of the underbody, making it possible to use this part of the vehicle to reinforce the attachment of the cover without requiring significant modifications to the design of the vehicle.
[0023] The invention further relates to a method for manufacturing a module defined as above, the method comprising the following steps: - a step of centering the second lid relative to the cell; - a step of folding the second lid, the edge folding down against the first lid.
[0024] The centering of the second cover ensures its alignment with the cell before folding, this guarantees uniform coverage and sealing of the cell with respect to the electrical terminal once the edge is folded down onto the first cover.
[0025] The invention will be further detailed by describing non-limiting embodiments, and based on the accompanying figures illustrating variants of the invention, in which: - [Fig. 1] schematically illustrates a front view of a module for an electric or hybrid vehicle battery, the module comprising a first cover and a second cover comprising a border folded against the first cover according to a first embodiment of the invention; - [Fig.2] schematically illustrates a profile view of a cell of the module illustrated in [Fig.1], the border not being illustrated; - [Fig.3] schematically illustrates a front view of the module shown in [Fig.1], the edge being raised relative to the first lid; - [Fig. 4] schematically illustrates a front view of a battery module of an electric or hybrid vehicle according to a second embodiment of the invention; - [Fig. 5] schematically illustrates a profile view of a cell of the module illustrated in [Fig.4], the border not being illustrated; - [Fig. 6] schematically illustrates a front view of a battery module of an electric or hybrid vehicle according to a third embodiment of the invention; - [Fig.7] schematically illustrates a profile view of a cell of the module illustrated in [Fig.6], the border not being illustrated; - [Fig.8] illustrates a flowchart representing the steps of a process for manufacturing a module illustrated in [Fig.1] and [Fig.3], according to an embodiment of the invention.
[0026] Figures 1 and 2 illustrate a module for an electric or hybrid vehicle battery, the module comprising at least one cell according to a first embodiment of the present invention. The cell extends longitudinally along a second axis X2 and transversely along a first axis X1, the cell being parallel to a median plane comprising the first axis XI and the second axis X2, the first axis XI being perpendicular to the second axis X2. For example, the cell has a prismatic shape of the right rectangular prism type.
[0027] According to the invention, the module for an electric or hybrid vehicle battery comprises the cell and an additional cell extending longitudinally along an axis parallel to the second axis X2, the additional cell being parallel to the median plane, the cell and the additional cell being distributed along a third axis X3 perpendicular to the first axis XI and to the second axis X2.
[0028] In practice, the module is arranged in a chassis configured to receive the cell and the additional cell. The chassis notably has a lower surface and an upper surface extending respectively in planes parallel to a transverse plane comprising the second axis X2 and the third axis X3.
[0029] Furthermore, the cell has a lower face and an upper face extending respectively in planes parallel to the transverse plane. The lower face is positioned opposite the lower surface, while the upper face is positioned opposite the upper surface. Thus, the cell forms a compact assembly with the chassis.
[0030] In [Fig. 1], the cell has, on either side, a first lateral face and a second lateral face. The first lateral face and the second lateral face extend in planes parallel to a lateral plane comprising the first axis XI and the third axis X3.
[0031] The first lateral face includes a positive electrical terminal. Furthermore, the additional cell has, on either side, a first additional lateral face and a second additional lateral face extending equally. The first additional lateral face includes a negative electrical terminal.
[0032] In practice, a connecting bar links the positive electrical terminal and the negative electrical terminal. The connecting bar is configured to allow an electric current to flow. Thus, the cell is electrically connected to the additional cell.
[0033] Thus, the cell includes an electrical terminal 11. The module has a first cover 10 comprising the electrical terminal 11, for example, the positive electrical terminal. The first cover 10 extends in a plane parallel to the lateral plane. The first cover 10 includes a first rim and a second rim.
[0034] The invention provides fastening methods including gluing, welding, riveting or crimping. The first edge of the first cover 10 is advantageously fixed to the module by at least one of said fastening methods, preferably crimping.
[0035] The cell advantageously comprises a third lid 30 fixed to the first lid 10. The third lid 30 comprises a first rim and a second rim. The second rim of the first cover 10 and the first rim of the third cover 30 form a rim 50 of the cell, these being fixed to each other by at least one of said fixing methods. Thus, the rim 50 has a predetermined extension along the second axis X2.
[0036] Furthermore, the second rim of the third cover 30 is fixed to the lower surface by at least one of said fixing methods. Thus, the first cover 10 and the third cover 30 are fixed in such a way as to ensure the sealing of the cell.
[0037] The first cover 10 comprises a first material. The first material preferably comprises aluminum. Generally, the first material is chosen so as to exhibit resistance to heat and / or pressure in the event of thermal runaway of the cell.
[0038] Furthermore, the third cover 30 comprises a second material. The second material comprises aluminum or, preferably, plastic. Generally, the second material is chosen so that it ruptures when the cell experiences thermal runaway, thus allowing the cell to degas.
[0039] The cell includes a second cover 20 having an edge 21 folded against the first cover 10. In practice, the second cover 20 includes a portion 22 extending in a plane parallel to the transverse plane. Preferably, the second cover 20 is fixed to the upper surface by at least one of said fixing means.
[0040] On [Fig.3], the border 21 extends in a plane forming an angle α with the plane of the part 22 of the second cover 20. The border 21 is configured to be in a first position or in a second position.
[0041] In the first position, the angle a is less than 90°, while in the second position, the angle a is substantially equal to 90°, the edge 21 being folded against the first cover 10.
[0042] In the second position, the rim 21 is advantageously provided to have in the second position a predetermined extension along the first axis XI greater than the extension of the first cover 10 along the first axis XL Thus, the second cover 20 provides protection against electric shock as indicated in the IPXXb regulations.
[0043] The second cover 20 comprises a third material advantageously comprising mica.
[0044] The first cover 10 advantageously comprises a foam 40. The foam 40 is configured to have a first conformation or a second conformation.
[0045] For example, foam 40 is a closed-cell silicone foam 40, a thermosetting polyurethane foam 40, or a ceramic-based foam 40.
[0046] According to the first embodiment, the foam 40 is placed on the second rim of the first lid 10.
[0047] In the first conformation, the foam 40 has a first extension along the second axis X2, preferably greater than or equal to the predetermined extension of the rim 50.
[0048] In the second conformation, the foam 40 has a second extension along the second axis X2, preferably substantially equal to the predetermined extension of the rim 50. The rim 21 is folded down, in the second position, against the first cover 10, the foam 40 being in the second conformation, the rim 21 being in contact with the foam 40.
[0049] Figures 4 and 5 illustrate a module for an electric or hybrid vehicle battery according to a second embodiment of the present invention. The module comprises at least one cell having an electrical terminal 11.
[0050] The module includes: - a first cover 10 including the electrical terminal 11; - a second lid 20 having a rim 21 configured to be folded down onto the first lid 10.
[0051] The first cover 10 extends longitudinally along the third axis X3 and transversely along the first axis XI, the first cover being parallel to the lateral plane comprising the third axis X3 and the first axis XL. The first cover 10 includes a first rim and a first end. Similarly, the third cover 30 extends in a plane parallel to the lateral plane. The third cover 30 includes a second rim and a second end.
[0052] The first end and the second end are fixed to each other by at least one of said fixing methods. Thus, the first cover 10 and the third cover 30 are fixed so as to ensure the sealing of the cell.
[0053] According to the second embodiment, the cell advantageously comprises a foam 40. The foam 40 is even more advantageously disposed at the intersection between the first lid 10 and the third lid 30. For example, the foam 40 is disposed at the intersection between the first end and the second end.
[0054] Alternatively, a sealing gasket is disposed at the intersection between the first end and the second end.
[0055] The foam 40 is configured to exhibit a first conformation and a second conformation, the foam 40 conforming from the first conformation towards the second conformation when a mechanical stress is applied to the foam 40.
[0056] In the first conformation, the foam 40 has a first extension along the first axis XI, preferably less than the predetermined extension of the first cover 10 along the first axis XI.
[0057] In the second conformation, the foam 40 has a second extension along the first axis XI, preferably greater than the first extension. Furthermore, the second conformation is designed so that the foam 40 covers the intersection between the first and second ends, contributing to the cell's airtightness. The rim 21 is folded down in the second position against the first cover 10, the foam 40 being in the second conformation when the rim 21, in the second position, is in contact with the foam 40.
[0058] A module for an electric or hybrid vehicle battery according to a third embodiment of the present invention is illustrated in [Fig. 6] and [Fig. 7]. The module comprises at least one cell having an electrical terminal 11.
[0059] The module includes: - a first cover 10 including the electrical terminal 11; - a second lid 20 having a rim 21 configured to be folded down onto the first lid 10.
[0060] According to the third embodiment, the module has an end advantageously comprising an additional foam 40'. The additional foam 40' extends longitudinally along an axis parallel to the second axis X2. Preferably, the module has a first end and a second end extending respectively parallel to the median plane. Thus, the module comprises a first additional foam and a second additional foam extending respectively longitudinally along an axis parallel to the second axis X2.
[0061] The additional foam 40' is configured to exhibit a first conformation and a second conformation, the additional foam 40' conforming from the first conformation to the first conformation when a mechanical stress is applied to the additional foam 40'.
[0062] In the first conformation, the additional foam 40' has a first extension along the first axis XL. Similarly, in the second conformation, the additional foam 40' has a second extension along the first axis XI, preferably less than or equal to the first extension.
[0063] The cell advantageously comprises an additional cover. The additional cover extends in a plane parallel to the transverse plane, the additional foam 40' being in the second conformation when the additional cover rests on the foam 40. Advantageously, the base of the The vehicle includes the additional cover. The additional cover includes a beam 60 extending longitudinally along an axis parallel to the third axis X3.
[0064] Thus, the additional cover and the additional 40' foam contribute to the sealing of the cell, in particular against dust, as well as to the thermal insulation of the cell and to the rising of gases.
[0065] A flowchart of a process for manufacturing a cell, according to the first embodiment, is illustrated in [Fig.8], according to an embodiment of the invention, the steps of the assembly process being described below.
[0066] In a centering step E1, the second cover 20 is centered with respect to the cell. Thus, the second cover 20 is positioned so that the outer periphery of the rim 21 is substantially parallel to the second axis X2. This ensures that the rim 21 is correctly positioned with respect to the cell, facilitating the manufacture of the module.
[0067] The method advantageously includes a fixing step E' 1, the second cover 20 being fixed to the cell, for example to the upper surface, by at least one of said fixing means.
[0068] The method advantageously comprises a movement step E'2, a beam 60 being moved in translation towards the module along the first axis XL
[0069] In a folding step E2, the second cover 20 is folded, the edge 21 folding down against the first cover 10. The movement of the beam 60 along the first axis XI in contact with the edge 21 causes the edge 21 to move from the first position to the second position.
[0070] Furthermore, the foam 40 conforms from the first conformation to the second conformation when this movement is transmitted to the foam 40 via the edge 21. In particular, the foam 40 undergoes a compressive force mainly along the direction of the second axis X2.
Claims
Demands
1. Module for electric or hybrid vehicle battery, the module comprising at least one cell, the cell comprising an electrical terminal (11), the module comprising: - a first cover (10) comprising the electrical terminal (11); - a second cover (20) having an edge (21) folded against the first cover (10) so as to cover the first cover (10).
2. Module according to claim 1, characterized in that the first cover comprises a foam (40).
3. Module according to claim 2, characterized in that the first cover (10) and a third cover (30) form a rim (50) comprising the foam (40).
4. Module according to claim 2, characterized in that the foam (40) is arranged at the intersection between the first cover (10) and the third cover (30).
5. Module according to any one of claims 1 to 4, characterized in that the module has an end comprising an additional foam (40').
6. Module according to any one of claims 1 to 5, characterized in that the second cover (20) is fixed to the module by at least gluing, welding, crimping or riveting.
7. Battery for electric or hybrid vehicle, characterized in that the battery comprises: - a module according to any one of claims 1 to 6; - a beam (60) configured to fold down the second cover (20).
8. Electric or hybrid vehicle comprising a battery according to claim 7.
9. Vehicle according to claim 8, characterized in that the vehicle comprises a base including the beam (60).
10. A method for manufacturing a module according to any one of claims 1 to 6, the method comprising the following steps: - a centering step (E1) of the second cover (20) with respect to the cell; - a folding step (E2) of the second cover (20), the edge (21) folding down against the first cover (10).