Cell stack, and a jig assembly for assembling a cell stack

Abstract

A cell stack 600 may comprise an array of cells stacked between first 604 and second endcaps to form an elongate face. A cooling plate 620 may comprise a mount portion having an aperture 628a,b, and an engaging portion on the first surface configured to contact with the elongate face of the cell stack. A fastener assembly 300 may comprise a distal portion that is inserted through the aperture and couples with the cells, and a proximal portion that contacts the mount and urges the engaging portion into contact with the cells, and a spacer element which may project from the proximal portion away from the distal portion. The spacer element is intended to contact a battery frame and be deformed towards the distal portion during mounting of the frame. A jig assembly for supporting a fastener for coupling to a reference member is also disclosed.

Description

TECHNICAL FIELD The present disclosure relates to a cell stack and a jig assembly. Aspects of the invention relate to a cell stack, particularly an electric vehicle cell stack, including an array of cells, a cooling plate and fastener assembly, a battery assembly and a vehicle. Aspects of the invention relate to a jig assembly for supporting the fastener assembly during coupling to a reference member of the cell stack. BACKGROUND It is known to provide cell stacks that include an array of cells stacked in parallel along an axis. Battery cells in such arrays abut each other and generally need to be held in a housing or cell support assembly. The array of cells are cooled by securing a cooling plate against a longitudinal face of the series in the cell support assembly. Typically, known cell stacks for vehicles are sufficiently large to require two operators to assembly. The operators require multiple supports and tools to assist assembly, requiring costly equipment to manufacture the cell stack. Using such equipment adds complexity to the assembling process, requiring time to coordinate the various components and adding cost to the manufacturing process. Cell stacks also require electrical grounding, to discharge unwanted electrical charge that may accumulate in use. In particular, the cell support assembly and the cooling plate each require grounding. Pathways for the discharge of unwanted electrical charge on the cell stack require a convenient means to connect to a suitable conductor provide either on the vehicle body or on other components mounted to the vehicle body. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a cell stack having an array of cells, a cooling plate, and a fastener assembly to couple the cooling plate to the array of cells, as claimed in the appended claims. Aspects and embodiments of the invention provide a jig assembly having a static member and a moveable member, in which the moveable member includes a cover element that selectively provides access for a driving tool to urge a fastener assembly to engage a reference member, as claimed in the appended claims. According to another aspect of the invention, there is provided a cell stack including a first endcap, a second endcap, and an array of cells stacked along a first axis between the first endcap and the second endcap, where the array of cells are stacked to form a first elongate face; a cooling plate having a first surface and an opposing, second surface, where the cooling plate includes a mount portion, having an aperture extending through the cooling plate from the first surface to the second surface, and an engaging portion disposed on the first surface, where the engaging portion is configured to provide a contacting engagement with the first elongate face and operably cool the array of cells in use; and a fastener assembly; wherein the fastener assembly includes: a distal portion, configured to be inserted through the aperture and operably couple the distal portion to the array of cells, a proximal portion operably engaged with the mount portion of the cooling plate and configured to urge the engaging portion of the cooling plate into the contacting engagement with the first elongate face when the distal portion is coupled to the array of cells, and at least one spacer element projecting from the proximal portion in a direction away from the distal portion; wherein the at least one spacer element is configured such that, when the cell stack is mounted to a battery frame by urging the first elongate face of the array of cells towards a first battery frame member, the at least one spacer element contactingly abuts the first battery frame member and is deformed by the first battery frame member towards the distal portion. In this way, the fastener assembly provides electrical grounding of both the array of cells and the cooling plate to the first battery frame member. The spacer also allows the cooling plate to be mounted to the array of cells of the cell stack while independently engaging a first battery frame member of a battery frame, particularly allowing for varying height differences between portions of the cooling plate and first battery frame member. Spacing between cooling plate and first battery frame member can thereby accommodate a range of tolerances and part dimensions while maintaining grounding contact. For example, when using multiple fastener assemblies, the respective spacer elements can each be compressed differing amounts while ensuring sufficient contact that each fastener assembly still provides electrical grounding. The cell stack may include a cell support assembly having a first endcap, a second endcap a pair of intermediary brackets extending between the first endcap and the second endcap. The cell support assembly may enclose the array of cells in the cell stack. The array of cells may be stacked to collectively form the first elongate face. The distal portion of the fastener assembly may be operably coupled to the first endcap or to the second endcap of the array of cells. The fastener assembly also provides electrical grounding of the cell support assembly, including the first endcap, second endcap and any intermediary bracket. Furthermore, the fastener assembly is thereby secured to the rigid endcaps of the array of cells. The cell stack may further include a second axis oriented perpendicular to the first axis, wherein the distal portion of the fastener assembly includes an elongate body configured to be operably coupled to the array of cells so that the proximal portion urges the first surface of the cooling plate into the contacting engagement in a direction parallel to the second axis. In this way, the cooling plate may be mounted accurately and squarely to the elongate face. The distal portion and the proximal portion may be separable from, and rotatable relative to, one another. The proximal portion may have a through-hole and an engagement surface proximal to the through-hole. The distal portion may have a head portion configured to bear against the engagement surface so that the head portion causes the proximal portion to urge the first surface of the cooling plate into the contacting engagement with the first elongate face when the distal portion is coupled to the array of cells. In these ways, the fastener assembly may be constructed of a simple bolt and retainer part. The at least one spacer element may be deformed towards the distal portion by the first battery frame member in response to a predetermined clamping force applied by the first battery frame member. The predetermined clamping force may be in a range of from 500 Newtons to 1,000 Newtons. In this way, a spacer element may be adaptable to a range of different battery assemblies. The at least one spacer element may be configured to be deformed a compression distance towards the distal portion by the first battery frame member. The compression distance may be in a range of from 5 millimetres to 10 millimetres, thereby provide a fastener assembly that can accommodate large range tolerances between cell stack and battery frame. The fastener assembly may include a plurality of spacer elements, typically wherein the plurality of spacer elements are disposed around a periphery of the proximal portion. The fastener assembly thereby provides multiple contact points to ensure electrical grounding, and also may distribute the clamping force between each spacer element. The proximal portion of the fastener assembly may include a locating tab oriented to contactingly engage the array of cells and constrain rotational movement of the proximal portion relative to the array of cells as the distal portion is coupled to the array of cells. That is, the locating tab may be mutually shaped to engage on or around a portion of the endcap, prevent rotation of the spacer when the fastener assembly is coupled to the cell stack. The arrangement further ensures electrical grounding of the cell support assembly. The cell stack cooling plate may include a plurality of mount portions, each mount portion of the plurality of mount portions having a respective aperture extending through the cooling plate from the first surface to the second surface. The cell stack may further include a plurality of fastener assemblies, each distal portion of the plurality of fastener assemblies inserted through one of the respective apertures and operably coupled to the array of cells so that each proximal portion of the plurality of fastener assemblies operably engages with a respective mount portion of the plurality of mount portions, and urges the first surface of the cooling plate into the contacting engagement with the first elongate face. In this way, the cell stack includes fastener assemblies to control spacing to the battery frame across the whole area of the cell stack. The clamping force urging the cell stack towards the battery frame is distributed over whole cooling plate surface, reducing localised stress. According to an aspect of the present invention there is provided a jig assembly for supporting a fastener assembly for coupling to a reference member, the jig assembly includes: a static member having an upper surface includes a fulcrum element, and a lower surface includes a contact portion for engaging a reference member, the static member further includes a bore extending from the upper surface to the lower surface along a bore axis; a moveable member, wherein the moveable member includes: - a guide element slidably received within the bore of the static member so that the moveable member is moveable along the bore axis, from a first position, in which an axial distance between the guide element and the fulcrum element is a first axial distance, to a second position, in which the axial distance is a second axial distance, where the first axial distance is greater than the second axial distance; - a cover element, pivotably mounted to the moveable member and configured to engage the fulcrum element so that, as the guide element moves along the bore axis, the cover element is pivoted relative to the support element by the fulcrum element; and - a holder element includes an inlet and an attachment means; wherein the attachment means is configured to releasably hold a fastener assembly in a received position ready to be coupled to a mutually-compatible coupling means of the reference member engaged with the contact portion of the static member; wherein the inlet is configured so that, with the fastener assembly held in the received position, the fastener assembly is actuatable through the inlet by a driving tool in order to urge the distal portion of fastener assembly to couple to the coupling means; and wherein the moveable member is configured so that, in moving the moveable member from the first position to the second position, the cover element selectively covers the inlet so that the proximal portion of the fastener assembly held in the received position is inaccessible to a driving tool. In this way, the jig assembly allows an operator to install a fastener assembly while ensuring that the fastener assembly is only available for coupling to coupling means when it is located in a correct position and / or orientation. Furthermore, a fastener assembly that is incorrectly located is displaced axially from the first position and made inaccessible, reducing the risk of error. The static member may also include a locating member projecting from the lower surface in a direction parallel to the bore axis, wherein the locating member is configured to be received within a reference slot on the reference member. In this way, the jig assembly may be located accurately with respect to coupling means, ensuring the bore axis is correctly aligned, providing easy coupling of the fastener assembly to a reference member. The attachment means may include at least one magnet configured to holding a magnetic proximal portion of the fastener assembly in the received position. The attachment means may include a recessed lip for locating with a proximal portion of the fastener assembly in the received position. In these ways, the fastener assembly may be readily loaded into the jig assembly prior to use. The static member may include an elongate member and the moveable member may include a retainer element engaged to move along the elongate member as the moveable member moves between the first position and the second position. The elongate member may form a shaft of fulcrum element. The elongate member may be aligned in a direction parallel to bore axis. In these ways, the moveable member may be held in a consistent orientation to ensure smooth movement between the first position and the second position. That is, the jig assembly is configured to ensure the guide element slides smoothly along the bore of the static member. The holder element of the attachment means may include at least one arm extending radially away from the attachment means and configured to limit rotational movement of the proximal portion of the fastener assembly as the fastener assembly is coupled to the reference member. The at least one arm thereby ensures the fastener assembly is always loaded into the holder element in the same rotational orientation. The cover element may be pivotably mounted to a support element extending away from the moveable member. The cover element may extend from the support element along a cover axis. In the second position, the cover element may be oriented so that the cover axis is aligned substantially parallel to a normal to the bore axis. In the first position, the cover element may be oriented so that the cover axis is at an angle to the normal to bore axis, where the angle is greater than or equal to 30 degrees. I n this way, the range of movement of the cover element is easily noticeable by the operator. The static member may have a handle so that the jig assembly may be easily held and manipulated by an operator. The bore of the jig assembly may be a first bore extending along a first bore axis, and the static member may also include a second bore extending from the upper surface to the lower surface along a second bore axis. The moveable member of the jig assembly may be a first moveable member with a first guide element slidably received within the first bore axis, and a first cover element pivotably mounted to the first moveable member. The jig assembly may further include a second moveable member including: a second guide element slidably received within the second bore to move between a corresponding first position and a corresponding second position; a second holder element includes a second inlet and a second attachment means correspondingly configured to releasably hold a second fastener assembly in a received position; and a second cover element, pivotably mounted to the second moveable member, and configured to engage the fulcrum element so that, as the second guide element moves along the second bore axis, the second cover element is pivoted relative to the second support element by the fulcrum element; wherein the second moveable member is configured so that, in moving from the corresponding first position to the corresponding second position, the second cover element selectively covers the second inlet so that the proximal portion of a second fastener assembly held in the received position is inaccessible to a driving tool. In this way, a user can couple two fastener assemblies using one jig assembly, in particular so that a first fastener assembly that is located correctly with coupling means remains accessible to a driving tool (and thereby for coupling). In contrast, any fastener incorrectly located is displaced axially from the first position and thereby made inaccessible to the driving tool. The jig assembly again reduces error and coupling time for the operator. The first moveable member may move independently of the second moveable member. The first bore axis may be aligned to be parallel to the second bore axis. According to a further embodiment of the invention, there is provided a battery assembly including any cell stack described here and a battery frame having a first battery frame member and a mutually opposed second battery frame member. The first battery frame member and the second battery frame member are configured to move relative to one another in the direction of a second axis, oriented perpendicular to the first axis of the array of cells of the cell stack, and, when moved in a direction towards one another along the second axis, clamp the cell stack within the battery assembly. The battery assembly may also include a second cell stack having a second elongate face, wherein the second cell stack is mounted to the second surface of the cooling plate so that the cooling plate provide a second contacting engagement with the second elongate face and operably cool the array of cells of the second cell stack in use. According to a still further embodiment of the invention, there is provided a vehicle including a vehicle body, and at least one cell stack or battery assembly as described here, wherein the respective cell stack or battery assembly is attached to the vehicle body. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 shows a perspective view of a jig assembly according to embodiments of the invention, arranged in a first position; FIG. 2 shows a perspective view of the jig assembly of FIG. 1 arranged in a second position; FIG. 3A shows a perspective view of fastener assembly according to embodiments of the invention, in a disassembled arrangement; FIG. 3B and FIG. 3C show the fastener assembly of FIG. 3A in an assembled arrangement; FIG. 4 shows a perspective view of a jig assembly according to embodiments of the invention; FIG. 5A shows a perspective view, and FIG. 5B shows a cross-sectional view along section A-A, of the jig assembly of FIG. 4 in use; FIG. 6 shows an expanded perspective view of the sub-assemblies of a cell stack according to embodiments of the invention; FIG. 7 shows a close up view of FIG. 6; and FIG. 8 shows a schematic view of a vehicle according to embodiments of the invention, with a cell stack mounted to the vehicle. DETAILED DESCRIPTION Certain terminology is used in the following description for convenience only and is not limiting. The words ‘inner’ and ‘outer’ refer to directions toward and away from, respectively, a designated centreline or a geometric centre of an element being described (e.g. central axis), the particular meaning being readily apparent from the context of the description. Further, as used herein, the terms ‘attached’, ‘coupled’, ‘mounted’ are intended to include direct connections between two members without any other members interposed therebetween, as well as, indirect connections between members in which one or more other members are interposed therebetween. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import. Further, unless otherwise specified, the use of ordinal adjectives, such as, ‘first’, ‘second’, ‘third’ etc. merely indicate that different instances of like objects are being referred to and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking or in any other manner. With reference to FIG. 1 to FIG. 4, there are illustrated jig assemblies and fastener assemblies for a cell stack, various features of which are illustrated with reference to certain specific figures. With reference to FIG. 5A to FIG. 7, there is illustrated a jig assembly and cell stack 600 according to embodiments of the invention. FIG. 8 illustrates a vehicle 800 including a cell stack 802 according to an embodiment of the invention. Referring now to FIG. 1 and FIG. 2, there is shown a jig assembly 100 for supporting a fastener assembly for coupling to a reference member (not shown). The fastener assembly may be a fastener assembly 300 as described below with reference to FIG. 3A to FIG. 3C. The jig assembly 100 includes a static member 110 with an upper surface 112 having a fulcrum element 120, and a lower surface 114 having a contact portion 116. The contact portion 116 is configured to engage a reference member, such as cooling plate of a cell stack. The static member 110 includes a bore 118 extending from the upper surface 112 to the lower surface 114 along a bore axis 119. The bore axis 119 extends perpendicular to the lower surface 114 so that when placed on a reference member, the jig assembly 100 rests with the bore axis 119 oriented perpendicular to the reference member surface. The static member 110 further includes a locating member 124 projecting from the lower surface 114. The locating member 124 projects from the lower surface 114 in a direction parallel to the bore axis 119. In this way, the locating member 124 is configured to be received within a reference slot on the reference member to position the jig assembly 100 relative to a mutually-compatible coupling means on the reference member. The locating member 124 has an elongate cross-sectional profile. Thus, once received within the reference slot, the jig assembly 100 is oriented so that a fastener assembly held in the jig assembly is positioned directly proximal to the coupling means of the reference member, and aligned with the axis of the coupling means. The fastener assembly is thereby quickly and conveniently aligned for coupling to the reference member without risk of error. The jig assembly 100 also includes a moveable member 130. The moveable member 130 is moveable relative to the static member 110 as described in more detail below. The moveable member includes a guide element 132, a cover element 134, and a holder element 140. The guide element 132, cover element 134 and holder element 140 are integrally formed as a unitary part so that each moves relative to the static member 110. The guide element 132 is slidably received within the bore 118 of the static member 110 so that the moveable member 130 is moveable along the bore axis 119. The moveable member 130 is moveable from a first position, in which an axial distance between the guide element 132 and the fulcrum element 120 of the static member 110 is a first axial distance, to a second position, in which the axial distance is a second axial distance. The axial distance between the guide element 132 and the fulcrum element 120 is the distance between the guide element 132 and the fulcrum element 120 in the direction of the bore axis 119. In particular, the axial distance is the distance in the direction of the bore axis 119 between the end portion of the guide element 132 that is outside the bore 118, and the fulcrum element 120. The static member 110 includes a handle 102. The handle 102 is mounted to the static member 110 and oriented to allow an operator to conveniently located the jig assembly 100 on the reference member, for example by locating the guide element 132 within the appropriate reference slot. The static member 110 includes a support element 126. The support element 126 forms a shaft between the base of the static member 110 and the fulcrum element 120. The support element 126 extends in a direction parallel to the bore axis 119. The support element 126 includes an elongate member 122 extending along an edge of the support element 126. In the example, the elongate member 122 is rounded profile extending along the edge. The moveable member 130 includes a retainer element 136. The retainer element 136 includes a recess shaped to match the rounded profile of the elongate member 122. In this way, the retainer element 136 engages the support element 126 and slides along the elongate member 122 as the moveable member 130 moves relative to the static member 110 between the first position and the second position. The cover element 134 is pivotably mounted to the moveable member 130. The cover element 134 is pivotably mounted to the moveable member 130 at a pivot 128. The cover element 134 is configured to engage the fulcrum element 120 so that, as the guide element 132 moves along the bore axis 119, the cover element 134 is pivoted relative to the support element 126 by the fulcrum element 120. That is, as the moveable member 130 moves from the first position to the second position the cover element 134 pivots relative to the support element 126. Referring particularly to FIG. 1, the jig assembly 100 is shown in the first position. The guide element 132 is substantially received within the bore 118 and the axial distance is the first axial distance. In the first position, the pivot 128 is below the fulcrum element 120. The cover element 134 rests against the fulcrum element 120 so as to be oriented upwards, that is oriented to extend away from the guide element 132 of the moveable member 130 to which it is mounted. The cover element 134 is spaced apart from the holder element 140 of the moveable member 130. Referring particularly to FIG. 2, the jig assembly 100 is shown in the second position. The guide element 132 is partially external to the bore 118, and the axial distance is the second axial distance. The first axial distance is greater than the second axial distance. In the second position, the pivot 128 is above the fulcrum element 120. The cover element 134 rests against the fulcrum element 120 so as to be oriented horizontally, that is oriented to perpendicular to the direction of the bore axis 119. The cover element 134 is proximal to the holder element 140 of the moveable member 130. The holder element 140 of the moveable member 130 includes an inlet 142 and an attachment means 144. The attachment means 144 is configured to releasably hold a fastener assembly such as described below. The fastener assembly is held by the attachment means 144 in a received position, readyto be coupled to the mutually-compatible coupling means of the reference member engaged with the contact portion 116 of the static member 110. In the example shown, the inlet 142 forms part of an opening extending through the holder element 140. The inlet 142 is provided on an upper surface of the holder element 140. The opening extends from the upper surface to the lower surface. In the example shown, the attachment means includes a magnet. The magnet is provided on the lower surface of the holder element 140 and positioned at the lower portion of the opening. In this way, the attachment means 144 is configured to hold a magnetic proximal portion of a fastener assembly in the received position. The inlet 142 is configured so that, with the fastener assembly held in the received position, the fastener assembly is actuatable through the inlet 142 by a driving tool in order to urge a distal portion of fastener assembly to couple to the coupling means. That is, the inlet 142 is suitably shaped to receive a rotatable bit of a driving tool so that the bit can engage with corresponding features on the proximal portion of the fastener assembly. Actuating the driving tool thereby enables the proximal portion to be rotated by the bit through the inlet 142, urging the fastener assembly towards the coupling means. The moveable member 130 is thereby configured so that, in moving the moveable member 130 from the first position to the second position, the cover element 134 selectively covers the inlet 142 so that the proximal portion of the fastener assembly held in the received position is inaccessible to the driving tool. Stated differently, in the first position, the cover element 134 is oriented so that the inlet 142 is uncovered and the proximal portion is accessible to a driving tool. In the second position, the cover element 134 is oriented so that the inlet 142 is covered and the proximal portion is inaccessible to the driving tool. The holder element 140 includes a pair of arms 146 extending away from the attachment means 144. The arms 146 locate around a spacer element of the fastener assembly so as to limit rotational movement of the proximal portion of the fastener assembly as the proximal portion is rotated by the driving tool. Referring now to FIG. 3A to FIG. 3C, there is shown an example fastener assembly 300. The fastener assembly 300 is suitable for use with the jig assemblies 100, 200 described here. The fastener assembly 300 is provided as two parts. In further examples, the fastener assembly may be a single part. FIG. 3A shows the two parts of fastener assembly 300 in a disassembled arrangement, prior to use. A bolt element includes a head portion 314 and an elongate body 312, and a washer including an engagement surface 324 with a through-hole 322, and a spacer element 326 extending from the engagement surface 324. The through-hole 322 of the washer is sized to allow the elongate body 312 of the bolt element to pass through while retaining the head portion 314 against the engagement surface 324. FIG. 3B and FIG. 3C show the fastener assembly 300 arranged for use so that a distal portion 310 is available to couple to a coupling means in a cell stack, and a proximal portion available to engage a battery frame. The elongate body 312 of the distal portion 310 extends along a central body axis, and is configured to be inserted into coupling means and operably couple within it, for example using mutually compatible screw threads. The coupling means is typically provided on an endcap of a cell stack that includes an array of cells and a cooling plate for cooling the array of cells in use, as described with reference to FIG. 7. In this way, the fastener assembly 300 is operably couplable to the endcap of the array of cells. The proximal portion 320 includes the head portion 314 of the bolt element, abutting the engagement surface 324 so that the spacer element 326 projects away from the proximal portion 320 in a direction away from the distal portion 310. The spacer element 326 extends away from the proximal portion 320 in the direction of the central body axis of the 312. In particular, the spacer element 326 projects away from the proximal portion 320 a distance beyond the head portion 314 so as to provide a compression distance 330 for the spacer element 326. Referring now to FIG. 4, there is shown a jig assembly 200 for supporting a fastener assembly for coupling to a reference member (not shown). The fastener assembly may be a fastener assembly 300 such as described here with reference to FIG. 3A to FIG. 3C. The jig assembly 200 is substantially the same as the jig assembly 100 described with reference to FIG. 1 and FIG. 2, other than there is a first moveable member 230a moveably mounted to the static member 210, and a second moveable member 230b moveably mounted to the static member 210. The static member 210 includes a first bore 218a extending from the upper surface 212 to the lower surface 214 along a first bore axis 219a, as well as a second bore 218b extending from the upper surface 212 to the lower surface 214 along a second bore axis 219b. The first bore axis 219a is oriented parallel to the second bore axis 219b. Each of the first moveable member 230a and the second moveable member 230b is the same as the moveable member 130 described above, and configured to move relative to the static member 210 independently of the other moveable member 230a, 230b. That is, the first moveable member 230a and the second moveable member 230b are moveable relative to the static member 210 independently of one another. Thus, each moveable member 230a, 230b includes a respective guide element 232a, 232b, holder element 240a, 240b and cover element 234a, 234b. The guide element 232a of the first moveable member 230a is received within the first bore axis 219a. The guide element 232b of the second moveable member 230b is received within the second bore axis 219b. In this way, the second cover element 234b is pivotably mounted to the second moveable member 230b, and configured to engage the fulcrum element 220 so that, as the second guide element 232b moves along the second bore axis 219b, the second cover element 234b is pivoted relative to the second support element 226 by the fulcrum element 220. The second moveable member 230b is moveable from a corresponding first position to a corresponding second position. In moving from the corresponding first position to the corresponding second position, the second cover element 234b selectively covers the second inlet 242b so that the proximal portion of a second fastener assembly held in the received position is inaccessible to a driving tool. The locating member 224 projects from the lower surface 214 in a direction parallel to the first and second bore axes 219a, 219b. The locating member 224 has a cross-sectional shape to accommodate both the first bore 218a and the second bore 218b adjacent to one another. In the example, the locating member 224 has an oval cross-sectional shape. The first moveable member 230a and second moveable member 230b are provided so that they hold respective fastener assemblies on opposing sides of the locating member 224. In this way, the jig assembly 200 may be used with a cell stack including one or more reference slots configured to receive the locating member 224 to selectively engage either a fastener assembly held by the first moveable member 230a or a fastener assembly held be the second moveable member 230b. As shown in FIG. 4, the first moveable member 230a is shown in the first position, such that the first cover element 234a is pivoted to be oriented away from the first holder element 240a. The first inlet 242a is uncovered so that the head portion of the fastener assembly held in the received position by the first holder element 240a is accessible to a driving tool. As shown in FIG. 4, the second moveable member 230b is shown in the second position, such that the second cover element 234b is pivoted to be oriented horizontally, that is towards the second holder element 240b. The second inlet 242b is covered by the second cover element 234b and thereby covers the second inlet 242b holding a second fastener assembly in a corresponding received position. The head portion of the second fastener assembly is inaccessible to a driving tool. Referring additionally to FIG. 5A and FIG. 5B, there is shown the jig assembly 200 in use with the example fastener assembly 300, in which the first moveable member 230a is disposed in its first position, and the second moveable member 230b is disposed in its second position. As shown particularly in the cross-sectional view of FIG. 5B, the jig assembly 200 is mounted to a cooling plate 620 so that the locating member 224 is received in a reference slot 626a through the cooling plate 620. The cooling plate 620, reference slots 626a, 626b and the other cell stack features are described in further detail below, with reference to FIG. 6 and FIG. 7. Prior to mounting the fastener assembly 300 to the cooling plate 620, a first fastener assembly 300 is loaded into the first holder element 240a so that the head portion is held in the received position and positioned for engaging a driving tool. A second fastener assembly 300 is loaded into the second holder element 240b so that the corresponding head portion is held in the received position and is also positioned for engaging a driving tool. With the fastener assembly 300 in an upright position, each fastener assembly 300 hangs from the underside of its holder element 240a, 240b. Each of the first moveable member 230a and the second moveable member 230b are positioned in their first position causing the respective holder element 240a, 240b to be pivoted to be oriented upwards, such that each inlet 242a, 242b is open to receive a driving tool. That is, under their own weight, each moveable member 230a, 230b rests at the lowest position within the respective bore 218a, 218b. Each guide element 232a, 232b is fully received within the respective bore 218a, 218b. To use the jig assembly 200 to couple the first fastener assembly 300 to the cell stack, the locating member 224 is inserted into a corresponding reference slot 626a in the cooling plate 620 (FIG. 7). The reference slot 626a is positioned adjacent a first aperture 628a in the cooling plate 620 for receiving the fastener assembly 300 held by the first holder element 240a. The first aperture 628a is positioned on the cooling plate 620 outwards of the reference slot 626a. As shown, with the cooling plate 620 mounted to the cell stack 600, the first aperture 628a is aligned with a coupling means 608 of the first endcap 604. Accordingly, as the locating member 224 is received into the reference slot 626a, the elongate body 312 of the first fastener assembly 300 is received through the first aperture 628a and engage the coupling means 608 without displacing the first moveable member 230a to which it is mounted. The first moveable member 230a remains in its first position with respect to the static members 210 of the jig assembly 200. The first cover element 234a remains oriented away from the first holder element 240a, and the first inlet 242a remains accessible to a driving tool. The cooling plate 620 does not have a corresponding aperture to receive the fastener assembly 300 held by the second holder element 240b. Accordingly, as the locating member 224 is inserted into the reference slot 626a of the cooling plate 620, the second fastener assembly 300 is retained against the upper surface of the cooling plate 620, causing the second holder element 240b to move relative to the static member 210 of the jig assembly 200. This relative movement thereby causes the second cover element 234b to pivot around the fulcrum element 220 and towards the second holder element 240b. With the locating member 224 fully received in the reference slot 626a, the lower surface 214 of the static member 210 rests on the upper surface of the cooling plate 620. The second moveable member 230b is displaced to its second position relative to the static member 210. The second cover element 234b is oriented towards the second holder element 240b, covering the second inlet 242b. The second inlet 242b is now inaccessible to a driving tool. The jig assembly 200 thereby ensures an operator will only actuate the fastener assembly 300 correctly located for coupling with a driving tool. In contrast, with the lower surface 214 resting on the cooling plate 620, the first moveable member 230a is not displaced from its first position. Instead the first holder element 240a holds the corresponding elongate body 312 within the first aperture 628a and ready for coupling to the coupling means 608 by inserting a driving tool though the first inlet 242a to engage the head portion 314 of the fastener assembly 300. Furthermore, due to the configuration of the lower surface 214 and bore axis 219a, the fastener assembly 300 is correctly aligned with the coupling means 608 for coupling without operator manipulation. The risk of error during coupling is reduced and assembly time is shortened (improved). With the first fastener assembly 300 coupled to the cell stack, the operator can lift the jig assembly 200 from the cooling plate 620, separating the first fastener assembly 300 from the first holder element 240a. Lifting the jig also allows the second moveable member 230b to return to its first position, while retaining the second fastener assembly 300 in the received position. Furthermore, with the second moveable member 230b returned to its first position, the corresponding cover element 234a is oriented away from the moveable member 230b so that the second inlet 242b is accessible to a driving tool. The jig assembly 200 is then ready for use coupling the second fastener assembly 300 to the cell stack. The second fastener assembly 300 is coupled to the cooling plate 620 using a second reference slot 626b to receive the locating member 224 and a second aperture 628b on the cooling plate 620. Typically, the second reference slot 626b and the second aperture 628b are on an opposing side of the upper face of the cooling plate 620 with the second aperture 628b positioned outwards of the second reference slot 626b, so that the second fastener assembly 300 locates through the second aperture 628b without displacing the second moveable member 230b from its first position. In this way, the second fastener assembly 300 may be located through a second aperture 628b, and engage a second coupling means, without requiring the operator to re-orientate the jig assembly 200. The operator is thus able to load the jig assembly 200 with two fastener assemblies 300 and position the jig assembly 200 on an underlying cooling plate 620 to selectively fix each to an appropriate position. The jig assembly 200 indicates to the operator which of the two inlets 242a, 242b should receive the driving tool to couple the correct fastener assembly 300 of the two loaded into the jig assembly 200. Furthermore the need for the operator to manipulate the fastener assemblies 300 is reduced, reducing the risk of errors and decreasing assembly time. Referring now to FIG. 6 and FIG. 7, there is shown a cell stack 600 including a cooling plate 620. In FIG. 6 the cooling plate 620 is spaced from the remainder of the cell stack 600. In FIG. 7, the fastener assemblies 300 are shown oriented for insertion through the apertures 628a, 628b, without showing a corresponding jig assembly retaining the fastener assemblies 300. The cell stack 600 includes a cell support assembly 602, a first carrier assembly 610a mounted to a first side of the cell support assembly 602, and a second carrier assembly 610b mounted to a second side of the cell support assembly 602. The cell support assembly 602, first carrier assembly 610a, and second carrier assembly 610b are each a sub-assembly of the cell stack 600. The cell support assembly 602 includes a first endcap 604, a second endcap 606, and a pair of brackets 603 secured between the first endcap 604 and the second endcap 606. Each bracket 603 extends in a direction parallel to a first axis 614. A first bracket 603 is disposed on the first side of the cell support assembly 602. A second bracket is disposed on the second side of the cell support assembly 602. The cell stack 600 includes an array of cells 601 stacked along a first axis 614 between the first endcap 604 and the second endcap 606. The array of cells 601 is stacked so that the cells form a first elongate face to which the cooling plate 620 is mounted. A first cell terminal of each cell of the array of cells 601 is disposed on the first side of the cell support assembly 602. A second cell terminal of each cell is disposed on the second side of the cell support assembly 602. As will be appreciated, the first cell terminals and second cell terminals may be disposed in various configurations on the respective cells of the array of cells 601. Each carrier assembly 610a, 610b includes a series of busbars 612 mounted to the carrier assembly 610a 610b The first carrier assembly 610a and the second carrier assembly 610b are substantially the same, other than the arrangement of busbars 612 on each carrier assembly 610a, 610b. The cooling plate 620 has a first surface 621 and an opposing, second surface 622. The cooling plate also includes a series of mount portions 624 and an engaging portion disposed on the first surface. The mount portions 624 each have an aperture 628a, 628b extending through the cooling plate from the first surface to the second surface. The engaging portion is configured to provide a contacting engagement with the first elongate face and operably cool the array of cells 601 in use, for example by including a series of undulations to conform to the array of cells. The first endcap 604 includes coupling means 608 for coupling to the elongate body of a fastener assembly that is inserted through the aperture 628a, 628b, such as theelongatebody 312 of the fastener assembly 300 shown in FIG. 7 and described with reference to FIG. 3. In the example, the first endcap 604 also includes reference slots that align with the reference slots 626a, 626b of the cooling plate 620 when mounted to the array of cells 601. In this way, when using a jig assembly, the locating member may be received by the reference slots of both the cooling plate 620 and the first endcap 604, ensuring alignment and of the loaded fastener assembly. To assemble the cell stack 600, the cooling plate 620 is mounted to the first elongate face of the array of cells 601. A fastener assembly 300, shown prior to assembly in FIG. 7, is used to couple each mount portion 624 of the cooling plate 620 to the cell support assembly 602. Details of the fastener assembly 300 are described with reference to FIG. 3. The distal portion 310 of the fastener assembly 300 is inserted through the aperture 628a, 628b to engage one of the coupling means 608. The proximal portion 320 of the fastener assembly 300 is then actuated, for example by an operator using a driving tool, to couple the elongate body 312 to the coupling means 608. Concurrently, the proximal portion 320 urges the engaging portion of the cooling plate 620 into contacting engagement with the first elongate face of the array of cells. With the fastener assembly 300 coupled to the coupling means 608, the spacer element 326 of the fastener assembly 300 projects away from the proximal portion in a direction away from the distal portion. The spacer element 326 also projects away from the cooling plate 620. In this way, when the cell stack 600 is mounted to a battery frame by urging the first elongate face of the array of cells towards a first battery frame member by urging the first elongate face towards the other cell stack, then each spacer element contactingly abuts the battery frame is deformed towards the distal portion. The spacer element 326 thereby provides a compression distance 330 when the cell stack 600 is mounted to the battery frame ensuring an effective contact with the battery frame. The fastener assembly 300 thereby provides an effective electrical grounding pathway, in order to discharge unwanted electrical charge from the cell stack. In particular, the spacer element 326 ensures each fastener assembly 300 provides an effective grounding pathway to a suitable conductor on the vehicle body from each of the array of cells, the cell support assembly 602, and the cooling plate 620. Optionally, the fastener assemblies 300 may be coupled to the cell stack 600 using a jig assembly such as the examples described above. For example, the fastener assemblies 300 may be coupled to the cell stack 600 using the jig assembly 200 including a first moveable member 230a and a second moveable member 230b each with a fastener assembly 300 loaded in the respective holder element 240a, 240b. The locating member 224 may be inserted first into the first reference slot 626a so that the first fastener assembly 300 is coupled through the aperture 628a while the second fastener assembly 300 is inaccessible to a driving tool. The locating member 224 may then be transferred to the second reference slot 626b to allow the second fastener assembly 300 to be coupled through the second aperture 628b without changing the orientation of the jig assembly 200. Alternatively, the operator may couple the second fastener assembly 300 before the first fastener assembly 300.1 n either case, accurate alignment of the corresponding fastener assembly 300 with the coupling means 608 is ensured, and the operator cannot unintentionally access the head portion 314 of the other fastener assembly 300 with the driving tool. Referring now FIG. 8, a vehicle 800 is shown including a vehicle body 801 with a cell stack 802 mounted to it for use. The cell stack 802 may be mounted to a battery frame of a battery assembly, or mounted directly the vehicle body 801, by using the spacer element of the fastener assemblies to provide an effective grounding pathway to a suitable conductor for unwanted electrical charge on the cell stack 802. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

1. A cell stack comprising:a first endcap, a second endcap, and an array of cells stacked along a first axis between the first endcap and the second endcap, wherein the array of cells are stacked to form a first elongate face;a cooling plate having a first surface and an opposing, second surface, wherein the cooling plate comprises a mount portion, having an aperture extending through the cooling plate from the first surface to the second surface, and an engaging portion disposed on the first surface, wherein the engaging portion is configured to provide a contacting engagement with the first elongate face and operably cool the array of cells in use; anda fastener assembly;wherein the fastener assembly comprises:a distal portion, configured to be inserted through the aperture and operably couple the distal portion to the array of cells;a proximal portion operably engaged with the mount portion of the cooling plate and configured to urge the engaging portion of the cooling plate into the contacting engagement with the first elongate face when the distal portion is coupled to the array of cells; andat least one spacer element projecting from the proximal portion in a direction away from the distal portion;wherein the at least one spacer element is configured such that, when the cell stack is mounted to a battery frame by urging the first elongate face of the array of cells towards a first battery frame member, the at least one spacer element contactingly abuts the first battery frame member and is deformed by the first battery frame member towards the distal portion.

2. A cell stack according to claim 1, wherein the distal portion of the fastener assembly is operably coupled to the first endcap or to the second endcap of the array of cells.

3. A cell stack according to claim 1 or 2, further comprising a second axis oriented perpendicular to the first axis, wherein the distal portion of the fastener assembly comprises an elongate body configured to be operably coupled to the array of cells so that the proximal portion urges the first surface of the cooling plate into the contacting engagement in a direction parallel to the second axis.

4. A cell stack according to any one of claims 1 to 3, wherein the distal portion and proximal portion are separable from, and rotatable relative to, one another.

5. A cell stack according to claim 4, wherein the proximal portion has a through-hole and an engagement surface proximal to the through-hole, and wherein the distal portion has a head portion configured to bear against the engagement surface so that the head portion causes the proximal portion to urge the first surface of the cooling plate into the contacting engagement with the first elongate face when the distal portion is coupled to the array of cells.

6. A cell stack according to any one of claims 1 to 5, wherein the at least one spacer element is deformed towards the distal portion by the first battery frame member in response to a predetermined clamping force applied by the first battery frame member, and wherein the predetermined clamping force in a range of from 500 Newtons to 1,000 Newtons.

7. A cell stack according to any one of claims 1 to 6, wherein the at least one spacer element is configured to be deformed a compression distance towards the distal portion by the first battery frame member, and wherein the compression distance is a range of from 5 millimetres to 10 millimetres.

8. A cell stack according to any one of claims 1 to 7, wherein the at least one spacer element comprises a plurality of spacer elements, and wherein the plurality of spacer element are disposed around a periphery of the proximal portion.

9. A cell stack according to any one of claims 1 to 8, wherein the proximal portion further comprises a locating tab oriented to contactingly engage the array of cells and constrain rotational movement of the proximal portion relative to the array of cells as the distal portion is coupled to the array of cells.

10. A cell stack according any one of claims 1 to 9, wherein the at least one spacer element comprises a plurality of spacer elements.

11. A cell stack according to any one of claims 1 to 10, wherein the cooling plate comprises a plurality of mount portions, each mount portion of the plurality of mount portions having a respective aperture extending through the cooling plate from the first surface to the second surface, andwherein the cell stack further comprises a plurality of fastener assemblies, each distal portion of the plurality of fastener assemblies inserted through one of the respective apertures and operably coupled to the array of cells so that each proximal portion of the plurality of fastener assemblies operably engages with a respective mount portion of the plurality of mount portions, and urges the first surface of the cooling plate into the contacting engagement with the first elongate face.

12. A cell stack according to claim 11, wherein the respective distal portions of a first proportion of the plurality of fastener assemblies is operably coupled to the first endcap of the array of cells, and wherein the respective distal portions of a second proportion of the plurality of fastener assemblies is operably coupled to the second endcap of the array of cells.

13. A battery assembly comprising:the cell stack of any one of claims 1 to 12; anda battery frame having a first battery frame member and a mutually opposed second battery frame member, wherein the first battery frame member and the second battery frame member are configured to move relative to one another in the direction of a second axis, oriented perpendicular to the first axis of the array of cells and, when moved in a direction towards one another along the second axis, clamp the cell stack within the battery assembly.

14. A battery assembly of claim 13, further comprising a second cell stack having a second elongate face;wherein the second cell stack is mounted to the second surface of the cooling plate so that the respective cooling plate provides a second contacting engagement with the second elongate face and operably cool the array of cells of the second cell stack in use.

15. A vehicle comprising:a vehicle body, and at least one of:the cell stack of any one of claims 1 to 12, wherein the respective cell stack is attached to the vehicle body, orthe battery assembly of claim 13 of claim 4, wherein the respective battery assembly is attached to the vehicle body.

16. A jig assembly, for supporting a fastener assembly for coupling to a reference member, the jig assembly comprising:a static member having an upper surface comprising a fulcrum element, and a lower surface comprising a contact portion for engaging a reference member, the static member further comprising a bore extending from the upper surface to the lower surface along a bore axis; anda moveable member, wherein the moveable member comprises:a guide element slidably received within the bore of the static member so that the moveable member is moveable along the bore axis, from a first position, in which an axial distance between the guide element and the fulcrum element is a first axial distance, to a second position, in which the axial distance is a second axial distance, wherein the first axial distance is greater than the second axial distance;a cover element, pivotably mounted to the moveable member and configured to engage the fulcrum element so that, as the guide element moves along the bore axis, the cover element is pivoted relative to the support element by the fulcrum element; anda holder element comprising an inlet and an attachment means;wherein the attachment means is configured to releasably hold a fastener assembly in a received position ready to be coupled to a mutually-compatible coupling means of the reference member engaged with the contact portion of the static member;wherein the inlet is configured so that, with the fastener assembly held in the received position, the fastener assembly is actuatable through the inlet by a driving tool in order to urge the distal portion of fastener assembly to couple to the coupling means; andwherein the moveable member is configured so that, in moving the moveable member from the first position to the second position, the cover element selectively covers the inlet so that the proximal portion of the fastener assembly held in the received position is inaccessible to a driving tool.

17. The jig assembly of claim 16, wherein the static member further comprises a locating member projecting from the lower surface in a direction parallel to the bore axis, wherein the locating member is configured to be received within a reference slot on the reference member.

18. The jig assembly of claim 16 or 17, wherein the attachment means comprises at least one magnet configured to hold a magnetic proximal portion of the fastener assembly in the received position.

19. The jig assembly of any one of claims 16 to 18, wherein the static member includes an elongate member and the moveable member includes a retainer element engaged to move along the elongate member as the moveable member moves between the first position and the second position.

20. The jig assembly of any one of claims 16 to 19, wherein the holder element comprises at least one arm extending radially away from the attachment means and configured to limit rotational movement of the proximal portion of the fastener assembly as the fastener assembly is coupled to the reference member.

21. The jig assembly of any one of claims 16 to 20, wherein the cover element is pivotably mounted to a support element extending away from the moveable member, and wherein the cover element extends from the support element along a cover axis, and wherein, in the second position, the cover element is oriented so that the cover axis is aligned substantially parallel to a normal to the bore axis.

22. The jig assembly of claim 21, wherein in the first position, the cover element is oriented so that the cover axis is at an angle to the normal to bore axis, wherein the angle is greater than or equal to 30 degrees.

23. The jig assembly of any one of claims 16 to 22, wherein the static member has a handle.

24. The jig assembly of any one of claims 16 to 23, wherein the bore is a first bore extending along a first bore axis, and wherein the static member further comprises a second bore extending from the upper surface to the lower surface along a second bore axis, andwherein the moveable member is a first moveable member comprising a first guide element slidably received within the first bore axis, and a first cover element pivotably mounted to the first moveable member, andwherein the jig assembly further comprises a second moveable member comprising:a second guide element slidably received within the second bore to move between a corresponding first position and a corresponding second position, a second holder element comprising a second inlet and a second attachment means correspondingly configured to releasably hold a second fastener assembly in a received position; and a second cover element, pivotably mounted to the second moveable member, and configured to engage the fulcrum element so that, as the second guide element moves along the second bore axis, the second cover element is pivoted relative to the second support element by the fulcrum element;wherein the second moveable member is configured so that, in moving from the corresponding first position to the corresponding second position, the second cover element selectively covers the second inlet so that the proximal portion of a second fastener assembly held in the received position is inaccessible to a driving tool.

25. The jig assembly of claim 24, wherein the first bore axis is aligned to be parallel to the second bore axis.Application No: GB2402593.4Examiner:Dr Andrew WilliamsClaims searched: 1-15Date of search: 22 August 2024Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance Y 1-15 WO 2011 / 013767 Al (SANYO ELECTRIC CO) Figure 16; paragraphs 0039-0043. Integer 1 of combined inventive step. Y 1-15 WO 2014 / 155609 Al (HITACHI AUTOMOTIVE SYSTEMS LTD) Figure 2; paragraphs 0018. Integer 1 of combined inventive step. Y 1-15 US 2015 / 0171492 Al (RAMSAYER et al.) Figure 1. Integer 1 of combined inventive step. Y 1-15 Keystone Electronics Corp., 2015, Lockwasher Terminal Lug for #4 Stud P / N 7314, keyelco.com, [online], Available from: https: / / web.archive.Org / web / 20150609182635 / https: / / www.keyelco.com / product.cfm / Lockwasher-Terminal-Lugs / 7314 / product_id / 1272, [22 August 2024] Integer 2 of combined inventive step. Y 1-15 Concord Electronics (Amazon), 2019, MS77068-3, Lockwasher Terminal - Bronze -Electro Tin Plated -.169" (4.29mm) -Dim. A (50 Items), amazon.com, [online], Available from: https: / / www.amazon.com / MS77068-3-Lockwasher-Terminal-Bronze- Electro / dp / B07ZJWH7Yl, [22 August 2024] Integer 2 of combined inventive step. Y 1-15 Master Instruments Pty Ltd, 2023, STA-M5TOF2 Terminal Adaptors M5 to F2 Faston, master-instruments.com.au, [online], Available from: https: / / web.archive.org / web / 20230319014008 / https: / / www.master-instruments.com.au / products / 65715 / STA-M5TOF2.html, [22 August 2024] Integer 2 of combined inventive step.Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of same category. before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From HO IM 0050 / 204 01 / 01 / 2021 B25B 0023 / 08 01 / 01 / 2006 B25B 0023 / 12 01 / 01 / 2006 HO IM 0010 / 613 01 / 01 / 2014 HO IM 0010 / 6554 01 / 01 / 2014 HO IM 0050 / 244 01 / 01 / 2021Application No: GB2402593.4Examiner: Dr Andrew WilliamsClaims searched: 16-25Date of search: 12 March 2025Patents Act 1977Further Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance A - CN 203471299 U (WENZHOU T1ANQIU ELECTRICAL CO LTD) Figure 1; summary of invention. A - CN 204308539 U (YANG MINGSHUN) Figures 3-5; description.Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if p Document published on or after the declared priority date but combined with one or more other documents of same category. before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From HO IM 0050 / 204 01 / 01 / 2021 B25B 0023 / 08 01 / 01 / 2006 B25B 0023 / 12 01 / 01 / 2006 HO IM 0010 / 613 01 / 01 / 2014 HO IM 0010 / 6554 01 / 01 / 2014 HO IM 0050 / 244 01 / 01 / 2021

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