Battery module system, assembly, and manufacturing method
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- ELECTRIC POWER SYSTEMS INC
- Filing Date
- 2024-04-26
- Publication Date
- 2026-06-09
AI Technical Summary
【0007】 本明細書に開示されるバッテリシステムは、電動車両(例えば、電動航空機、電動船舶、電動潜水艦、その他これらに類するもの)に電力を供給可能なように構成され得るものである。当該バッテリシステムは、相互に結合してエネルギー貯蔵装置を構成する複数のバッテリモジュールを備える。複数のバッテリモジュールはそれぞれ、電気コネクタを介して隣接するバッテリモジュールに電気的に結合されるように構成されて、モジュール間に電気的経路を形成する。同様に、複数のバッテリモジュールの各々は、通信コネクタを介して通信経路を形成するように構成されている。これに関連して、複数のバッテリモジュールの各々は、組み立ての容易性を考慮して設計及び構成されている。言い換えれば、第1のバッテリモジュールの第1の電気コネクタ(例えばオスコネクタ)及び通信コネクタ(例えばオスコネクタ)を、第2のバッテリモジュールの電気コネクタ(例えばメスコネクタ)及び通信コネクタ(例えばメスコネクタ)に向かってかつその中にスライドさせることに応じて形成され得る、コネクタインターフェース及び通信インターフェースを有することによって、電動車両用の一般的なバッテリシステムに比べて、本バッテリシステムの組立は迅速かつ効率的に行うことが可能である。
Smart Images
Figure 2026518547000001_ABST
Abstract
Claims
1. A battery system for supplying power to an electric vehicle, A plurality of battery modules, each of the plurality of battery modules is configured to be coupled to an adjacent battery module of the plurality of battery modules to form a battery, and each of the plurality of battery modules is A housing comprising a first lateral wall, a second lateral wall, a first wide side wall, a second wide side wall, a bottom panel, and a lid, wherein the first lateral wall is longitudinally separated from the second lateral wall, and the first wide side wall is laterally separated from the second wide side wall, Multiple cells arranged within the housing, A first vane plate coupled to the first wide side wall, wherein a first fluid tube is defined at least partially between the first vane plate and the first wide side wall, A first port, which is arranged through the first lateral wall, and which is in fluid communication with the first fluid pipe, A second port, positioned through the second lateral wall, the second port is in fluid communication with the first fluid pipe, The plurality of battery modules, including, The assembly configuration of the battery system, wherein the assembly configuration is configured to form the battery by electrically coupling each of the plurality of battery modules with each other, A piping system configured to receive fluid during the charging of the battery and to provide thermal management for the plurality of battery modules during the charging, wherein the piping system includes an inlet, an outlet, and a fluid path extending from the inlet through at least a portion of the plurality of battery modules to the outlet, A first straight pipe extending from the second port of the first battery module of the plurality of battery modules to the first port of the second battery module of the plurality of battery modules, wherein the first straight pipe is fixed to the second port of the first battery module of the plurality of battery modules and the first port of the second battery module of the plurality of battery modules, The assembly configuration includes, The battery system, including the battery system.
2. Each of the aforementioned plurality of battery modules is A second vane plate coupled to the second wide side wall, wherein a second fluid tube is defined at least partially between the second vane plate and the second wide side wall, A third port is arranged through the first lateral wall, and the third port is in fluid communication with the second fluid pipe, A fourth port is arranged through the second lateral wall, and the fourth port is in fluid communication with the second fluid pipe, The battery system according to claim 1, further comprising:
3. The battery system according to claim 2, wherein the assembly configuration further includes a second straight pipe extending from the fourth port of the first battery module of the plurality of battery modules to the third port of the second battery module of the plurality of battery modules.
4. The battery system according to claim 1, wherein the first port and the second port each include a central axis aligned longitudinally with respect to the first battery module and the second battery module of the plurality of battery modules.
5. Each of the aforementioned plurality of battery modules is A first connector located within the first port, A second connector disposed within the second port, wherein the first connector and the second connector each include an annular groove, It further includes, The assembly configuration includes a first O-ring positioned in the annular groove of the second connector of the first battery module of the plurality of battery modules, and a second O-ring positioned in the annular groove of the first connector of the second battery module of the plurality of battery modules. The battery system according to claim 1.
6. The battery system according to claim 5, wherein in the assembly configuration, the first O-ring is compressed between the annular groove of the second connector of the first battery module of the plurality of battery modules and the outer diameter surface of the first straight pipe, and the second O-ring is compressed between the annular groove of the first connector of the second battery module of the plurality of battery modules and the outer diameter surface of the first straight pipe.
7. The battery system according to claim 1, wherein in the assembly configuration, the fluid path is at least partially defined to go from the first port of the first battery module of the plurality of battery modules, through the first fluid pipe of the first battery module of the plurality of battery modules, out of the second port of the first battery module of the plurality of battery modules, through the first straight pipe, into the first port of the second battery module of the plurality of battery modules, through the first fluid pipe of the second battery module of the plurality of battery modules, out of the second port of the second battery module of the plurality of battery modules, through the second straight pipe, to at least a portion of the remaining battery modules of the plurality of battery modules.
8. The battery system according to claim 1, wherein the assembly configuration further includes a second straight pipe extending from the second port of the second battery module of the plurality of battery modules to the first port of the third battery module of the plurality of battery modules, the second straight pipe being fixed to the second port of the second battery module of the plurality of battery modules and the first port of the third battery module of the plurality of battery modules.
9. The battery system according to claim 8, wherein the piping system does not include a fluid source, and the piping system is configured such that there is no fluid placed therein during the discharge of the battery.
10. An electric aircraft comprising a battery system for the aircraft 100 according to claim 9, wherein the inlet and outlet of the piping system are each configured to be coupled to a fluid source located away from the electric aircraft during charging of the battery system.
11. The electric aircraft according to claim 10, wherein the piping system is configured to receive fluid during charging, and the piping system is configured to be free of fluid during operation of the electric aircraft.
12. The battery system according to claim 1, wherein the first straight pipe has no joints, adapters, or attachment mechanisms.
13. The battery system according to claim 1, wherein the housing has a first lateral wall, a second lateral wall, a first wide lateral wall, a second wide lateral wall, a lid, and a bottom panel that form a substantially rectangular parallelepiped shape.
14. Each of the aforementioned plurality of battery modules is A first joint, wherein the first lateral side wall is fused to the first wide side wall by the first joint, A second joint, wherein the first lateral side wall is fused to the second wider side wall along the second joint, A third joint, wherein the second lateral side wall is fused to the first wide side wall along the third joint, A fourth joint, wherein the second lateral side wall is fused to the second wide side wall along the fourth joint, The battery system according to claim 1, including the following:
15. The battery system according to claim 14, wherein each of the plurality of battery modules includes a fifth seam, the lid is fused along the fifth seam to the first lateral side wall, the second lateral side wall, the first wide side wall, and the second wide side wall, and the fifth seam defines a first peripheral edge around the lid.
16. The battery system according to claim 15, wherein each of the plurality of battery modules includes a sixth seam, the bottom panel is fused along the sixth seam to the first lateral side wall, the second lateral side wall, the first wide side wall, and the second wide side wall, and the sixth seam defines a second periphery around the panel.
17. Each of the aforementioned plurality of battery modules is A first electrical connector coupled to the first side wall of the housing, A second electrical connector coupled to the second side wall of the housing, It further includes, The assembly configuration includes the second electrical connector of the first battery module of the plurality of battery modules, which is directly coupled to the first electrical connector of the second battery module of the plurality of battery modules. The battery system according to claim 1.
18. Each of the aforementioned plurality of battery modules is A first communication connector coupled to the first side wall of the housing, A second communication connector coupled to the second side wall of the housing, Includes, The assembly configuration includes the second communication connector of the first battery module of the plurality of battery modules, which is directly coupled to the first communication connector of the second battery module of the plurality of battery modules. The battery system according to claim 17.
19. The battery system according to claim 18, wherein the assembly configuration includes an electrical path extending from the first electrical connector of the first battery module of the plurality of battery modules, through the plurality of cells of each of the plurality of battery modules, to the second electrical connector of the last battery module of the plurality of battery modules.
20. The first electrical connector of the first battery module of the plurality of battery modules is the negative terminal of the battery. The second electrical connector of the last battery module of the plurality of battery modules is the positive terminal of the battery. The battery system according to claim 19.
21. It is a battery module, A metal housing including multiple side walls that form a roughly rectangular parallelepiped shape, A plurality of metal anchors forming an anchor structure for the metal housing, wherein each of the plurality of metal anchors is fused to the side wall of the plurality of side walls, each of the plurality of metal anchors defines a blind opening, and the anchor structure is A first anchor substructure including a first set of the plurality of metal anchors coupled to the first side walls of the plurality of side walls, and a second set of the plurality of metal anchors coupled to the second side walls of the plurality of side walls, A second anchor substructure including a third set of the plurality of metal anchors coupled to the first side wall of the plurality of side walls, and a fourth set of the plurality of metal anchors coupled to the third side wall of the plurality of side walls, Multiple cells arranged within the aforementioned metal housing, The plurality of metal anchors, including, The battery module, including the battery module.
22. The plurality of side walls include a first wide side wall, a second wide side wall, a first lateral side wall, a second lateral side wall, an upper side wall, and a lower side wall. The first side wall among the plurality of side walls is one of the first lateral side wall, the second lateral side wall, the upper side wall, and the lower side wall. The second side wall among the plurality of side walls is adjacent to the first side wall of the plurality of side walls and is another one of the first lateral side wall, the second lateral side wall, the upper side wall, and the lower side wall with respect to the first side wall of the plurality of side walls. The third side wall of the plurality of side walls is adjacent to the first side wall of the plurality of side walls and is separated from the second side wall of the plurality of side walls and from the first side wall of the plurality of side walls and the second side wall of the plurality of side walls, from another one of the first side wall, the second side wall, the upper side wall, and the lower side wall. The battery module according to claim 21.
23. A first bracket attached to each of the first set of the plurality of metal anchors and the second set of the plurality of metal anchors, A second bracket attached to each of the third set of the plurality of metal anchors and the fourth set of the plurality of metal anchors, The battery module according to claim 22, further comprising:
24. The battery module according to claim 23, wherein the first bracket and the second bracket each comprise a first flange that engages with the first side wall of the plurality of side walls, a second flange that engages with either the second side wall of the plurality of side walls or the third side wall of the plurality of side walls, and a third flange spaced apart from either the first wide side wall or the second wide side wall.
25. The battery module according to claim 24, wherein the first bracket and the second bracket each include a fourth flange spaced apart from the other of the first wide sidewall or the second wide sidewall.
26. The first bracket and the second bracket each have a first attachment opening and a second attachment opening, The battery module according to claim 24, wherein the first attachment opening is disposed through one of the first flange or the second flange, and the second attachment opening is disposed through the third flange.
27. The battery module according to claim 26, wherein the first attachment opening and the second attachment opening of the first bracket and the second bracket, respectively, are provided with nuts configured to receive fasteners.
28. The first flange defines a first plane, the second flange defines a second plane, and the third flange defines a third plane. The battery module according to claim 24, wherein the first plane, the second plane, and the third plane are each substantially perpendicular to each other.
29. The battery module according to claim 21, wherein each of the first set, second set, third set, and fourth set of the plurality of metal anchors includes at least two metal anchors.
30. The battery module according to claim 21, wherein each of the first set, second set, third set, and fourth set of the plurality of metal anchors includes a first metal anchor positioned laterally apart from a second metal anchor.
31. The battery module according to claim 30, wherein the first and second metal anchors of each of the first, second, third, and fourth sets of the plurality of metal anchors are substantially equidistant from the edges defined by the adjacent side walls of the first or second anchor substructure.
32. The aforementioned anchor structure is A third anchor substructure including a fifth set of the plurality of metal anchors coupled to the second side wall of the plurality of side walls, and a sixth set of the plurality of metal anchors coupled to the fourth side wall of the plurality of side walls, A fourth anchor substructure including a seventh set of the plurality of metal anchors coupled to the third side wall of the plurality of side walls, and an eighth set of the plurality of metal anchors coupled to the fourth side wall of the plurality of side walls, The battery module according to claim 30, further comprising:
33. The first side wall, the second side wall, the third side wall, and the fourth side wall of the plurality of side walls each include an outer surface relative to the interior of the metal housing. The outer surface of the first side wall among the plurality of side walls defines a first plane substantially parallel to a second plane defined by the outer surface of the fourth side wall among the plurality of side walls. The outer surface of the second side wall among the plurality of side walls defines a third plane that is substantially parallel to a fourth plane defined by the outer surface of the third side wall among the plurality of side walls. The battery module according to claim 32.
34. The battery module according to claim 33, wherein the first plane is substantially perpendicular to the third plane and the fourth plane, respectively.
35. A first bracket coupled to the first set and the second set of the plurality of metal anchors, A second bracket coupled to the third and fourth sets of the plurality of metal anchors, A third bracket coupled to the fifth and sixth sets of the plurality of metal anchors, A fourth bracket coupled to the seventh set and the eighth set of the plurality of metal anchors, The battery module according to claim 32, further comprising:
36. The mounting structure is further defined by at least two brackets from the first bracket, the second bracket, the third bracket, and the fourth bracket, and the mounting structure is The mounting surface comprises a first mounting opening, a second mounting opening, and a third mounting opening defined by the at least two brackets, The fourth mounting opening from at least two of the brackets is located within the first mounting surface, and the mounting structure further comprises A second mounting surface defined by the fifth and sixth mounting openings from the at least two brackets, and a normal direction substantially parallel to the first mounting surface, A third mounting surface substantially parallel to the second mounting surface and spaced apart from the second mounting surface in the direction normal to the second mounting surface, wherein the third mounting surface includes a seventh mounting opening and an eighth mounting opening from at least two brackets, The battery module according to claim 35, comprising:
37. A battery system comprising a plurality of battery modules, each having a battery module as described in claim 36, wherein a row of the plurality of battery modules is configured to be mounted along the first mounting surface.
38. An electric aircraft comprising the battery system according to claim 37, wherein the electric aircraft comprises an airframe, and the module-to-airframe interface between a first battery module among the plurality of battery modules and the airframe is defined by the first mounting surface.
39. The electric aircraft according to claim 38, wherein each of the rows of the plurality of battery modules has a mounting interface to the aircraft body, and the mounting interfaces are located within the first mounting surface, the second mounting surface, and the third mounting surface, respectively.
40. The electric aircraft according to claim 39, further comprising an electric motor, wherein the battery system is configured to supply power to the electric motor.
41. The battery module according to claim 21, wherein the plurality of side walls and the plurality of metal anchors are all made of either a titanium alloy or pure titanium.
42. The battery module according to claim 21, wherein screws are attached to the blind openings for each of the plurality of metal anchors.
43. The battery module according to claim 21, wherein the length of each of the plurality of metal anchors is 0.25 (0.635 cm) to 1 inch (2.54 cm).
44. It is a battery module, A housing comprising a first lateral wall, a second lateral wall, an upper side wall, and a lower side wall, wherein the first lateral wall is positioned longitudinally apart from the second lateral wall, the upper side wall is positioned vertically apart from the lower side wall, the first lateral wall is welded to the upper side wall and the lower side wall, and the second lateral wall is welded to the upper side wall and the lower side wall, the housing, A first electrical terminal located on the first side wall, The second electrical terminal located on the second side wall, An anchor structure comprising a first set of anchors positioned close to the first electrical terminal and a second set of anchors positioned close to the second electrical terminal, wherein each of the first set of anchors and the second set of anchors defines a blind opening. Each of the first subsets of the first set of anchors is fused to the first lateral wall, Each of the second subsets of the first set of anchors is fused to the upper side wall, Each of the first subsets of the second set of anchors is fused to the second lateral wall. Each of the second subsets of the second set of anchors is fused to the upper side wall, the anchor structure The battery module comprising the above.
45. A method for manufacturing a housing for a battery module, The first set of multiple anchors are welded to the first lateral wall, The second set of anchors is welded to the second lateral wall, The third set of anchors is welded to the upper side wall, The fourth set of anchors is welded to the lower side wall, The welding involves welding each joint between adjacent side walls of the housing to form a rectangular parallelepiped, wherein the housing defines a battery storage structure. The method, including the method described above.
46. The method according to claim 45, wherein the first lateral wall, the second lateral wall, the upper lateral wall, and the lower lateral wall are each made of titanium or a titanium alloy.
47. The method according to claim 45, wherein the first lateral wall, the second lateral wall, the upper wall, and the lower wall are each formed of sheet metal.
48. It is a battery module, A housing including a vent port, wherein the vent port defines a radial inner surface, and the radial inner surface defines a threaded portion having a pitch diameter to thread pitch ratio greater than 30:1, Multiple cells arranged within the housing, The battery module comprising the above.
49. The battery module according to claim 48, wherein the pitch diameter to thread ratio is 30:1 to 60:
1.
50. The battery module according to claim 48, wherein the starting thread pitch diameter of the threaded portion is 1 inch (2.54 cm) to 2 inches (3.1 cm), and the thread pitch is 20 to 40 threads per inch.
51. The battery module according to claim 48, further comprising a fitting coupled to the vent port, the fitting comprising a male thread configured to engage with the threaded portion of the vent port.
52. The aforementioned joint is made from a first material, The vent port is made from a second material. The battery module according to claim 51, wherein the first material is different from the second material.
53. The battery module according to claim 52, wherein the first material is a first metal and the second material is a second metal.
54. The battery module according to claim 51, wherein the threaded interface between the fitting and the vent port is configured to self-seal in response to one of the plurality of cells entering thermal runaway.
55. The aforementioned fitting is an adapter, and the adapter is Flange and, A tubular element extending axially from the flange, wherein the tubular element includes a radially outer surface, and the radially outer surface includes a second threaded portion including the male thread, The battery module according to claim 51, including the following:
56. The battery module according to claim 55, further comprising a plurality of openings arranged circumferentially around the flange.
57. An exhaust system for a battery system, A plurality of battery modules, each of which includes a vent port, and the vent port is configured to communicate fluidly with the internal cavity of the battery module in response to the cells in the battery module entering thermal runaway, A plurality of adapters, each adapter coupled to the vent port of a corresponding module from the plurality of battery modules, the adapter being made of a different material from the vent port, and the interface between the adapter and the vent port being configured to self-seal in response to being exposed to temperatures that the interface is exposed to during a thermal runaway event caused by the cells in the battery module entering a thermal runaway state, The exhaust system, including the exhaust system.
58. The vent port includes a female threaded portion, and the adapter is Flange and, A tubular element extending axially from the flange, wherein the tubular element includes a male threaded portion configured to interface with the female threaded portion, The exhaust system according to claim 57, including the following:
59. The exhaust system according to claim 58, wherein the female thread portion includes a pitch diameter to thread pitch ratio greater than 30:
1.
60. The exhaust system according to claim 57, wherein the adapter is made of a stainless steel alloy and the vent port is made of a titanium alloy.
61. The exhaust system according to claim 57, further comprising a plurality of pipe assemblies, wherein each pipe assembly in the plurality of pipe assemblies is coupled to the adapter of the corresponding module from the plurality of battery modules and to an adjacent pipe assembly in the plurality of pipe assemblies.
62. The exhaust system according to claim 61, wherein the plurality of pipe assemblies form a gang vent assembly.
63. A vent adapter for a battery module, Flange and, A tubular element extending axially from the flange, wherein the tubular element includes a male threaded portion on its radially outer surface, and the male threaded portion has a pitch diameter to thread pitch ratio greater than 30:1, The vent adapter comprising the above.
64. The vent adapter according to claim 63, wherein the pitch diameter to thread ratio is 30:1 to 60:
1.
65. The vent adapter according to claim 63, wherein the starting thread pitch diameter is 1 inch (2.54 cm) to 2 inches (3.1 cm) and the thread pitch is 20 to 40 threads per inch.
66. The vent adapter according to claim 63, wherein the flange defines a hexagon and a plurality of openings are spaced circumferentially around the flange.
67. The vent adapter according to claim 66, wherein each of the multiple openings is threaded.
68. A vent pipe for the exhaust system of a battery module, A pipe extending from a first longitudinal end to a second longitudinal end, defining the first longitudinal axis, A fitting connected to the pipe, wherein the fitting defines a second longitudinal axis, the second longitudinal axis is substantially perpendicular to the first longitudinal axis, the fitting defines a radially inner surface and a radially outer surface, the radially outer surface includes a threaded portion, the threaded portion having a pitch diameter to thread pitch ratio greater than 30:1, The vent pipe, including the vent pipe.
69. The bent pipe according to claim 68, wherein the pitch diameter to thread ratio is 30:1 to 60:
1.
70. The fitting is welded to the pipe, as described in claim 68.
71. The bent pipe according to claim 68, wherein the bent pipe defines a T-shape.
72. The bent pipe according to claim 68, wherein the pipe is a straight pipe without a curved section.
73. The vent pipe according to claim 68, wherein the starting thread pitch diameter is 1 inch (2.54 cm) to 2 inches (3.1 cm) and the thread pitch is 20 to 40 threads per inch.
74. An exhaust system for a battery system, A plurality of pipe assemblies, each pipe assembly comprising a pipe and a fitting connected to the pipe, the pipe extending from a first longitudinal end to a second longitudinal end, the fitting connected to the pipe and extending radially outward from the pipe, and the fitting comprising a threaded portion having a pitch diameter to thread pitch ratio greater than 30:1, A coupler is connected to the first longitudinal end of the first pipe assembly of the plurality of pipe assemblies and to the second longitudinal end of the second pipe assembly of the plurality of pipe assemblies, wherein the first pipe assembly, the second pipe assembly, and the coupler define a portion of a common vent, and the coupler The exhaust system comprising the above.
75. The exhaust system according to claim 74, wherein the coupler comprises a polymer material.
76. The exhaust system according to claim 75, wherein the polymer material is configured to be in direct contact with a flame of 2000°F (1093.3°C) for 15 minutes without back penetration.
77. The exhaust system according to claim 74, further comprising a plurality of couplers, wherein each of the plurality of pipe assemblies is coupled to an adjacent pipe assembly within the plurality of pipe assemblies by a corresponding coupler among the plurality of couplers.
78. The exhaust system according to claim 74, wherein the fitting is welded to the pipe.
79. The fitting of the first pipe assembly defines a first port oriented in a first direction, The exhaust system according to claim 74, wherein the fitting of the second pipe assembly defines a second port oriented in a second direction.
80. The exhaust system according to claim 79, wherein the first direction is approximately 180 degrees with respect to the second direction.
81. The exhaust system according to claim 79, wherein the first direction is the same as the second direction with respect to the longitudinal axis defined by the pipe.
82. It is a battery system, A plurality of battery modules, each battery module including a vent port, and the plurality of battery modules, An exhaust system for the battery system, the exhaust system comprising a plurality of pipe assemblies, each of the plurality of pipe assemblies comprising a pipe and a fitting coupled to the pipe, the pipe extending from a first longitudinal end to a second longitudinal end, the fitting coupled to the pipe and extending radially outward from the pipe, and the fitting of each pipe assembly coupled to the vent port of the corresponding module from the plurality of battery modules, the exhaust system The battery system, including the battery system.
83. The battery system according to claim 82, wherein each of the plurality of battery modules includes a housing that defines the longitudinal, transverse, and vertical directions, and the vent port is located on the upper wall of the housing.
84. The first pipe assembly in the plurality of pipe assemblies is coupled to the vent port of the first battery module in the plurality of battery modules. A second pipe assembly in the plurality of pipe assemblies is coupled to the vent port of the second battery module in the plurality of battery modules. The battery system according to claim 83, wherein the first pipe assembly is coupled to the second pipe assembly by a coupler.
85. The battery system according to claim 84, wherein the first pipe assembly and the second pipe assembly are arranged between the upper wall of the housing of the first battery module and the upper wall of the housing of the second battery module.
86. The battery system according to claim 85, wherein the first direction defined by the first port of the fitting of the first battery module is about 180 degrees with respect to the second direction defined by the second port of the fitting of the second battery module.
87. The battery system according to claim 84, wherein the pipe of the first pipe assembly and the pipe of the second pipe assembly are coaxial.
88. The battery system according to claim 87, wherein the axes of the pipes in the first pipe assembly and the second pipe assembly are parallel to the longitudinal direction.
89. The battery system according to claim 88, wherein the vent port of each of the plurality of battery modules is offset in the longitudinal direction from the central longitudinal plane of the battery module.
90. The battery system according to claim 87, wherein the axes of the pipes in the first pipe assembly and the second pipe assembly are parallel to the lateral direction.
91. The battery system according to claim 84, wherein the coupler comprises a polymer material.
92. The first pipe assembly is connected to the first port of the common vent pipe. The battery system according to claim 84, wherein the second pipe assembly is coupled to the second port of the common vent pipe.