A modular battery pack

Abstract

A modular battery pack with six sides includes a plurality of battery cells, a first cell holder and a second cell holder having an opening or recess for receiving the ends of the battery cells, a power socket connected to one of the plurality of battery cells, two plates attached to the sides of the cell holders, and two side housings that together form four sides of the modular battery pack, wherein the two plates form the fifth and sixth sides of the battery pack.

Description

[Technical Field]

[0001] The present invention relates generally to an apparatus for holding an array of battery cells in a modular battery pack inside a mobile vehicle such as a light electric vehicle. [Previous Technology]

[0002] A device for holding an array of battery cells in a modular battery pack. [Summary of the Invention]

[0003] In one embodiment, a modular battery pack having six sides includes: a plurality of battery cells, each cell having a first end and a second end; a first cell holder having a first side and a second side disposed opposite to the first side, the first side having an opening or a recess to receive the first end of the battery cell; a second cell holder having a first side and a second side disposed opposite to the first side, the first side having an opening or a recess to receive the second end of the battery cell; an electrical outlet connected to the plurality of battery cells; a first plate attached to the second side of the first cell holder; a second plate attached to the second side of the second cell holder; and a first side housing and a second side housing, which together form four sides of the modular battery pack, wherein the first plate forms a fifth side of the battery pack, and wherein the second plate forms a sixth side of the battery pack.

[0004] In another embodiment, the first cell holder includes slats on the second side and may further include fittings on the second side. In various embodiments, the modular battery pack may further include a thermally conductive adhesive in contact with one of the battery cells and the first and second slats. In another embodiment, the modular battery pack further includes bus bars in contact with one of the first and second cell holders.

[0005] In yet another embodiment, the first unit retainer and the second unit retainer may comprise polycarbonate, and may further comprise at least one compound selected from the group consisting of acrylonitrile butadiene styrene, polytetrafluoroethylene, aromatic phosphate ester, phosphazene, bisphenol-A diphenyl phosphate, triphenyl phosphate, and resorcinol bis-diphenyl phosphate. In various embodiments, the first unit retainer and the second unit retainer comprise thermally conductive polycarbonate.

[0006] In embodiments not yet disclosed, the first side shell and the second side shell are made of a thermoplastic plastic, preferably polycarbonate, and may also contain at least one compound selected from the group consisting of acrylonitrile-butadiene-styrene, polytetrafluoroethylene, aromatic phosphates, phosphazenes, bisphenol A diphenylphosphazene, triphenylphosphazene, and resorcinol bis(diphenylphosphazene).

[0007] In yet another embodiment, the first plate and / or the second plate comprises metal, preferably more than 80% metal, preferably aluminum. In another embodiment, the first plate and / or the second plate comprises thermally conductive polycarbonate. In various embodiments, the first plate or the second plate further comprises cooling channels.

[0008] In different embodiments of the present invention, each of the six sides of the modular battery pack faces four other sides spaced 90 degrees apart, and another side spaced 180 degrees apart. In another embodiment, two of these sides comprise metal plates and may be primarily metal, while four of these sides are substantially plastic and may be primarily plastic.

[0009] In yet another embodiment, the first side housing and the second side housing substantially surround the first plate, the second plate, the front unit holder, the rear unit holder, and the battery cell. In another embodiment, the first side housing and the second side housing together protrude further than the first plate and the second plate in any direction.

[0010] In another embodiment, the modular battery pack further includes a foam disposed between the first cell holder and the second cell holder, preferably wherein the foam has a thermal conductivity of 1 W / mK or higher. In another embodiment, an electric vehicle includes any of the above-described modular battery packs.

[0011] These and other advantages and benefits of the present invention will become apparent from the following detailed description of the invention.

Implementation Method

[0029] This invention provides a modular battery pack that can be used in a lightweight electric vehicle, such as an electric motorcycle or rickshaw. The battery pack used in these applications should be compact, shock-resistant, and modular, so that it can be connected to other battery packs as needed. As described herein, the battery configuration securely holds an array of battery cells for use in a moving vehicle. Polycarbonate molded parts surround the battery cell array on four sides, while metal plates surround the battery cells on two sides, providing both structural strength and shock resistance, as well as the ability to cool the battery cells during operation.

[0030] The modular battery pack includes an array of battery cells held in place by two cell holders located on opposite sides of the array. The cell holders may be made of fire-resistant polycarbonate, polycarbonate, and a mixture of acrylonitrile-butadiene-styrene (ABS), thermally conductive polycarbonate, or mixtures of such materials. One of the cell holders may have busbars to aid in thermal conductivity for cooling.

[0031] The modular battery pack also includes two plates, which are preferably substantially flat and parallel to each other, and preferably made of metal, such as aluminum, or thermally conductive polycarbonate, to provide structural stability and thermal conductivity. Two plastic parts, preferably comprising a main polycarbonate layer, are mounted around the battery cell array, cell holders, and plates, surrounding the battery cells on four sides, and preferably mounted on top of the plates, providing impact resistance to the battery pack in the event of an accident involving the electric vehicle. Finally, the modular battery pack includes electrical connections from the battery cells to the outside of the modular battery pack. Polycarbonate

[0032] Suitable aromatic polycarbonates and / or aromatic polyester carbonates are known in the literature or can be prepared by processes known in the literature (for the preparation of aromatic polycarbonates, see, for example, Schnell, "Chemical and Physical Properties of Polycarbonates", Transscience Press, 1964, and DE-AS 1 495 626, DE-A 2 232 877, DE-A 2 703 376, DE-A 2 714 544, DE-A 3 000 610, DE-A 3 832 396; for the preparation of aromatic polyester carbonates, see, for example, DE-A 3 007 934).

[0033] Aromatic polycarbonates can be prepared, for example, via an interfacial process by reacting a bisphenol with a carbonate halide, preferably phosgene, and / or with an aromatic dicarboxylic acid dihalide, preferably a benzene dicarboxylic acid dihalide, and optionally by using a chain terminator, such as a monophenol, and optionally by using branching agents having three or more functions, such as triphenols or tetraphenols. They can also be prepared via a melt polymerization process involving the reaction of a bisphenol with, for example, diphenyl carbonate.

[0034] The bisphenol used to prepare aromatic polycarbonates and / or aromatic polyester carbonates is preferably a bisphenol of formula (I). (I), wherein A is a single bond, C1- to C5-alkylene, C2- to C5-alkylene, C5- to C6-cycloalkylene, O, SO-, -CO-, -S-, -SO2-, C6- to C12-arylene, or a group of formula (II) or (III), optionally containing other aromatic rings that can be further melted to A. (II) (III) B in each case is C1- to C12-alkyl, preferably methyl, halogen, preferably chlorine and / or bromine, x is independently 0, 1 or 2, p is 1 or 0, and R5 and R6 may be individually selected for each X1, and each is independently hydrogen or C1- to C6-alkyl, preferably hydrogen, methyl or ethyl. X1 is a carbon atom, and m is an integer from 4 to 7, preferably 4 or 5, provided that R5 and R6 are both alkyl atoms on at least one X1 atom.

[0035] Preferred diphenol-based hydroquinones, resorcinols, dihydroxydiphenols, bis(hydroxyphenyl)-C1-C5-alkanes, bis(hydroxyphenyl)-C5-C6-cycloalkanes, bis(hydroxyphenyl) ethers, bis(hydroxyphenyl) sulfoxides, bis(hydroxyphenyl) ketones, bis(hydroxyphenyl)-sulfones, and α,α-bis(hydroxyphenyl)-diisopropyl-benzenes, and their derivatives brominated and / or chlorinated on the ring.

[0036] Particularly preferred are bisphenols such as 4,4'-dihydroxydiphenyl, bisphenol A, 2,4-bis(4-hydroxy-phenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4'-dihydroxydiphenyl sulfide, 4,4'-dihydroxydiphenylsulfone, and their di- and tetrabrominated forms. Tetra-brominated or chlorinated derivatives, such as 2,2-bis(3-chloro-4-hydroxyphenyl)-propane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)-propane, or 2,2-bis(3,5-dibromo-4-hydroxyphenyl)-propane, are particularly preferred.

[0037] Diphenols may be used alone or in any mixture. Diphenols are known in the literature or may be obtained according to processes known in the literature.

[0038] The chain terminator system suitable for preparing thermoplastic aromatic polycarbonates is, for example, phenol, p-chlorophenol, p-tert-butylphenol, or 2,4,6-tribromophenol, but also includes long-chained alkylphenols, such as 4-[2-(2,4,4-trimethylpentyl)]-phenol, 4-(1,3-tetramethyl-butyl)-phenol according to DE-A 2 842 005, or monoalkylphenols or dialkylphenols having a total of 8 to 20 carbon atoms in the alkyl substituents, such as 3,5-ditert-butylphenol. The chain terminator includes di-tert-butylphenol, p-isooctylphenol, p-tert-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)-phenol, and 4-(3,5-dimethylheptyl)-phenol. The amount of chain terminator used ranges from approximately 0.5 mol% to 10 mol%, depending on the total molar amount of diphenols used in a particular case.

[0039] The thermoplastic aromatic polycarbonate has an average molecular weight (Mw, measured by means of GPC (gel permeation chromatography) of polycarbonate standard) of 15,000 to 80,000 g / mol, more preferably 19,000 to 32,000 g / mol, particularly preferably 22,000 to 30,000 g / mol.

[0040] Thermoplastic aromatic polycarbonates can be branched in a known manner, preferably based on the total amount of bisphenols used, by incorporating 0.05 to 2.0 mol% of compounds having three or more functional groups, such as compounds having three or more phenolic groups. Linear polycarbonates are preferred, and more preferably based on bisphenol A.

[0041] Both homopolycarbonates and copolycarbonates are suitable. For the preparation of the copolycarbonate of component A, based on the total amount of bisphenol to be used, 1 to 25 wt.%, preferably 2.5-25 wt.%, of polydiorganosiloxanes having hydroxyaryloxy end groups may also be used. These are known (US 3 419 634) and can be prepared according to processes known in the literature. Copolycarbonates containing polydiorganosiloxanes are also suitable; for example, the preparation of copolycarbonates containing polydiorganosiloxanes described in DE-A 3 334 782.

[0042] The aromatic dicarboxylic acid dihalides used to prepare aromatic polyester carbonates are preferably isophthalic acid, terephthalic acid, diphenyl ether 4,4'-dicarboxylic acid, and naphthalene-2,6-dicarboxylic acid dichlorides.

[0043] Particularly preferred is a mixture of isophthalic acid and terephthalic acid dichloride in a ratio of 1:20 to 20:1.

[0044] In the preparation of polyester carbonate, a carbonate halide and a preferred phosgene are used as bifunctional acid derivatives.

[0045] In addition to the monophenols already mentioned, suitable chain terminators for the preparation of aromatic polyester carbonates are also chlorocarbonates and acid chlorides of aromatic monocarboxylic acids, which can be selectively replaced by C1- to C22-alkyl groups or by halogen atoms, and aliphatic C2- to C22-monocarboxylic acid chlorides.

[0046] In each case, the amount of the chain terminator ranges from 0.1 to 10 mol%, based on the mole number of the bisphenol in the case of the phenolic chain terminator, and based on the mole number of the dicarboxylic acid dichloride in the case of the monocarboxylic acid chloride chain terminator.

[0047] In the preparation of aromatic polyester carbonates, one or more aromatic hydroxycarboxylic acids may be used in addition.

[0048] Aromatic polyester carbonates can be linear and branched in a known manner (see DE-A 2 940 024 and DE-A 3 007 934 in this regard), with linear polyester carbonates being preferred.

[0049] For example, carboxylic acid chlorides having three or more functions can be used as branching agents, such as trimesic acid trichloride, cyanuric acid trichloride, 3,3',4,4'-benzophe-none-tetracarboxylic acid tetrachloride, 1,4,5,8-naphthalene-tetracarboxylic acid tetrachloride, or pyromellitic acid tetrachloride, in an amount from 0.01 to 1.0 mol% (based on the dicarboxylic acid dichloride used), or phenols having three or more functionalities, such as phloroglucinol, 4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-hept-2-ene, 4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-heptane, 1,3,5-tri-( 1,3,5-tri-(4-hydroxyphenyl)-benzene, 1,1,1-tri-(4-hydroxyphenyl)-ethane, tri-(4-hydroxyphenyl)-phenylmethane, 2,2-bis[4,4-bis(4-hydroxyphenyl)-cyclohexyl]propane l]-propane), 2,4-bis(4-hydroxyphenyl-isopropyl)-phenol, tetra-(4-hydroxyphenyl)-methane, 2,6-bis(2-hydroxy-5-methylbenzyl)-4-methylphenol, 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)- Propane (2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)-propane), tetra-(4-[4-hydroxyphenyl-isopropyl]-phenoxy)-methane, and 1,4-bis[4,4'-dihydroxytriphenyl)-methyl]-benzene are used in amounts from 0.01 to 1.0 mol%, based on the use of bisphenols. Phenolic branching agents can be placed in containers containing bisphenols; acidic chloride branching agents can be introduced together with acidic dichloride.

[0050] The content of carbonate structural units in the thermoplastic aromatic polyester carbonate can be varied as needed. Based on the sum of ester groups and carbonate groups, the content of carbonate groups is preferably up to 100 mol%, particularly up to 80 mol%, and especially preferably up to 50 mol%. The esters and carbonates contained in the aromatic polyester carbonate can exist in the polycondensation product in a bulk form or be randomly distributed.

[0051] Thermoplastic aromatic polycarbonates and polyester carbonates may be used alone or in any mixture. Other ingredients

[0052] In some compositions, a thermally conductive additive may be included, particularly in those parts or portions of the components, which can assist in cooling the battery by transferring heat to the plate or other components. This additive may be graphene, graphite, aluminum or other metal particles, carbon fiber, or another conductor, or a thermally conductive polymer. In a preferred embodiment, expanded graphite is used as the thermally conductive additive.

[0053] Expanded graphite and its production method are known to those skilled in the art. The amount of useful expanded graphite present in the composition of the present invention is from 10% to 70%, more preferably from 20% to 60%, and most preferably from 30% to 50%. Expanded graphite may be present in the composition of the present invention, and the amount present may range between any combination of these values, including the listed values. The inventors have found that at least 90% of the expanded graphite particles should have a particle size of at least 200 micrometers.

[0054] The plastic molded parts may further include at least one compound selected from the group consisting of acrylonitrile butadiene styrene (ABS), polytetrafluoroethylene, aromatic phosphates, phosphazenes, bisphenol A diphenyl phosphate, triphenyl phosphate, and resorcinol bis(diphenyl phosphate).

[0055] The phosphazene used is a cyclic phosphazene (X) according to chemical formula (X), wherein R is identical or different in each case and represents -amino, -C1- to C8-alkyl, preferably methyl, ethyl, propyl or butyl, each of which may be selectively halogenated, preferably fluorinated, more preferably monohalogenated, -C1- to C8-alkoxy, preferably methoxy, ethoxy, propoxy or butoxy, -C5- to C6-cycloalkyl, each of which may be selectively substituted by alkyl, preferably C1-C4-alkyl, and / or by halogen, preferably chlorine and / or bromine, -C6- to C20-aryloxy, preferably phenoxy, naphthoxy, each of which may be selectively substituted by alkyl, preferably C1-C4-alkyl, and / or by halogen, preferably chlorine, bromine, and / or by hydroxyl. -C7 to C12-aralkyl, preferably phenyl-C1-C4-alkyl, each may be optionally substituted by an alkyl group, preferably C1-C4-alkyl, and / or by a halogen, preferably chlorine and / or bromine, or a halogen radical, preferably chlorine or fluorine, or an OH radical, k having the above meanings.

[0056] Preferably, the compounds are propoxyphosphazene, phenoxyphosphazene, methylphenoxyphosphazene, aminophosphazene and fluoroalkylphosphazenes, and phosphazenes having the following structure: in the compounds shown above, k = 1, 2 or 3.

[0057] Preferably, it is phenoxyphosphazene (all R=phenoxy) having an oligomer content of k=1 (C1) from 60 to 98 mol%. (XI)

[0058] In cases where the phosphazene according to chemical formula (X) is halogenated on phosphorus, for example from starting materials of incomplete reaction, the content of the halogenated phosphazene on phosphorus is preferably less than 1000 ppm, more preferably less than 500 ppm.

[0059] Phosphazene can be used alone or in mixtures, that is, the free radicals R can be completely identical, or the two or more free radicals of chemical formula (X) can be different. It is preferable that the free radicals R of phosphazene are completely identical.

[0060] In another preferred embodiment, only phosphazenes with free radical R are used. In a preferred embodiment, the content of tetramer (k=2) (C2) is from 2 to 50 mol%, more preferably from 5 to 40 mol%, even more preferably from 10 to 30 mol%, and particularly preferably from 10 to 20 mol%, depending on the amount of phosphazene.

[0061] In a preferred embodiment, based on the amount of phosphazene, the content of higher oligomeric phosphazenes (k=3, 4, 5, 6 and 7) (C3) is from 0 to 30 mol%, more preferably from 2.5 to 25 mol%, even more preferably from 5 to 20 mol%, and particularly preferably from 6 to 15 mol%.

[0062] In a preferred embodiment, the content of oligomers having k >= 8 (C4) is from 0 to 2.0 mol%, and more preferably from 0.10 to 1.00 mol%, based on the amount of phosphazene.

[0063] In another preferred embodiment, as far as the contents (C2-C4) are concerned, the phosphazene satisfies all three conditions above.

[0064] Based on the total amount of phosphazenes, the preferred phosphazenes are phenoxyphosphazenes having a trimer content of 65 to 85 mol% (k=1), a tetramer content of 10 to 20 mol% (k=2), a higher oligomeric phosphazene content of 5 to 20 mol% (k=3, 4, 5, 6 and 7), and a phosphazene oligomer with k>=8 having a content of 0 to 2 mol%.

[0065] Based on the total amount of phosphazenes, the phosphazenes are particularly preferably phenoxyphosphazenes having a trimer content of 70 to 85 mol% (k=1), a tetramer content of 10 to 20 mol% (k=2), a higher oligomeric phosphazene content of 6 to 15 mol% (k=3, 4, 5, 6 and 7), and a phosphazene oligomer with k>=8 having a content of 0.1 to 1 mol%.

[0066] In another particularly preferred embodiment, based on the total amount of phosphazene, the phosphazene is a phenoxyphosphazene having a trimer content of 65 to 85 mol% (k=1), a tetramer content of 10 to 20 mol% (k=2), a higher oligomeric phosphazene content of 5 to 15 mol% (k=3, 4, 5, 6 and 7), and a phosphazene oligomer having a k>=8 content of 0 to 1 mol%.

[0067] n The weighted arithmetic mean of k is defined by the following formula: where xi is the content of oligomer ki, and the sum of all xi is 1.

[0068] In another alternative embodiment, n is in the range of 1.10 to 1.75, preferably from 1.15 to 1.50, more preferably from 1.20 to 1.45, and especially preferably from 1.20 to 1.40 (inclusive of the limits of the range).

[0069] For example, phosphazenes and their preparation are described in EP A 728 811, DE A 1 961668 and WO 97 / 40092.

[0070] The oligomers of phosphazenes in the mixed sample can also be detected and quantified by 31P NMR (chemical shift; δ trimer: 6.5 to 10.0 ppm; δ tetramer: -10 to 13.5 ppm; δ higher oligomer: -16.5 to -25.0 ppm) after recombination.

[0071] Plastic molded parts may further contain traditional polymer additives, such as fire retardants (other than antidripping agents), lubricants and release agents (e.g., pentaerythritol tetrastearate), nucleating agents, stabilizers (e.g., UV / light stabilizers, heat stabilizers, antioxidants, transesterification inhibitors, hydrolysis stabilizers), antistatic agents (e.g., conductive blacks, carbon fibers, carbon nanotubes, and organic antistatic agents such as polyalkylene ethers, alkyl sulfonates, or polyamide-containing polymers), as well as colorants, pigments, fillers, talc, and reinforcing materials, especially glass fibers, mineral-reinforcing materials, and carbon fibers.

[0072] As a stabilizer, sterically hindered phenols and phosphites or mixtures thereof are preferred, such as Irganox® B900 (Ciba Speciality Chemicals). Pentaerythritol tetrastearate is preferred as a release agent. Carbon black is further preferred as a black pigment (e.g., Blackpearls).

[0073] It also includes optional further additives, particularly preferably a molded compound containing a release agent, particularly preferably pentaerythritol tetrastearate, in an amount of 0.1 to 1.5 parts by weight, more preferably 0.2 to 1.0 parts by weight, and particularly preferably 0.3 to 0.8 parts by weight. It also includes optional additional additives, particularly preferably at least one stabilizer selected from sterically hindered phenols, phosphites, and mixtures thereof, and particularly preferably Irganox® B900, in an amount of 0.01 to 0.5 parts by weight, more preferably 0.03 to 0.4 parts by weight, and particularly preferably 0.06 to 0.3 parts by weight.

[0074] As described above, the composition of the plastic molded parts may further include anti-drip polytetrafluoroethylene (PTFE) or a PTFE-containing composition, for example, a PTFE masterbatch containing a polymer or copolymer of styrene or methyl methacrylate, in powder form or in the form of a condensed mixture.

[0075] The fluorinated polyolefin used as an anti-drip agent has a high molecular weight and a glass transition temperature exceeding -30°C and generally exceeding 100°C. It preferably has a fluorine content of 65 to 76 wt.%, particularly 70 to 76 wt.%, and an average particle diameter d50 of 0.05 to 1000 μm, more preferably 0.08 to 20 μm. Generally, the fluorinated polyolefin has a density of 1.2 to 2.3 g / cm³. Preferred fluorinated polyolefins are polytetrafluoroethylene, polyvinylidene fluoride, tetrafluoroethylene / hexafluoropropylene, and ethylene / tetrafluoroethylene copolymers. Fluorinated polyolefins are known (see "Vinyl and Related Polymers" pp. 484-494, Schildknecht, John Wiley & Sons, Inc., New York, 1962; "Fluorinated Polymers" pp. 623-654, Volume 13, Wall, Wiley-Interscience, John Wiley & Sons, Inc., New York, 1970; "Encyclopedia of Modern Plastics" pp. 134 and 774, Volume 47, No. 10A, October 1970, McGraw-Hill, New York, McGraw-Hill, New York, 1975-1976, Volume 52, No. 10A, October 1975; and US-PS 3 671 487, 3 723 373 and 3 723 373 3 72 ... 838 092).

[0076] They can be prepared by known processes, for example by polymerizing tetrafluoroethylene in an aqueous medium using a free radical-formed catalyst, such as sodium persulfate, potassium persulfate, or ammonium persulfate, at a pressure of 7 to 71 kg / cm² and at a temperature of 0 to 200°C, preferably at a temperature of 20 to 100°C (see U.S. Patent 2,393,967 for further details). Depending on the form in which they are used, these materials can have a density of 1.2 to 2.3 g / cm³ and an average particle size of 0.05 to 1000 μm.

[0077] The preferred fluorinated polyolefin has an average particle diameter of 0.05 to 20 μm, more preferably 0.08 to 10 μm, and a density of 1.2 to 1.9 g / cm3.

[0078] Suitable fluorinated polyolefin tetrafluoroethylene polymers that can be used in powder form have an average particle diameter of 100 to 1000 μm and a density of 2.0 g / cm³ to 2.3 g / cm³. Suitable tetrafluoroethylene polymer powders are commercial products and are supplied, for example, by DuPont under the trade name Teflon®.

[0079] It also includes optional additional additives, particularly preferably refractory compounds including fluorinated polyolefins, in an amount of 0.05 to 5.0 parts by weight, preferably 0.1 to 2.0 parts by weight, and particularly preferably 0.3 to 1.0 parts by weight of the plastic molded parts.

[0080] In one embodiment, the plastic molded part is substantially non-conductive and thermally conductive.

[0081] The embodiments discussed below refer to additional materials for the structure, such as thermally conductive adhesives, foams, or other thermally conductive materials. Modular battery pack

[0082] One embodiment of the present invention, namely the modular battery pack 10, is shown in FIG1. ​​FIG2 and FIG3 show additional views of the modular battery pack 10. Although the description herein uses front and back views, the modular battery pack 10 can be used in any orientation. These descriptions are merely for illustrating the various parts described herein.

[0083] Figure 4 shows the front unit holder 12 with its outer side facing upwards. On the outer side, there are slats 16 and attachments 18, designed to accommodate a busbar as described herein. Figure 5 shows the front unit holder 12 with its inner side facing upwards. This side includes an opening 20 for holding the battery unit. Figure 6 shows the rear unit holder 14 with its outer side facing upwards. On the outer side, an opening 22 for the battery unit is visible. Figure 7 shows the rear unit holder 14 with its inner side facing upwards. This view also shows the battery unit opening 22.

[0084] Figure 8 shows how the array 24 of battery cells 26 is assembled with the front cell holder 12 and the rear cell holder 14. Structural element 28 is also shown, which provides structural support and impact resistance by positioning along the edges and corners of the array 24. Figure 9 shows a cross-section of the cell holder holding the battery cells 30. Cross-section 32 is part of the cell holder, and as described above, it may be made of polycarbonate including thermally conductive polycarbonate. The battery cells 30 may be further held in place by a thermally conductive adhesive 34, which assists in cooling the battery cells 30. As shown in Figures 5 through 7, the thermally conductive adhesive 34 is attached to the battery cells 30, cross-section 32, and any surfaces adjacent to the cell holder through openings 20 or 22. As shown in Figure 13, the rear plate 52 is adjacent to the rear cell holder 14, and therefore the thermally conductive adhesive 34 will also be attached to the rear plate 52. As shown in Figure 10, the busbar 36 is positioned on the outside of the front unit holder 12 and held in place and aligned by the fitting 18. Figure 11 shows how the array 24 is assembled with the front unit holder and the rear unit holder 14 with the busbar 38. Also shown are the openings 40 for the electrical connections (not shown) to each battery cell. Figure 12 shows the battery wiring assembly 44, including the front unit holder, the rear unit holder 14, and the array 24 with the busbar 38. Also shown are the electrical connectors 42 and the power socket plug 46 connected by insulated wires 48.

[0085] In embodiments of the invention not shown, a foam composed of one or two portions of polyurethane or other suitable chemicals creates a unit structure to fill the space between battery cells in an array. The foam may be confined to the central region surrounding the cells, such as between a front cell holder and a rear cell holder, or it may fill the entire module space between a front panel and a rear panel. The foam can absorb impact forces that improve collision performance, provide improved resistance by increasing the creepage distance, and improve the module's moisture resistance and thermal management.

[0086] In one embodiment, the foam having a thermal conductivity of 1 W / mK or higher can provide a thermal path to or from the unit, allowing the unit to be cooled or heated depending on operating conditions. In another embodiment, the insulating foam can be used as a thermal break, having the ability to contain or slow flame propagation in cases of thermal runaway.

[0087] The foam used has a sufficiently low viscosity before curing, allowing it to be poured into the module before final assembly or injected into the module housing through a port after assembly. The volume of the introduced foam is calibrated according to its expansion properties to avoid excessive filling and expansion forces on the module. The modular battery pack may further include internal baffle components to prevent foam from filling areas where foam filling is not required.

[0088] Figure 13 shows the battery holder wiring assembly 44, with a front panel 50 and a rear panel 52 each attached to it via a connector 54. The front panel 50 is adjacent to the front cell holder with busbar 38, and the rear panel 52 is adjacent to the rear cell holder 14. In one embodiment, the front panel 50 does not directly contact any busbar on the front cell holder with busbar 38, but is offset from the busbar to avoid short circuits. Accessory 18 (shown in Figure 10) and other supports allow the front panel 50 to remain off-center from any busbar. Conversely, the rear panel 52 may directly contact the rear cell holder 14 and the thermally conductive adhesive 34 to form a thermal circuit from the battery cell 30 to the rear panel 52 for heat cooling. The rear plate 52 is preferably made of a conductive metal such as aluminum and has sufficient thickness to act as a thermal conductor for cooling the battery within the assembly 44, while the front plate 50 may be a thinner metal and may only provide structural strength and minimal cooling. Each of the front plate 50 and the rear plate 52 may contain 80% or more aluminum by weight. Alternatively, each of the front plate 50 and the rear plate 52 may be made of thermally conductive polycarbonate. In another embodiment, the front plate 50 is made of non-thermally conductive polycarbonate. In yet another embodiment, the rear plate is an active cooling plate, meaning it includes cooling channels through which coolant flows or contacts the rear plate to actively cool the plate during battery cell operation. In this embodiment, the rear plate may further include inlets and outlets for the cooling channels.

[0089] Figure 14 shows a wired battery holder with a plate assembly 60, which, along with side housings 56 and 58, are formed on four sides to substantially enclose the assembly 60 and together form a modular battery pack. While the side housings may not completely enclose the assembly 60 on all four sides, "substantially" means that the housing will continuously surround all four sides of the assembly, allowing for one or more holes or other openings in the housing. Furthermore, side housings 56 and 58 are designed as overlapping plates and enclose electrical connectors and wiring, except that the electrical connectors are exposed from the housing to allow connection to other electrical connections, such that the side housings protrude as far as possible in any direction. In this way, the battery can benefit from the impact resistance of the polycarbonate side housings while still utilizing plates for structural stability and cooling. In other embodiments, the side housings are primarily plastic, meaning that, viewed from the side, more than 50% of the area comprises plastic. In one embodiment, the side housings 56 and 58 will have grooves that capture the edges of one or both of the front panel 50 and the rear panel 52, and a sealant may be used to provide a watertight connection.

[0090] The modular battery pack described herein has six sides, as viewed from the front, rear, top, bottom, right, and left. In another embodiment, the six sides can be considered as six views, with four of these views forming a 90-degree angle with the first view and the sixth view forming a 180-degree angle with the first view. These sides are for reference only and do not need to be perfectly flat, horizontal, or of the same length, width, or area. Similarly, these sides can be rotated in any direction or orientation. These sides are described herein to demonstrate how many parts are assembled together, particularly plates 50 and 52, and side housings 56 and 58. However, when viewed from each of these six sides, four of the sides are substantially composed of plastic housings, and two sides comprise plates, preferably metal plates. In a further embodiment, two sides are primarily metal, and / or four sides are primarily plastic.

[0091] In another embodiment of FIG. 15, the front cell holder 62 is shown with its inner side facing upward and has an opening 64 for the battery cell. Furthermore, the front cell holder 62 includes recesses 66 aligned to accommodate a long rectangular strip, which may be present at the end of a prismatic or pouch-type battery. This rectangular feature will be designed as the exterior of a specially designed prismatic cell housing or as part of an adapter assembly of an existing prismatic or pouch-type cell. In this way, the front cell holder 62 can accommodate batteries of different formats without altering its design. In one embodiment, different types of batteries are modified or fitted with parts to secure them in the front cell holder 62. FIG. 16 shows a rear cell holder 68 with its inner side facing upward and having an opening 70 and a recess 72. The size of the recesses 66 and 72 can be designed in both shape and size to accommodate the intended size and shape of the battery they can support.

[0092] The modular battery pack can be connected to other modular battery packs as needed to increase power or capacity to power electric vehicles, such as electric motorcycles and rickshaws, or other electric vehicles or mobile power supply devices as needed.

[0093] The present invention includes: 1. A modular battery pack having six sides, comprising: a plurality of battery cells, each cell having a first end and a second end; a first cell holder having a first side and a second side disposed opposite to the first side, the first side having an opening or a recess to receive the first end of the battery cell; a second cell holder having a first side and a second side disposed opposite to the first side, the first side having an opening or a recess to receive the second end of the battery cell; a power socket connected to the plurality of battery cells; a first plate attached to the second side of the first cell holder; a second plate attached to the second side of the second cell holder; and a first side housing and a second side housing, which together form four sides of the modular battery pack, wherein the first plate forms a fifth side of the battery pack, and wherein the second plate forms a sixth side of the battery pack.

[0094] 2.1 The modular battery pack, wherein the first unit holder includes a strip on the second side.

[0095] 3.1 or 2 of the modular battery pack, wherein the first unit holder is included in the fitting on the second side.

[0096] 4. The modular battery pack described in any of the foregoing embodiments further includes a thermally conductive adhesive that contacts one of the battery cells and the first plate and the second plate.

[0097] 5. The modular battery pack described in any of the foregoing embodiments further includes a busbar that contacts one of the first cell holder and the second cell holder.

[0098] 6. The modular battery pack described in any of the foregoing embodiments, wherein the first cell holder and the second cell holder comprise polycarbonate.

[0099] 7. The modular battery pack described in any of the foregoing embodiments, wherein the first cell holder and the second cell holder further comprise at least one compound selected from the group consisting of acrylonitrile-butadiene-styrene, polytetrafluoroethylene, aromatic phosphates, phosphazenes, bisphenol A diphenylphosphazene, triphenylphosphazene, and resorcinol bis(diphenylphosphazene).

[0100] 8. The modular battery pack described in any of the foregoing embodiments, wherein the first cell holder and the second cell holder comprise thermally conductive polycarbonate.

[0101] 9. The modular battery pack described in any of the foregoing embodiments, wherein the first side shell and the second side shell are made of a thermoplastic plastic.

[0102] 10. The modular battery pack described in any of the foregoing embodiments, wherein the first side housing and the second side housing comprise polycarbonate.

[0103] 11. The modular battery pack described in any of the foregoing embodiments, wherein the first side shell and the second side shell further comprise at least one compound selected from the group consisting of acrylonitrile-butadiene-styrene, polytetrafluoroethylene, aromatic phosphates, phosphazenes, diphenol-A diphenylphosphazene, triphenylphosphazene, and resorcinol bis(diphenylphosphazene).

[0104] 12. The modular battery pack described in any of the foregoing embodiments, wherein the first plate or the second plate comprises metal, preferably more than 80% metal, preferably aluminum.

[0105] 13. The modular battery pack described in any of the foregoing embodiments, wherein the first plate and the second plate comprise metal, preferably aluminum.

[0106] 14. The modular battery pack described in any of the foregoing embodiments, wherein the first plate or the second plate comprises thermally conductive polycarbonate.

[0107] 15. The modular battery pack described in any of the foregoing embodiments, wherein the first plate and the second plate comprise thermally conductive polycarbonate.

[0108] 16. The modular battery pack described in any of the foregoing states, wherein the first plate or the second plate further includes a cooling channel.

[0109] 17. The modular battery pack described in any of the foregoing states, wherein each of the six sides faces the other four sides spaced 90 degrees apart, and the other side is spaced 180 degrees apart.

[0110] 18. The modular battery pack described in any of the foregoing states, wherein two of the sides comprise metal plates and four of the sides are substantially plastic.

[0111] 19. The modular battery pack described in any of the foregoing states, wherein two of the sides are primarily metal and four of the sides are primarily plastic.

[0112] 20. The modular battery pack described in any of the foregoing states, wherein the first side housing and the second side housing substantially surround the first plate, the second plate, the front cell holder, the rear cell holder, and the battery cell.

[0113] 21. The modular battery pack described in any of the foregoing states, wherein the first side housing and the second side housing together protrude further than the first plate and the second plate in any direction.

[0114] 22. The modular battery pack described in any of the foregoing embodiments further includes a foam disposed between the first cell holder and the second cell holder, preferably wherein the foam has a thermal conductivity of 1 W / mK or higher.

[0115] 23. An electric vehicle comprising the modular battery pack described in any of the foregoing embodiments. [Simplified Explanation of the Diagram]

[0012] For illustrative purposes and not limiting, the invention will now be described in conjunction with the drawings, wherein:

[0013] Figure 1 is a perspective view of the modular battery pack of the present invention, showing the rear panel;

[0014] Figure 2 is another perspective view of the modular battery pack in Figure 1, showing the front panel;

[0015] Figure 3 is a rear view of the modular battery pack in Figure 1;

[0016] Figure 4 is a perspective view of the front unit retainer, showing the front exterior facing the side;

[0017] Figure 5 is a perspective view of the front unit holder, showing the side facing the battery unit;

[0018] Figure 6 is a perspective view of the rear unit retainer, showing the rear exterior facing the side;

[0019] Figure 7 is a perspective view of the rear unit retainer, showing the side facing the battery unit;

[0020] Figure 8 is an exploded view of the battery cell array and the front and rear cell holders;

[0021] Figure 9 shows a portion of the rear battery holder and a cross-sectional view of the battery cell;

[0022] Figure 10 is a perspective view of the front unit retainer, showing the front exterior with the busbar attached to it facing the side;

[0023] Figure 11 is another exploded view of the battery cell array, front and rear cell holders, and attached busbars;

[0024] Figure 12 is a perspective view of a battery cell array, with front and rear cell holders attached, and with electrical connectors attached;

[0025] Figure 13 is an exploded view of the battery cell array, with front and rear cell holders attached, and electrical connectors attached, together with the front and rear panels.

[0026] Figure 14 is an exploded view of the modular battery pack in Figure 1;

[0027] FIG15 is a perspective view of the front unit holder according to another embodiment, showing the side facing the battery unit; and

[0028] FIG16 is a perspective view of the rear battery holder of the embodiment of FIG15, showing the side facing the battery cell.

Claims

1. A modular battery pack having six sides, comprising: a plurality of battery cells, each cell having a first end and a second end; a first cell holder having a first side and a second side disposed opposite to the first side, the first side having an opening or a recess to receive the first end of the battery cells; a second cell holder having a first side and a second side disposed opposite to the first side, the first side having an opening or a recess to receive the second end of the battery cells; a power socket connected to the plurality of battery cells; a first plate attached to the second side of the first cell holder; a second plate attached to the second side of the second cell holder; and a first side housing and a second side housing, which together form four sides of the modular battery pack, wherein the first plate forms a fifth side of the modular battery pack, and wherein the second plate forms a sixth side of the modular battery pack.

2. The modular battery pack as claimed in claim 1, wherein the first cell holder is included in a strip on the second side.

3. The modular battery pack as claimed in claim 1, wherein the first unit holder is included in the fitting on the second side.

4. The modular battery pack as claimed in claim 1 further includes a thermally conductive adhesive in contact with the battery cells and one of the first plate and the second plate.

5. The modular battery pack as claimed in claim 1 further includes a busbar in contact with one of the first cell holder and the second cell holder.

6. The modular battery pack as claimed in claim 1, wherein the first cell holder and the second cell holder comprise polycarbonate.

7. The modular battery pack as claimed in claim 6, wherein the first cell holder and the second cell holder further comprise at least one compound selected from the group consisting of acrylonitrile-butadiene-styrene, polytetrafluoroethylene, aromatic phosphates, phosphazenes, diphenyl phosphate, triphenyl phosphate, and resorcinol bis(diphenyl phosphate).

8. The modular battery pack as claimed in claim 6, wherein the first cell holder and the second cell holder comprise thermally conductive polycarbonate.

9. The modular battery pack as claimed in claim 1, wherein the first side housing and the second side housing are made of a thermoplastic.

10. The modular battery pack as claimed in claim 9, wherein the first side housing and the second side housing comprise polycarbonate.

11. The modular battery pack of claim 10, wherein the first side housing and the second side housing further comprise at least one compound selected from the group consisting of acrylonitrile-butadiene-styrene, polytetrafluoroethylene, aromatic phosphates, phosphazenes, bisphenol A diphenyl phosphate, triphenyl phosphate, and resorcinol bis(diphenyl phosphate).

12. The modular battery pack as claimed in claim 1, wherein the first plate or the second plate comprises metal.

13. The modular battery pack as claimed in claim 12, wherein the first plate or the second plate comprises more than 80% metal.

14. The modular battery pack as claimed in claim 12, wherein the first plate and the second plate comprise metal.

15. The modular battery pack as claimed in claim 1, wherein the first plate or the second plate comprises thermally conductive polycarbonate.

16. The modular battery pack as claimed in claim 15, wherein the first plate and the second plate comprise thermally conductive polycarbonate.

17. The modular battery pack as claimed in claim 1, wherein the first plate or the second plate further includes cooling channels.

18. The modular battery pack as claimed in claim 1, wherein each of the six sides faces four other sides spaced 90 degrees apart, and another side spaced 180 degrees apart.

19. The modular battery pack as claimed in claim 1, wherein two of the sides comprise metal plates and four of the sides are substantially plastic.

20. The modular battery pack as claimed in claim 1, wherein two of the sides are primarily metal and four of the sides are primarily plastic.

21. The modular battery pack as claimed in claim 1, wherein the first side housing and the second side housing substantially surround the first plate, the second plate, a front cell holder, a rear cell holder, and the battery cells.

22. The modular battery pack as claimed in claim 1, wherein the first side housing and the second side housing together protrude further than the first plate and the second plate in any direction.

23. The modular battery pack as claimed in claim 1 further includes a foam disposed between the first cell holder and the second cell holder.

24. The modular battery pack as claimed in claim 23, wherein the foam has a thermal conductivity of 1 W / mK or higher.

25. An electric vehicle comprising a modular battery pack as described in claim 1.

Images