Battery system having a battery module

Abstract

The battery system includes a battery module that uses first and second holding housings to hold battery cell holding frames that can be air-cooled or fluid-cooled. In particular, the first and second holding housings have inlet and outlet ports, respectively, for transmitting fluid through the battery cell holding frames to cool the cylindrical battery cells. Alternatively, the battery cell holding frames can be air-cooled to cool the cylindrical battery cells. Also, the first and second holding housings provide improved structural integrity to the battery module.

Description

[Technical field]

[0001] Battery modules having cylindrical battery cells are used in many fields. [Background technology]

[0002] Battery modules having cylindrical battery cells are used in many fields. Since it is preferable for the battery module to have a high energy / power output, the battery module requires an effective and efficient cooling system for optimal performance. To achieve the desired cooling efficiency, other cooling systems have used complex tooling / assembly and components. This significantly increases the overall cost. Also, known battery modules can be air-cooled or fluid-cooled, but do not have the flexibility to allow both air and fluid cooling. Summary of the Invention [Problem to be solved by the invention]

[0003] The present inventors have recognized a need for a battery system using a battery module having first and second holding housings that hold battery cell holding frames, which may be air-cooled or fluid-cooled. In particular, the first and second holding housings each have inlet and outlet ports for transmitting fluid through the battery cell holding frames to cool the cylindrical battery cells. Alternatively, the battery cell holding frames may be air-cooled to cool the cylindrical battery cells. Additionally, the first and second holding housings provide improved structural integrity to the battery module. [Means for solving the problem]

[0004] A battery system according to an exemplary embodiment is provided. The battery system includes a battery module having a battery cell retention frame, a first retention housing, and a second retention housing. The battery cell retention frame has a central cold plate member and first and second outer plates. The central cold plate member has first and second manifold portions and first and second intermediate walls disposed between and coupled to the first and second manifold portions. The first and second intermediate walls form an internal cooling channel therebetween that is in fluid communication with the first and second manifold portions. The first and second outer plates are coupled to the first and second manifold portions, respectively, and extend perpendicular to the central cold plate member. The first retention housing is disposed within a region formed between the first intermediate wall and the first and second outer plates. The first retention housing has an end wall and first, second, third, and fourth side walls that form a first interior region. The first, second, third and fourth side walls of the first retention housing are coupled to the end wall to form a first open end. The first retention housing retains a first plurality of cylindrical battery cells therein in thermal communication with the first intermediate wall. The first side wall of the first retention housing has an inlet port in fluid communication with the first manifold portion. The second retention housing is disposed within the region formed by the second intermediate wall and the first and second outer plates. The second retention housing has an end wall and first, second, third and fourth side walls forming a second interior region. The first, second, third and fourth side walls of the second retention housing are coupled to the end wall to form a second open end. The second retention housing retains a second plurality of cylindrical battery cells therein in thermal communication with the second intermediate wall. The first side wall of the second retention housing has an outlet port in fluid communication with the second manifold portion.The battery system further includes a fluid supply system fluidly coupled to the inlet port and the outlet port, the fluid supply system supplying fluid to the inlet port such that the fluid flows through a first manifold portion of the battery cell holding frame and an internal cooling channel of the battery cell holding frame, through a second manifold portion of the battery cell holding frame, and out the outlet port to extract thermal energy from the first and second plurality of battery cells.

[0005] A battery module according to an exemplary embodiment is provided. The battery module includes a battery cell holding frame having a central cooling plate member and first and second outer plates. The central cooling plate member has first and second manifold portions and first and second intermediate walls disposed between and coupled to the first and second manifold portions. The first and second intermediate walls form an internal cooling channel therebetween that is in fluid communication with the first and second manifold portions. The first and second outer plates are coupled to the first and second manifold portions, respectively, and extend perpendicular to the central cooling plate member. The battery module further includes a first holding housing disposed within an area formed between the first intermediate wall and the first and second outer plates. The first holding housing has an end wall and first, second, third and fourth side walls that form a first interior region. The first, second, third and fourth side walls of the first holding housing are coupled to the end wall to form a first open end. The first retention housing internally retains a first plurality of cylindrical battery cells in thermal communication with the first intermediate wall. The first side wall of the first retention housing has an inlet port in fluid communication with the first manifold portion. The battery module includes a second retention housing disposed within an area formed by the second intermediate wall and the first and second outer plates. The second retention housing has an end wall and first, second, third and fourth side walls forming a second interior area. The first, second, third and fourth side walls of the second retention housing are coupled to the end wall to form a second open end. The second retention housing internally retains a second plurality of cylindrical battery cells in thermal communication with the second intermediate wall. The first side wall of the second retention housing has an outlet port in fluid communication with the second manifold portion. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic diagram of a battery system having a battery module and a fluid supply system according to an exemplary embodiment. [Diagram 2] FIG. 2 is an isometric view of the battery module of FIG. 1. [Diagram 3] FIG. 2 is another isometric view of the battery module of FIG. 1. [Figure 4] FIG. 2 is a top view of the battery module of FIG. [Diagram 5] FIG. 2 is a side view of the battery module of FIG. [Figure 6] 12 is a cross-sectional view of the battery module of FIG. 1 taken along line 6-6 of FIG. 11. [Figure 7] 1. FIG. 4 is another side view of the battery module of FIG. [Figure 8] FIG. 2 is an exploded view of the battery module of FIG. [Figure 9] 1. FIG. 4 is another exploded view of the battery module of FIG. [Figure 10] 10 is a cross-sectional view of the battery module of FIG. 3 taken along line 10-10 of FIG. 3, illustrating heat transfer from the cylindrical battery cells into the battery cell holding frame. [Figure 11] FIG. 2 is an isometric view of a battery cell holding frame used in the battery module of FIG. 1. [Figure 12] FIG. 12 is another isometric view of the battery cell holding frame shown in FIG. [Figure 13] FIG. 12 is another isometric view of the battery cell holding frame shown in FIG. [Figure 14] FIG. 12 is another isometric view of the battery cell holding frame shown in FIG. [Figure 15] FIG. 12 is an enlarged isometric view of the battery cell holding frame of FIG. [Figure 16] FIG. 12 is a front view of the battery cell holding frame of FIG. [Figure 17] FIG. 12 is a side view of the battery cell holding frame of FIG. [Figure 18] FIG. 12 is a top view of the battery cell holding frame of FIG. [Figure 19] 19 is a cross-sectional view of the battery cell holding frame of FIG. 13 taken along line 19-19 of FIG. 13. [Figure 20] 14 is a cross-sectional view of the battery cell holding frame of FIG. 13 taken along line 20-20 of FIG. 13. [Figure 21] FIG. 12 is an isometric view of the battery cell holding frame of FIG. 11 showing fluid entering and exiting the battery cell holding frame. [Figure 22] 12 is a top view of the battery cell holding frame of FIG. 11 showing fluid moving across the battery cell holding frame within internal cooling channels. [Diagram 23] FIG. 2 is an isometric view of a first retention housing used in the battery module of FIG. 1. [Figure 24] FIG. 24 is an isometric view of the first retention housing of FIG. 23 retaining therein a first plurality of cylindrical battery cells and first and second retention plates. [Diagram 25] 24 is a top view of the first retention housing of FIG. 23. FIG. [Figure 26] 25 is a bottom view of the first retention housing, the first plurality of cylindrical battery cells, and the first and second retention plates of FIG. 24. FIG. [Figure 27] 24 is a side view of the first retention housing of FIG. 23. FIG. [Figure 28] 24 is another side view of the first retention housing of FIG. 23. FIG. [Figure 29] 24 is another side view of the first retention housing of FIG. 23. FIG. [Diagram 30] FIG. 24 is a partial exploded view of the first retainer housing, the first plurality of cylindrical battery cells, and the first and second retainer plates of FIG. 23; [Diagram 31] FIG. 31 is another partial exploded view of the first retention housing, the first plurality of cylindrical battery cells, and the first and second retention plates of FIG. 30; [Diagram 32] FIG. 24 is an isometric view of the first retention housing of FIG. 23 without the first and second electrical bus bars. [Diagram 33] FIG. 33 is another isometric view of the first retention housing of FIG. 32. [Diagram 34] 33 is an enlarged top view of the first retention housing of FIG. 32. FIG. [Diagram 35] 33 is an enlarged bottom view of the first retention housing of FIG. 32. FIG. [Diagram 36]33 is a side view of the first retention housing of FIG. 32. FIG. [Figure 37] 33 is another side view of the first retention housing of FIG. 32. FIG. [Figure 38] FIG. 38 is a partial cutaway view of the first retention housing of FIG. 37 showing the inlet port. [Figure 39] 2 is a schematic diagram of a first plurality of cylindrical battery cells used in the battery module of FIG. 1. [Diagram 40] 40 is an enlarged view of a cylindrical battery cell of the first plurality of cylindrical battery cells of FIG. 39. [Diagram 41] FIG. 2 is an isometric view of a second retention housing used in the battery module of FIG. 1. [Diagram 42] FIG. 42 is an isometric view of the second retention housing of FIG. 41 retaining therein a second plurality of cylindrical battery cells and third and fourth retention plates. [Diagram 43] FIG. 42 is a top view of the second retention housing of FIG. 41. [Diagram 44] FIG. 43 is a bottom view of the second retention housing, the second plurality of cylindrical battery cells, and the third and fourth retention plates of FIG. [Diagram 45] FIG. 42 is a side view of the second retention housing of FIG. 41. [Diagram 46] 42 is another side view of the second retention housing of FIG. 41. FIG. [Figure 47] 42 is another side view of the second retention housing of FIG. 41. FIG. [Figure 48] FIG. 42 is a partial exploded view of the second retainer housing, the second plurality of cylindrical battery cells, and the third and fourth retainer plates of FIG. 41; [Figure 49] FIG. 49 is another partial exploded view of the second retainer housing, the second plurality of cylindrical battery cells, and the third and fourth retainer plates of FIG. 48. [Figure 50] FIG. 42 is an isometric view of the second retention housing of FIG. 41 without the first and second electrical bus bars. [Figure 51] FIG. 51 is another isometric view of the second retention housing of FIG. 50. [Figure 52] FIG. 51 is an enlarged top view of the second retention housing of FIG. 50. [Diagram 53] 51 is an enlarged bottom view of the second retention housing of FIG. 50. FIG. [Figure 54] FIG. 51 is a side view of the second retention housing of FIG. 50. [Figure 55] 51 is another side view of the second retention housing of FIG. 50. FIG. [Figure 56] FIG. 56 is a partial cutaway view of the second retention housing of FIG. 55 showing the outlet port. [Figure 57] 2 is a schematic diagram of a second plurality of cylindrical battery cells used in the battery module of FIG. 1. [Figure 58] FIG. 2 is an isometric view of a first exterior plate used in the battery module of FIG. 1. [Figure 59] FIG. 59 is another isometric view of the first exterior plate of FIG. 58. [Figure 60] FIG. 59 is a bottom view of the first outer plate of FIG. 58. [Figure 61] FIG. 59 is a top view of the first outer plate of FIG. 58. [Figure 62] FIG. 2 is an isometric view of a second exterior plate used in the battery module of FIG. 1. [Figure 63] FIG. 63 is another isometric view of the second exterior plate of FIG. 62. [Figure 64] FIG. 63 is a bottom view of the second outer plate of FIG. 62. [Figure 65] FIG. 63 is a top view of the second outer plate of FIG. 62. [Figure 66] 2 is an enlarged schematic view of a portion of the battery module of FIG. 1. [Figure 67] FIG. 2 is an isometric view of a cover plate used in the battery module of FIG. 1. [Figure 68] FIG. 68 is another isometric view of the cover plate of FIG. 67. [Figure 69] 1 is a schematic diagram of the first and second retaining housings and the battery cell retaining frame prior to coupling the components together. FIG. [Figure 70] 1 is a schematic diagram of the first and second holding housings and the battery cell holding frame coupled together; [Figure 71]71 is an enlarged schematic view of a portion of the first retention housing and the battery cell retention frame of FIG. 70. FIG. [Figure 72] 4 is a schematic diagram of the first and second retention housings before the first and second outer plates are coupled to the first and second retention housings, respectively; FIG. [Figure 73] 1 is a schematic diagram of first and second outer plates coupled to first and second retention housings, respectively; [Figure 74] 10 is a cross-sectional view of the battery module of FIG. 3 taken along line 10-10 of FIG. 3, illustrating heat transfer from the cylindrical battery cells into the battery cell holding frame when the fluid supply system is not coupled to the battery module. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] 1-10, a battery system 20 having a fluid delivery system 30 and a battery module 32 is provided according to an exemplary embodiment.

[0008] A fluid supply system 30 is provided for supplying fluid to the battery module 32 to cool the cylindrical battery cells therein. The fluid supply system 30 includes a fluid supply 40 and conduits 42, 44. The conduit 42 is positioned between and coupled to the fluid supply 40 and the inlet port 640 of the battery module 32. And, the conduit 44 is positioned between and coupled to the fluid supply 40 and the outlet port 1640 of the battery module 32. During operation, the fluid supply 40 pumps fluid through the conduit 42 and into the inlet port 640. The fluid is transferred through the battery module 32 to cool the cylindrical battery cells therein and subsequently transferred out the outlet port 1640 and back to the fluid supply 30 via the conduit 44.

[0009] 8 and 9, a battery module 32 is provided for outputting an operating voltage. The battery module 32 includes a battery cell holding frame 50, a first holding housing 54, a first plurality of cylindrical battery cells 56, first and second holding plates 60, 62 (shown in FIG. 24), a second holding housing 74, a second plurality of cylindrical battery cells 76 (shown in FIG. 42), third and fourth holding plates 80, 82 (shown in FIG. 42), a first outer plate 90, bolts 91, 92, 93, 94, a second outer plate 100, bolts 101, 102, 103, 104, a circuit board 120, an electrical bus bar 122, a circuit board 124, and a cover plate 126.

[0010] 1-10, an advantage of the battery module 32 is that the battery module 32 uses first and second holding housings 54, 74 to hold the battery cell holding frame 50, which may be air-cooled or fluid-cooled. In particular, the first and second holding housings 54, 74 have inlet and outlet ports 640, 1640, respectively, for transmitting fluid through the battery cell holding frame 50 to cool the cylindrical battery cells. Alternatively, the battery cell holding frame 50 may be air-cooled to cool the cylindrical battery cells. Additionally, the first and second holding housings 54, 74 provide the battery module 32 with improved structural integrity.

[0011] Battery Cell Retaining Frame 11-22, a battery cell holding frame 50 is provided to hold and cool a first plurality of cylindrical battery cells 56 and a second plurality of cylindrical battery cells 76. The battery cell holding frame 50 includes a central cooling plate member 140, a first outer plate 141, a second outer plate 142, a first thermally conductive layer 151, and a second thermally conductive layer 152. An advantage of the battery cell holding frame 50 is that the frame 50 can support and protect the battery cells 56, 76 on the first and second outer plates 141, 142, and hold and cool the first and second plurality of cylindrical battery cells 56, 76 on opposite sides of the central cooling plate member 140. In an exemplary embodiment, the central cooling plate member 140, the first outer plate 141, and the second outer plate 142 are constructed of a metal, such as aluminum. The first and second thermally conductive layers (151 and 152) are composed of a thermally conductive material that is not electrically conductive.

[0012] Central cooling plate member 19 and 20, the central cooling plate member 140 includes a first manifold portion 161, a second manifold portion 162, a first intermediate wall 171, a second intermediate wall 172, a first end plate 181, a second end plate 182, and internal cooling channels 184.

[0013] First manifold section 14 and 18-20, the first manifold portion 161 includes a first end 191 (shown in FIG. 18), a second end 192, a central body portion 200, a first extension portion 201, and a second extension portion 202.

[0014] central body part Central body portion 200 extends along a longitudinal axis 212 (shown in FIG. 18). Central body portion 200 includes an inlet opening 208 (shown in FIGS. 14 and 20) and a longitudinal opening 210 (shown in FIG. 19). Inlet opening 208 extends through a lower end surface of central body portion 200 and is in fluid communication with longitudinal opening 210. Longitudinal opening 210 extends along longitudinal axis 212 from first end 191 to second end 192.

[0015] First and second extensions The first and second extension portions 201, 202 are coupled to opposing sides of the central body portion 200. The first extension portion 201 has a flow opening 214 extending therethrough, such flow opening being in fluid communication with the longitudinal opening 210 of the central body portion 200 and the interior cooling channels 184. The flow opening 214 has a vertical height that is less than the diameter of the longitudinal opening 210. The second extension portion 202 is coupled between the central body portion 200 and the first outer plate 141.

[0016] Second manifold section The second manifold portion 162 includes a first end 221 (shown in FIG. 18), a second end 222 , a central body portion 230 , a first extension portion 231 , and a second extension portion 232 .

[0017] central body part Central body portion 230 extends along a longitudinal axis 242 (shown in FIG. 18 ). Central body portion 230 includes an outlet opening 238 and a longitudinal opening 240. Outlet opening 238 extends through a top surface of central body portion 230 and is in fluid communication with longitudinal opening 240. Longitudinal opening 240 extends along longitudinal axis 242 from first end 221 to second end 222.

[0018] First and second extensions The first and second extension portions 231, 232 are coupled to opposing sides of the central body portion 230. The first extension portion 231 has a flow opening 244 extending therethrough, such flow opening being in fluid communication with the longitudinal opening 240 of the central body portion 230 and the interior cooling channel 184. The flow opening 244 has a vertical height that is less than the diameter of the longitudinal opening 240. The second extension portion 232 is coupled between the central body portion 230 and the second outer plate 142.

[0019] First and second intermediate walls 18-20, the first and second intermediate walls 171, 172 are disposed between and coupled to the first and second manifold portions 161, 162. The first and second intermediate walls 171, 172 form an internal cooling channel 184 therebetween that is in fluid communication with the first and second manifold portions 161, 162. The first intermediate wall 171 includes a first end 251 (shown in FIG. 18), a second end 252, and an exterior surface 253. And, the second intermediate wall 172 includes a first end 261 (shown in FIG. 18), a second end 262, and an exterior surface 263.

[0020] 1st end plate 11, 13, and 18, a first end plate 181 is provided and surrounds an end of the battery cell holding frame 50. In particular, the first end plate 181 is coupled to a first end 251 (shown in FIG. 18) of the first intermediate wall 171, a first end 261 of the second intermediate wall 172, a first end 191 of the first manifold portion 161, and a first end 221 of the second manifold portion 162.

[0021] 2nd end plate A second end plate 182 is provided and surrounds the other end of the battery cell retaining frame 50. In particular, the second end plate 182 is coupled to the second end 252 (shown in FIG. 18 ) of the first intermediate wall 171, the second end 262 of the second intermediate wall 172, the second end 192 of the first manifold portion 161, and the second end 222 of the second manifold portion 162.

[0022] Internal Cooling Channels

[0023] 19 and 20 , the internal cooling channels 184 have a vertical height that is greater than the vertical height of the flow openings 214 of the first extension portion 201 of the first manifold portion 161. The internal cooling channels 184 also have a vertical height that is greater than the vertical height of the flow openings 244 of the first extension portion 231 of the second manifold portion 162.

[0024] First Thermally Conductive Layer 10, 19 and 20, a first thermally conductive layer 151 is provided to transfer thermal energy from the first plurality of cylindrical battery cells 56 to the central cold plate member 140. The first thermally conductive layer 151 is disposed on a first exterior surface 253 of the first intermediate wall 171.

[0025] Second Thermally Conductive Layer A second thermally conductive layer 152 is provided to transfer thermal energy from the second plurality of cylindrical battery cells 76 to the central cold plate member 140. The second thermally conductive layer 152 is disposed on an exterior surface 263 of the second intermediate wall 172.

[0026] First and second outer plates 19 and 20, the first and second outer plates 141, 142 are coupled to the first and second manifold portions 161, 162, respectively, of the central cooling plate member 140 and extend perpendicular to the central cooling plate member 140. The first and second intermediate walls 171, 172 have first and second exterior surfaces 253, 263, respectively, disposed opposite one another and between the first and second outer plates 141, 142.

[0027] 1st outer plate A first outer plate 141 is provided to radiate thermal energy from the central cold plate member 140 to the surrounding atmosphere to protect the first and second pluralities of cylindrical battery cells 56, 76. The first outer plate 141 includes a central outer plate portion 280, a first rail portion 281, and a second rail portion 282.

[0028] First and second rail portions 281, 282 extend longitudinally and are respectively coupled to first and second ends of a central outer plate portion 280. The central outer plate portion 280 has a corrugated outer surface 290.

[0029] First rail portion 281 includes a curved portion 296 (shown in FIG. 19), and a head portion 298 having an end surface 299. Curved portion 296 is coupled between head portion 298 and central outer plate portion 280. First rail portion 281 further includes openings 301, 302 (shown in FIG. 13) that extend into end surface 299.

[0030] The second rail portion 282 includes a curved portion 306, and a head portion 308 having an end surface 309. The curved portion 306 is coupled between the head portion 308 and the central outer plate portion 280. The second rail portion 282 further includes openings 311, 312 (shown in FIG. 13 ) that extend into the end surface 309.

[0031] Second outer plate A second outer plate 142 is provided to radiate thermal energy from the central cold plate member 140 to the surrounding atmosphere to protect the first and second pluralities of cylindrical battery cells 56, 76. The second outer plate 142 includes a central outer plate portion 340, a first rail portion 341, and a second rail portion 342.

[0032] The first and second rail portions 341, 342 extend longitudinally and are respectively coupled to first and second ends of a central outer plate portion 340. The central outer plate portion 340 has a corrugated outer surface 350.

[0033] First rail portion 341 includes a curved portion 356 (shown in FIG. 19), and a head portion 358 having an end surface 359. Curved portion 356 is coupled between head portion 358 and central outer plate portion 340. First rail portion 341 further includes openings 361, 362 (shown in FIG. 13) that extend into end surface 359.

[0034] The second rail portion 342 includes a curved portion 366, and a head portion 368 having an end surface 369. The curved portion 366 is coupled between the head portion 368 and the central outer plate portion 340. The second rail portion 342 further includes openings 371, 372 (shown in FIG. 13 ) that extend into the end surface 369.

[0035] region The first and second outer panels 141, 142 and the first intermediate wall 171 form an area 401 for receiving therein the first plurality of cylindrical battery cells 56. Additionally, the first and second outer panels 141, 142 and the thermally conductive layer 152 form an area 402 for receiving therein the second plurality of cylindrical battery cells 76.

[0036] First Retaining Housing 19 and 23-38, the first retention housing 54 retains the first plurality of cylindrical battery cells 56 therein and against the first thermally conductive layer 151 (shown in FIG. 19), thereby placing the battery cells 56 in thermal communication with the first intermediate wall 171 through the first thermally conductive layer 151. The first retention housing 54 is disposed within an area 401 (shown in FIG. 19) formed by the first intermediate wall 171 and the first and second outer panels 141, 142. Referring to FIGS. 23 and 25, the first retention housing 54 has an end wall 450, a first side wall 451, a second side wall 452, a third side wall 453, a fourth side wall 454, an electrical bus bar 456, and an electrical bus bar 458. The first and second side walls 451, 452 extend substantially parallel to one another. Additionally, the third and fourth side walls 453, 454 extend substantially parallel to one another and perpendicular to the first and second side walls 451, 452. In an exemplary embodiment, the end wall 450 and the first, second, third and fourth side walls 451, 452, 453, 454 are constructed from plastic, and the electrical bus bars (456 and 458) are constructed from copper.

[0037] end wall An end wall 450 is coupled to first, second, third and fourth side walls 451 , 452 , 453 , 454 to form an inner region 460 (shown in FIG. 24) and an open end 462 .

[0038] 34 , the end wall 450 includes a wall portion 600 having a plurality of apertures 470 extending therethrough. Each aperture of the plurality of apertures 470 is associated with a cylindrical battery cell of the first plurality of cylindrical battery cells 56. The plurality of apertures 470 includes a first row of apertures 471, a second row of apertures 472, a third row of apertures 473, a fourth row of apertures 474, a fifth row of apertures 475, a sixth row of apertures 476, and a seventh row of apertures 477.

[0039] 34 and 35, the end wall 450 includes a plurality of alignment tabs 490 extending from the wall portion 600 into an interior region 460 (shown in FIG. 24 ) of the first retention housing 54 for receiving the first plurality of cylindrical battery cells 56, in alignment with the plurality of openings 470. The plurality of alignment tabs 490 include a first row of alignment tabs 491, a second row of alignment tabs 492, a third row of alignment tabs 493, a fourth row of alignment tabs 494, a fifth row of alignment tabs 495, a sixth row of alignment tabs 496, and a seventh row of alignment tabs 497. The first, second, third and fourth, fifth, sixth and seventh plurality of alignment tabs 491, 492, 493, 494, 495, 496, 497 are aligned with the first, second, third and fourth, fifth, sixth and seventh plurality of apertures 471, 472, 473, 474, 475, 476, 477, respectively. Additionally, each alignment tab of the plurality of alignment tabs 490 is associated with a respective cylindrical battery cell of the first plurality of cylindrical battery cells 56 and a respective aperture of the plurality of apertures 470. For example, the alignment tabs 500 in the first row of the alignment tabs 491 are aligned with the apertures 480 in the first row of apertures 471 to retain the cylindrical battery cell 800 (shown in FIG. 39 ).

[0040] 34, end wall 450 further includes tab members 601, 602, 603, 604, 605, 606 extending upwardly from wall portion 600 for alignment with first exterior plate 90 (shown in FIG. 8). End wall 450 also includes grooves 610, 612 extending into wall portion 600 for receiving electrical bus bars 456, 458 (shown in FIG. 25).

[0041] First side wall 25 and 29, first side wall 451 is coupled to end wall 450 and to third and fourth side walls 453, 454 and extends in a first direction perpendicular to end wall 450. First side wall 451 includes wall portion 628, retaining clip member 630, and tab members 632, 634, 636, and inlet port 640.

[0042] 29 and 47, a retaining clip 630 is coupled to wall portion 628 and extends in a first direction from wall portion 628. A tab member 632 extends outwardly from wall portion 628. Retaining clip member 630 is coupled to tab member 632 (shown in FIG. 47) to couple first retention housing 54 to second retention housing 74. Tab member 632 is coupled to retaining clip member 1630 (shown in FIG. 47) to couple first retention housing 54 to second retention housing 74.

[0043] 29 and 59, the tab members 634 are coupled to the retaining clip members 1904 (shown in FIG. 59) of the first outer plate 90 to couple the first outer plate 90 to the first retention housing 54. The tab members 636 are also coupled to the retaining clip members 1902 (shown in FIG. 59) of the first outer plate 90 to couple the first outer plate 90 to the first retention housing 54.

[0044] 38, the first side wall 451 has an inlet port 640 coupled to the wall portion 628 such that such inlet port is in fluid communication with the inlet opening 208 (shown in FIG. 20) of the first manifold portion 161 of the central cooling plate member 140 of the battery cell retaining frame 50. The inlet port 640 is routed at a 90° angle within the interior region 460 (shown in FIG. 24) of the first retaining housing 54.

[0045] Second Side Wall 25 and 28, second side wall 452 is coupled to end wall 450 and to third and fourth side walls 453, 454 and extends in a first direction perpendicular to end wall 450. Second side wall 452 includes a wall portion 648, a retaining clip member 650, and a tab member 652.

[0046] 28 and 46, a retaining clip 650 is coupled to wall portion 648 and extends in a first direction from wall portion 648. A tab member 652 extends outwardly from wall portion 648. Retaining clip member 650 is coupled to tab member 1652 (also shown in FIG. 46) to couple first retention housing 54 to second retention housing 74. Tab member 652 is coupled to retaining clip member 1650 (shown in FIG. 46) to couple first retention housing 54 to second retention housing 74.

[0047] Third side wall 25 and 27, the third side wall 453 is coupled to the end wall 450 and to the first and second side walls 451, 452 and extends in a first direction perpendicular to the end wall 450. The third side wall 453 includes a wall portion 660.

[0048] 4th side wall 23 and 25, the fourth side wall 454 is coupled to the end wall 450 and to the first and second side walls 451, 452 and extends in a first direction perpendicular to the end wall 450. The fourth side wall 454 includes a wall portion 670.

[0049] A first plurality of cylindrical battery cells 10 , 30 , 31 and 39 , a first plurality of cylindrical battery cells 56 is held within the first retention housing 54 and against the battery cell retention frame 50. The first plurality of cylindrical battery cells 56 includes a first row of battery cells 751, a second row of battery cells 752, a third row of battery cells 753, a fourth row of battery cells 754, a fifth row of battery cells 755, a sixth row of battery cells 756, and a seventh row of battery cells 757.

[0050] In an exemplary embodiment, the respective battery cells in the first row of battery cells 751 are electrically coupled in parallel to each other. The respective battery cells in the second row of battery cells 752 are electrically coupled in parallel to each other. The respective battery cells in the third row of battery cells 753 are electrically coupled in parallel to each other. The respective battery cells in the fourth row of battery cells 754 are electrically coupled in parallel to each other. The respective battery cells in the fifth row of battery cells 755 are electrically coupled in parallel to each other. The respective battery cells in the sixth row of battery cells 756 are electrically coupled in parallel to each other. The respective battery cells in the seventh row of battery cells 757 are electrically coupled in parallel to each other. The first, second, third, fourth, fifth, sixth, and seventh rows of battery cells 756 are electrically coupled in series to each other. Additionally, the respective negative terminals of the battery cells in the first row of battery cells 751 are electrically coupled to the electrical bus bar 456 (shown in FIG. 31 ). Additionally, the negative terminals of each of the battery cells in the seventh row of battery cells 757 are also electrically coupled to an electrical bus bar 458 (shown in FIG. 31).

[0051] 39 and 40, since each of the cylindrical battery cells in the first plurality of cylindrical battery cells 56 has the same structure, for simplicity, only the structure of the cylindrical battery cell 800 will be specifically described. The cylindrical battery cell 800 includes an outer surface 802, a bottom surface 804, a positive electrode 806, and a negative electrode 808. The positive electrode 806 is surrounded by the negative electrode 808. And the bottom surface 804 contacts the first thermally conductive layer 151 (shown in FIG. 19 ) of the battery cell holding frame 50 so that the thermal energy from the cylindrical battery cell 800 is transferred to the first thermally conductive layer 151.

[0052] First and second retaining plates 30, 31, 34 and 39, the first and second retention plates 60, 62 are coupled to the first, second, third and fourth side walls 451, 452, 453, 454 of the first retention housing 54 to retain the first plurality of cylindrical battery cells 56 within an interior region 460 (shown in FIG. 24) of the first retention housing 54. In an exemplary embodiment, the first and second retention plates 60, 62 are constructed of plastic.

[0053] 30, the first retainer plate 60 includes a plurality of apertures 830 extending therethrough. The plurality of apertures 830 includes a first row of apertures 831, a second row of apertures 832, a third row of apertures 833, a fourth row of apertures 834, a fifth row of apertures 835, a sixth row of apertures 836, and a seventh row of apertures 837. Each aperture of the first plurality of apertures 830 has a size to retain a cylindrical battery cell within the interior region 460 (shown in FIG. 24) of the first retainer housing 54 and to allow a bottom surface of each cylindrical battery cell to contact the first thermally conductive layer 151.

[0054] The second retaining plate 62 includes a plurality of apertures 860 extending therethrough. The plurality of apertures 860 includes a first row of apertures 861, a second row of apertures 862, a third row of apertures 863, a fourth row of apertures 864, a fifth row of apertures 865, a sixth row of apertures 866, and a seventh row of apertures 867 (aligned with a first row of apertures 831, a second row of apertures 832, a third row of apertures 833, a fourth row of apertures 834, a fifth row of apertures 835, a sixth row of apertures 836, and a seventh row of apertures 837, respectively). Each aperture of the plurality of apertures 860 has a size to retain a cylindrical battery cell within the interior region 460 of the first retaining housing 54 and to allow a bottom surface of each cylindrical battery cell to contact the first thermally conductive layer 151.

[0055] 30 and 39, the first row of the openings 831 of the first retaining plate 60 and the first row of the openings 861 of the second retaining plate 62 are aligned with the first row of the battery cells 751. Also, the second row of the openings 832 of the first retaining plate 60 and the second row of the openings 862 of the second retaining plate 62 are aligned with the second row of the battery cells 752. Also, the third row of the openings 833 of the first retaining plate 60 and the third row of the openings 863 of the second retaining plate 62 are aligned with the third row of the battery cells 753. Also, the fourth row of the openings 834 of the first retaining plate 60 and the fourth row of the openings 864 of the second retaining plate 62 are aligned with the fourth row of the battery cells 754. Also, the fifth row of the openings 835 of the first retaining plate 60 and the fifth row of the openings 865 of the second retaining plate 62 are aligned with the fifth row of the battery cells 755. Additionally, the sixth row of openings 836 of the first retaining plate 60 and the sixth row of openings 866 of the second retaining plate 62 are aligned with the sixth row of battery cells 756. Additionally, the seventh row of openings 837 of the first retaining plate 60 and the seventh row of openings 867 of the second retaining plate 62 are aligned with the seventh row of battery cells 757.

[0056] Second Retaining Housing 19 and 41-56, the second retention housing 74 retains the second plurality of cylindrical battery cells 76 therein and against the second thermally conductive layer 152 (shown in FIG. 19), thereby placing the battery cells 76 in thermal communication with the second intermediate wall 172 through the second thermally conductive layer 152. The second retention housing 74 has the same structure as the first retention housing 54. The second retention housing 74 is disposed within the region 402 (shown in FIG. 19) formed by the second intermediate wall 172 and the first and second outer panels 141, 142. Referring to FIGS. 41 and 43, the second retention housing 74 has an end wall 1450, a first side wall 1451, a second side wall 1452, a third side wall 1453, a fourth side wall 1454, an electrical bus bar 1456, and an electrical bus bar 1458. The first and second side walls 1451, 1452 extend substantially parallel to one another, and the third and fourth side walls 1453, 1454 extend substantially parallel to one another and perpendicular to the first and second side walls 1451, 1452. In an exemplary embodiment, the end wall 1450 and the first, second, third and fourth side walls 1451, 1452, 1453, 1454 are constructed from plastic, and the electrical bus bars (1456 and 1458) are constructed from copper.

[0057] end wall An end wall 1450 is coupled to first, second, third and fourth side walls 1451 , 1452 , 1453 , 1454 to form an inner region 1460 (shown in FIG. 42) and an open end 1462 .

[0058] 52, the end wall 1450 includes a wall portion 1600 having a plurality of apertures 1470 extending therethrough. Each aperture of the plurality of apertures 1470 is associated with a cylindrical battery cell of the second plurality of cylindrical battery cells 756. The plurality of apertures 1470 includes a first row of apertures 1471, a second row of apertures 1472, a third row of apertures 1473, a fourth row of apertures 1474, a fifth row of apertures 1475, a sixth row of apertures 1476, and a seventh row of apertures 1477.

[0059] 52 and 53, the end wall 1450 includes a plurality of alignment tabs 1490 extending from the wall portion 1600 into an interior region 1460 (shown in FIG. 42) of the second retention housing 74 for receiving the second plurality of cylindrical battery cells 76, in alignment with the plurality of openings 1470. The plurality of alignment tabs 1490 includes a first row of alignment tabs 1491, a second row of alignment tabs 1492, a third row of alignment tabs 1493, a fourth row of alignment tabs 1494, a fifth row of alignment tabs 1495, a sixth row of alignment tabs 1496, and a seventh row of alignment tabs 1497. The first, second, third and fourth, fifth, sixth and seventh plurality of alignment tabs 1491, 1492, 1493, 1494, 1495, 1496, 1497 are aligned with the first, second, third and fourth, fifth, sixth and seventh plurality of apertures 1471, 1472, 1473, 1474, 1475, 1476, 1477, respectively. Additionally, each alignment tab of the plurality of alignment tabs 1490 is associated with a respective cylindrical battery cell of the second plurality of cylindrical battery cells 76 and a respective aperture of the plurality of apertures 1470. For example, the alignment tabs 1500 in the first row of the alignment tabs 1491 are aligned with the apertures 1480 in the first row of apertures 1471 to retain a cylindrical battery cell 1800 (shown in FIG. 57).

[0060] 52, end wall 1450 further includes tab members 1601, 1602, 1603, 1604, 1605, 1606, 1606 extending upwardly from wall portion 1600 for alignment with second outer panel 100 (shown in FIG. 8). End wall 1450 also includes grooves 1610, 1612 extending into wall portion 1600 for receiving electrical bus bars 1456, 1458 (shown in FIG. 41).

[0061] First side wall 43 and 47, a first side wall 1451 is coupled to the end wall 1450 and to the third and fourth side walls 1453, 1454 and extends in a first direction perpendicular to the end wall 1450. The first side wall 1451 includes a wall portion 1628, a retaining clip member 1630, and tab members 1632, 1634, 1636, and an outlet port 1640.

[0062] 29 and 47, a retention clip 1630 is coupled to wall portion 1628 and extends in a first direction from wall portion 1628. A tab member 1632 extends outwardly from wall portion 1628. The retention clip member 1630 is coupled to tab member 632 (also shown in 29) to couple second retention housing 74 to first retention housing 54. The tab member 1632 is coupled to retention clip member 630 (also shown in 29) to couple second retention housing 74 to first retention housing 54.

[0063] 47 and 63, the tab members 1634 are coupled to the retaining clip members 2004 (shown in FIG. 63) of the second outer panel 100, coupling the second outer panel 100 to the first retention housing 74. The tab members 1636 are also coupled to the retaining clip members 2002 (shown in FIG. 63) of the second outer panel 100, coupling the second outer panel 100 to the second retention housing 74.

[0064] 56, the first side wall 1451 has an outlet port 1640 coupled to the wall portion 1628 such that such outlet port is in fluid communication with the outlet opening 238 (shown in FIG. 20) of the second manifold portion 162 of the central cold plate member 140 of the battery cell retaining frame 50. The outlet port 1640 is routed at a 90° angle within the interior region 1460 (shown in FIG. 42) of the second retaining housing 74.

[0065] Second Side Wall 43 and 46, the second side wall 1452 is coupled to the end wall 1450 and to the third and fourth side walls 1453, 1454 and extends in a first direction perpendicular to the end wall 1450. The second side wall 1452 includes a wall portion 1648, a retaining clip member 1650, and a tab member 1652.

[0066] 28 and 46, a retention clip 1650 is coupled to wall portion 1648 and extends in a first direction from wall portion 1648. A tab member 1652 extends outwardly from wall portion 1648. The retention clip member 1650 is coupled to tab member 652 (also shown in 28) to couple second retention housing 74 to first retention housing 54. The tab member 1652 is coupled to retention clip member 650 (also shown in 28) to couple second retention housing 74 to first retention housing 54.

[0067] Third side wall 43 and 45, the third side wall 1453 is coupled to the end wall 1450 and to the first and second side walls 1451, 1452 and extends in a first direction perpendicular to the end wall 1450. The third side wall 1453 includes a wall portion 1660.

[0068] 4th side wall 41 and 43, the fourth side wall 1454 is coupled to the end wall 1450 and to the first and second side walls 1451, 1452 and extends in a first direction perpendicular to the end wall 1450. The fourth side wall 1454 includes a wall portion 1670.

[0069] A second plurality of cylindrical battery cells 10, 48, 49 and 57, a second plurality of cylindrical battery cells 76 is held within the second retention housing 74 and against the battery cell retention frame 50. The second plurality of cylindrical battery cells 76 includes a first row of battery cells 1751, a second row of battery cells 1752, a third row of battery cells 1753, a fourth row of battery cells 1754, a fifth row of battery cells 1755, a sixth row of battery cells 1756, and a seventh row of battery cells 1757.

[0070] In an exemplary embodiment, the battery cells in the first row of battery cells 1751 are electrically coupled in parallel to each other. The battery cells in the second row of battery cells 1752 are electrically coupled in parallel to each other. The battery cells in the third row of battery cells 1753 are electrically coupled in parallel to each other. The battery cells in the fourth row of battery cells 1754 are electrically coupled in parallel to each other. The battery cells in the fifth row of battery cells 1755 are electrically coupled in parallel to each other. The battery cells in the sixth row of battery cells 1756 are electrically coupled in parallel to each other. The battery cells in the seventh row of battery cells 1757 are electrically coupled in parallel to each other. The first, second, third, fourth, fifth, sixth, and seventh rows of battery cells 1751, 1752, 1753, 1754, 1755, 1756, and 1757 are electrically coupled in series to each other. Additionally, the negative terminals of each of the battery cells in the first row of battery cells 1751 are electrically coupled to electrical bus bar 1456 (shown in FIG. 49). Additionally, the negative terminals of each of the battery cells in the seventh row of battery cells 1757 are electrically coupled to electrical bus bar 1458 (shown in FIG. 49).

[0071] 40 and 57, each of the cylindrical battery cells in the second plurality of cylindrical battery cells 76 has the same structure as the cylindrical battery cell 800 described previously in this application, and has a lower end surface in contact with the second thermally conductive layer 152 (shown in FIG. 19) of the battery cell holding frame 50.

[0072] Third and fourth retaining plates 48, 49, 52 and 57, the third and fourth retention plates 80, 82 are coupled to the first, second, third and fourth side walls 1451, 1452, 1453, 1454 of the second retention housing 74 to retain the second plurality of cylindrical battery cells 76 within an interior region 1460 (shown in FIG. 42) of the second retention housing 74. In an exemplary embodiment, the third and fourth retention plates 80, 82 are constructed of plastic.

[0073] 48, the third retention plate 80 includes a plurality of apertures 1830 extending therethrough. The plurality of apertures 1830 includes a first row of apertures 1831, a second row of apertures 1832, a third row of apertures 1833, a fourth row of apertures 1834, a fifth row of apertures 1835, a sixth row of apertures 1836, and a seventh row of apertures 1837. Each aperture of the first plurality of apertures 1830 has a size to retain a cylindrical battery cell within the interior region 1460 of the second retention housing 74 and to allow a bottom surface of each cylindrical battery cell to contact the second thermally conductive layer 152.

[0074] The fourth retaining plate 82 includes a plurality of apertures 1860 extending therethrough. The plurality of apertures 1860 includes a first row of apertures 1861, a second row of apertures 1862, a third row of apertures 1863, a fourth row of apertures 1864, a fifth row of apertures 1865, a sixth row of apertures 1866, and a seventh row of apertures 1867 (aligned with a first row of apertures 1831, a second row of apertures 1832, a third row of apertures 1833, a fourth row of apertures 1834, a fifth row of apertures 1835, a sixth row of apertures 1836, and a seventh row of apertures 1837, respectively). Each aperture of the plurality of apertures 1860 has a size to retain a cylindrical battery cell within the interior region 1460 (shown in FIG. 42 ) of the second retaining housing 74 and to allow a bottom surface of each cylindrical battery cell to contact the second thermally conductive layer 152.

[0075] 48 and 57, the first row of openings 1831 of the third retention plate 80 and the first row of openings 1861 of the fourth retention plate 82 are aligned with the first row of battery cells 1751. Additionally, the second row of openings 1832 of the third retention plate 80 and the second row of openings 1862 of the fourth retention plate 82 are aligned with the second row of battery cells 1752. Additionally, the third row of openings 1833 of the third retention plate 80 and the third row of openings 1863 of the fourth retention plate 82 are aligned with the third row of battery cells 1753. Additionally, the fourth row of openings 1834 of the third retention plate 80 and the fourth row of openings 1864 of the fourth retention plate 82 are aligned with the fourth row of battery cells 1754. Additionally, the fifth row of openings 1835 of the third retention plate 80 and the fifth row of openings 1865 of the fourth retention plate 82 align with the fifth row of battery cells 1755. Additionally, the sixth row of openings 1836 of the third retention plate 80 and the sixth row of openings 1866 of the fourth retention plate 82 align with the sixth row of battery cells 1756. Additionally, the seventh row of openings 1837 of the third retention plate 80 and the seventh row of openings 1867 of the fourth retention plate 82 align with the seventh row of battery cells 1757.

[0076] First outer panel 8, 14, 29, and 58-61, the first outer plate 90 is coupled to the first retention housing 54 and the first and second outer plates 141, 142 of the battery cell retention frame 50. The first outer plate 90 includes a plate portion 1900 and retention clip members 1902, 1904. Referring to FIG. 59, the plate portion 1900 has tab members (1910 and 1912) extending outwardly from the plate portion 1900. The plate portion 1900 also has through extension openings 1921, 1922, 1923, 1924. The retention clip members 1902, 1904 are coupled to the plate portion 1900 and extend in a first direction from the plate portion 1900. In an exemplary embodiment, the first outer plate 90 is constructed of plastic.

[0077] 29 and 59, the retaining clip member 1902 is coupled to the tab member 636 (shown in FIG. 29) of the first retention housing 54. Additionally, the retaining clip member 1904 is coupled to the tab member 634 (shown in FIG. 29) of the first retention housing 54.

[0078] 59 and 68, tab member 1912 is coupled to a retaining clip member 2202 (shown in FIG. 68) on cover plate 126. Tab member 1910 is also coupled to a retaining clip member 2201 (shown in FIG. 68) on cover plate 126.

[0079] 8, 13, 14 and 59, bolts 91 (shown in FIG. 8) extend through openings 1921 in the first outer plate 90 and into openings 311 (shown in FIG. 14) in the first outer plate 141 of the battery cell holding frame 50 to couple the first outer plate 90 to the battery cell holding frame 50.

[0080] Additional bolts 92 (shown in FIG. 8) extend through openings 1922 in the first outer plate 90 and into openings 312 (shown in FIG. 14) in the first outer plate 141 of the battery cell holding frame 50 to couple the first outer plate 90 to the battery cell holding frame 50.

[0081] Additional bolts 93 (shown in FIG. 8) extend through openings 1923 in the first outer plate 90 and into openings 371 (shown in FIG. 14) in the second outer plate 142 of the battery cell holding frame 50 to couple the first outer plate 90 to the battery cell holding frame 50.

[0082] Additional bolts 94 (shown in FIG. 8) extend through openings 1924 in the first outer plate 90 and into openings 372 (shown in FIG. 14) in the second outer plate 142 of the battery cell holding frame 50 to couple the first outer plate 90 to the battery cell holding frame 50.

[0083] Second outer panel 8, 13, 47, and 62-64, the second outer plate 100 is coupled to the second retention housing 74 and the first and second outer plates 141, 142 of the battery cell retention frame 50. The second outer plate 100 includes a plate portion 2000 and retention clip members 2002, 2004. The plate portion 2000 has tab members (2010 and 2012) extending outwardly from the plate portion 2000. The plate portion 2000 also has through extension openings 2021, 2022, 2023, 2024. The retention clip members 2002, 2004 are coupled to the plate portion 2000 and extend in a first direction from the plate portion 2000. In an exemplary embodiment, the second outer plate 100 is constructed of plastic.

[0084] 47 and 63, the retaining clip member 2002 is coupled to the tab member 1636 (shown in FIG. 47) of the second retention housing 74. Additionally, the retaining clip member 2004 is coupled to the tab member 1634 (shown in FIG. 47) of the second retention housing 74.

[0085] 63 and 67, tab member 2012 is coupled to a retaining clip member 2204 (shown in FIG. 67) on cover plate 126. Tab member 2010 is also coupled to a retaining clip member 2203 (shown in FIG. 67) on cover plate 126.

[0086] 8, 13, and 63, the bolts 101 (shown in FIG. 8) extend through the openings 2023 in the second outer plate 100 and into the openings 301 (shown in FIG. 13) in the first outer plate 141 of the battery cell holding frame 50 to couple the second outer plate 100 to the battery cell holding frame 50.

[0087] Additional bolts 102 (shown in FIG. 8) extend through openings 2024 in the second outer plate 100 and into openings 302 (shown in FIG. 11) in the first outer plate 141 of the battery cell holding frame 50 to couple the second outer plate 100 to the battery cell holding frame 50.

[0088] Additional bolts 103 (shown in FIG. 8) extend through openings 2021 in the second outer plate 100 and into openings 361 (shown in FIG. 13) in the second outer plate 142 of the battery cell holding frame 50 to couple the second outer plate 100 to the battery cell holding frame 50.

[0089] Additional bolts 104 (shown in FIG. 8) extend through openings 2022 in the second outer plate 100 and into openings 362 (shown in FIG. 13) in the second outer plate 142 of the battery cell holding frame 50 to couple the second outer plate 100 to the battery cell holding frame 50.

[0090] Circuit Board 8 and 66, the circuit board 120 includes a battery management controller 2100 (shown in FIG. 8) electrically coupled to the first and second plurality of cylindrical battery cells 56, 76 for monitoring operation of the battery cells 56, 76. The circuit board 120 is coupled to ends of the first and second retention housings 54, 74.

[0091] Electrical Busbar 8, an electrical bus bar 122 is provided to electrically couple together the first plurality of cylindrical battery cells 56 and the second plurality of cylindrical battery cells 76. In particular, the electrical bus bar 122 is electrically coupled to electrical bus bar 458 (electrically coupled to the battery cells 56) and to electrical bus bar 1456 (electrically coupled to the battery cells 76).

[0092] Cover plate 8 and 66-68, a cover plate 126 is attached to the first and second outer plates 90, 100 to cover the circuit board 120. The cover plate 126 includes a plate portion 2200 and retention clip members 2201, 2202, 2203, 2204, 2205, 2206 extending in a first direction from the plate portion 2200. The retention clip members 2201, 2202 are coupled to the tab members 1912, 1910 (shown in FIG. 59) of the first outer plate 90, respectively. The retention clip members 2203, 2204 are coupled to the tab members 2010, 2012 (shown in FIG. 63) of the second outer plate 100, respectively. The retention clip members 2205, 2206 are coupled to the corresponding tab members to couple the cover plate 126 to the first and second retention housings 54, 74. In the exemplary embodiment, the cover plate 126 is constructed from plastic.

[0093] 69-73, some of the assembly steps for assembling the battery module 32 are shown. As shown in FIG. 69, the first and second holding housings 54,74 holding the first and second plurality of cylindrical battery cells 56,76 therein, respectively, are moved toward the battery cell holding frame 50. As shown in FIG. 70 and FIG. 71, the first and second holding housings 54,74 are coupled together and additionally coupled to the battery cell holding frame 50. As shown in FIG. 72, the first and second outer plates 90,100 are moved toward the first and second holding housings 54,74, respectively. As shown in FIG. 73, the first and second outer plates 90,100 are coupled to the first and second holding housings 54,74.

[0094] 1, 10 and 20, the operation of the battery system 20 will be described in more detail.

[0095] In general overview, the fluid supply 40 pumps fluid through the inlet port 640 of the first retention housing 54 and into the central cooling plate member 140 of the battery cell retention frame 50. The central cooling plate member 140 transfers thermal energy from the first and second pluralities of cylindrical battery cells 56, 76 into the fluid. The fluid flows from the central cooling plate member 140 out the outlet port 1640 of the second retention housing 74, cooling the first and second pluralities of cylindrical battery cells 56, 76.

[0096] The operation of the battery system 20 will now be described more specifically. The fluid supply 40 pumps fluid through the conduit 42 to the inlet port 640 of the battery cell holding frame 50. The fluid flows from the inlet port 640 into the inlet opening 208 (shown in FIG. 20) of the first manifold portion 161 and then into the longitudinal opening 210 of the first manifold portion 161. From the longitudinal opening 210, the fluid flows through the flow opening 214 of the first manifold portion 161 and into the internal cooling channel 184. The fluid flows through the internal cooling channel 184 and through the flow opening 244 of the second manifold portion 162 and into the longitudinal opening 240 of the second manifold portion 162. From the longitudinal opening 240, the fluid flows through the outlet opening 238 and the outlet port 1640 of the second manifold portion 162 and then through the conduit 44 to the fluid supply 40. Referring to FIG. 10 , while fluid flows through the battery cell holding frame 50, thermal energy is transferred from the first plurality of cylindrical battery cells 56 and the second plurality of cylindrical battery cells 76 to the battery cell holding frame 50 and into the fluid flowing through the battery cell holding frame 50 to cool the battery cells 56, 76.

[0097] 3, 19, and 74, the battery module 32 can cool the first and second pluralities of cylindrical battery cells 56, 76 without using a fluid supply system 30. In particular, the central cooling plate member 140 of the battery cell holding frame 50 transfers thermal energy from the first and second pluralities of cylindrical battery cells 56, 76 through the frame 54 to the first and second outer plates 141, 142 of the battery cell holding frame 50 to cool the battery cells 56, 76. The first and second outer plates 141, 142 transfer the thermal energy to the surrounding air proximate the first and second outer plates 141, 142.

[0098] The battery system 20 with the battery module 32 offers significant advantages over other systems. In particular, the battery module 32 has an advantage in that the battery module 32 uses the first and second holding housings 54, 74 to hold the battery cell holding frame 50, which may be air-cooled or fluid-cooled. In particular, the first and second holding housings 54, 74 have inlet and outlet ports 640, 1640, respectively, for transmitting fluid through the battery cell holding frame 50 to cool the cylindrical battery cells. Alternatively, the battery cell holding frame 50 may be air-cooled to cool the cylindrical battery cells. Additionally, the first and second holding housings 54, 74 provide the battery module 32 with improved structural integrity.

[0099] While the claimed invention has been specifically described in connection with only a limited number of embodiments, it will be readily understood that the invention is not limited to such disclosed embodiments. Instead, the claimed invention can be modified to include various modifications, alterations, substitutions or equivalent arrangements not described herein, but which are consistent with the spirit and scope of the invention. Moreover, while several embodiments of the claimed invention have been described, it will be understood that aspects of the invention may include only some of the described embodiments. Thus, the claimed invention is not limited by the foregoing description.

Claims

1. A battery module, a battery cell holding frame having a central cooling plate member and first and second outer side plates, said central cooling plate member having first and second manifold portions and first and second intermediate walls disposed between said first and second manifold portions and coupled to said first and second manifold portions, said first and second intermediate walls forming internal cooling channels therebetween in fluid communication with said first and second manifold portions, said first and second outer side plates being coupled to said first and second manifold portions, respectively, and extending perpendicular to said central cooling plate member; a first retention housing disposed within an area defined by the first intermediate wall and the first and second outer plates, the first retention housing having an end wall defining a first interior area, and a first side wall, a second side wall, a third side wall and a fourth side wall, the first side wall, the second side wall, the third side wall and the fourth side wall of the first retention housing being coupled to the end wall to define a first open end, the first retention housing retaining therein a first plurality of cylindrical battery cells in thermal communication with the first intermediate wall, the first side wall of the first retention housing having an inlet port in fluid communication with the first manifold portion; a second retention housing disposed within an area defined by the second intermediate wall and the first and second outer panels, the second retention housing having an end wall forming a second interior area, and a first side wall, a second side wall, a third side wall and a fourth side wall, the first side wall, the second side wall, the third side wall and the fourth side wall of the second retention housing being coupled to the end wall to define a second open end, the second retention housing retaining therein a second plurality of cylindrical battery cells in thermal communication with the second intermediate wall, the first side wall of the second retention housing having an outlet port in fluid communication with the second manifold portion.

2. the first retention housing has a first retention clip member on the first side wall; 2. The battery module of claim 1, wherein the second retention housing has a first tab member on the first side wall such that the first retention clip member is engaged with a first tab member to couple the first retention housing to the second retention housing.

3. the first retention housing has a second retention clip member on the second side wall; 3. The battery module of claim 2, wherein the second retention housing has a second tab member on the second side wall such that the second retention clip member is engaged with the second tab member to couple the first retention housing to the second retention housing.

4. a first electrical bus bar coupled to the third side wall of the first retention housing, the first electrical bus bar additionally electrically coupled to the first plurality of cylindrical battery cells; and 4. The battery module of claim 1, further comprising a second electrical bus bar coupled to the fourth side wall of the first retention housing, the second electrical bus bar additionally electrically coupled to the second plurality of cylindrical battery cells.

5. The battery module of any one of claims 1 to 4, wherein the end wall of the first retention housing has a plurality of apertures extending therethrough.

6. 6. The battery module of claim 5, wherein each of the plurality of openings in the end wall of the first retention housing is sized and shaped such that each cylindrical battery cell has a positive terminal and a negative terminal accessible through a respective opening of the plurality of openings.

7. 6. The battery module of claim 5, wherein the end wall of the first retention housing has a plurality of mating tab groups extending toward the first open end, each mating tab group contacting an outer surface of a respective cylindrical battery cell of the first plurality of cylindrical battery cells such that each cylindrical battery cell of the first plurality of cylindrical battery cells is aligned with a respective opening of a plurality of openings in the end wall of the first retention housing.

8. a first retaining wall having a plurality of holes extending therethrough, a first retention wall coupled to the first retention housing within the first interior region to retain the first plurality of cylindrical battery cells between the first retention wall and an end wall of the first retention housing; and 8. The battery module of claim 1, further comprising bottom end surfaces of the cylindrical battery cells extending through the holes and contacting a first thermally conductive layer on the first intermediate wall.

9. 9. The battery module according to claim 1, further comprising a first outer plate coupled to the first holding housing and to the first and second outer plates of the battery cell holding frame.

10. 10. The battery module of claim 9, further comprising a second outer plate coupled to said second holding housing and to said first and second outer plates of said battery cell holding frame.

11. the first outer panel having a first retaining clip member; 11. The battery module of claim 10, wherein the first retention housing has a first tab member on the first side wall such that the first retention clip member of the first outer panel is engaged with a first tab member to couple the first outer panel to the first retention housing.

12. further comprising a first bolt and a second bolt; the first exterior panel has a first opening and a second opening extending therethrough; the first and second outer plates of the battery cell holding frame have first and second openings extending therethrough; the first bolt extends through the first opening in the first outer plate and the first opening in the first outer side plate to couple the first outer plate to the battery cell holding frame; 12. The battery module of claim 11, wherein the second bolt extends through the second opening in the second outer plate and the second opening in the first outer plate to couple the first outer plate to the battery cell holding frame.

13. The battery module according to any one of claims 1 to 12, wherein the battery cell holding frame further comprises a first thermally conductive layer and a second thermally conductive layer coupled to the first intermediate wall and the second intermediate wall, respectively.

14. The battery module according to any one of claims 1 to 13, wherein the structure of the first retaining housing is the same as the structure of the second retaining housing.

15. 15. The battery module of claim 1, wherein fluid flows through an inlet port of the first holding housing and into the central cooling plate member, the central cooling plate member transfers thermal energy from the first plurality of cylindrical battery cells and the second plurality of cylindrical battery cells into the fluid, and the fluid flows from the central cooling plate member and out an outlet port of the second holding housing to cool the first plurality of cylindrical battery cells and the second plurality of cylindrical battery cells.

16. 2. The battery module of claim 1, wherein the central cooling plate member transfers thermal energy from the first plurality of cylindrical battery cells and the second plurality of cylindrical battery cells through the central cooling plate member to the first outer plate and the second outer plate to cool the first plurality of cylindrical battery cells and the second plurality of cylindrical battery cells, and the first outer plate and the second outer plate transfer the thermal energy to ambient air proximate to the first outer plate and the second outer plate.

17. 1. A battery system comprising: A battery module having a battery cell holding frame, a first holding housing, and a second holding housing, the battery cell holding frame has a central cold plate member, and first and second outer side plates, the central cold plate member having first and second manifold portions, and first and second intermediate walls disposed between and coupled to the first and second manifold portions, the first and second intermediate walls forming internal cooling channels therebetween in fluid communication with the first and second manifold portions, the first and second outer side plates being coupled to the first and second manifold portions, respectively, and extending perpendicular to the central cold plate member, the first retention housing is disposed within an area defined by the first intermediate wall and the first and second outer plates, the first retention housing having an end wall defining a first interior area, and a first side wall, a second side wall, a third side wall and a fourth side wall, the first side wall, the second side wall, the third side wall and the fourth side wall of the first retention housing being coupled to the end wall to define a first open end, the first retention housing retaining therein a first plurality of cylindrical battery cells in thermal communication with the first intermediate wall, the first side wall of the first retention housing having an inlet port in fluid communication with the first manifold portion; the second retention housing is disposed within an area defined by the second intermediate wall and the first and second outer plates, the second retention housing having an end wall forming a second interior area, and a first side wall, a second side wall, a third side wall and a fourth side wall, the first side wall, the second side wall, the third side wall and the fourth side wall of the second retention housing being coupled to the end wall to form a second open end, the second retention housing retaining therein a second plurality of cylindrical battery cells in thermal communication with the second intermediate wall, and the first side wall of the second retention housing having an outlet port in fluid communication with the second manifold portion. A battery module, and a fluid supply system fluidly coupled to the inlet port and the outlet port, supplying fluid to the inlet port such that fluid flows through a first manifold portion of the battery cell holding frame and an interior cooling channel of the battery cell holding frame, through a second manifold portion of the battery cell holding frame, and out of the outlet port to extract thermal energy from the first plurality of cylindrical battery cells and the second plurality of cylindrical battery cells. a battery system.

18. 20. The battery system of claim 17, wherein the fluid supply system includes a fluid supply and a first conduit and a second conduit, the first conduit coupled to the fluid supply and the inlet port between the fluid supply and the inlet port, and the second conduit coupled to the fluid supply and the outlet port between the fluid supply and the outlet port.

Images