Housing assembly for battery cells

Abstract

The present subject matter relates to a housing assembly (100) for battery packs. The assembly (100) comprises a base plate (102), and a pair of manifolds (108). Each of the manifold (108) has a reservoir (214) for storing coolant fluid that is formed by an interconnection of a front wall (202), a rear wall (204), opposed side walls (206), a bottom wall (208), and a top wall (210) of the manifold. Each of the manifolds (108) is separately coupled to opposite side panels through the rear wall (204). The front wall (202) comprises a plurality of openings (212) for inlet or outlet of the coolant fluid. A cooling channel (110) is provided that includes a flow passage. The cooling channels (110) and the manifolds (108) contribute to the stiffness of the assembly (100).

Description

HOUSING ASSEMBLY FOR BATTERY CELLSBACKGROUND

[0001] Cell housing plays an important role in a battery pack designed to accommodate various types of individual battery cells in diverse configurations. With ongoing advancements in battery technology, battery- powered devices have seen a considerable enhancement in their durability. A cell housing assembly ensures the cell housing establishes electrical contact with terminals of the battery cells. Additionally, cables or busbars are frequently utilized to facilitate electrical connections with the battery cell terminals. Typically, the cell housing takes the form of a plastic case with molded compartments designed to accommodate the individual cells.BRIEF DESCRIPTION OF DRAWINGS

[0002] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.

[0003] Figure 1 illustrates a perspective-exploded view of a housing assembly for battery cells, according to an embodiment of the present subject matter.

[0004] Figure 2a illustrates a connection between a manifold and a cooling channel of the housing assembly, according to an embodiment of the present subject matter.

[0005] Figure 2b illustrates a connection between the manifold and bottom enclosure of the housing assembly, according to an embodiment of the present subject matter.

[0006] Figure 2c illustrates a cross-sectional view of the housing assembly, according to an embodiment of the present subject matter.

[0007] Figure 3a illustrates inlet ports in the bottom enclosure of the housing assembly, according to an embodiment of the present subject matter.

[0008] Figure 3b illustrates outlet ports in the bottom enclosure of the housing assembly, according to an embodiment of the present subject matter.

[0009] It may be noted that throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and / or implementations consistent with the description; however, the description is not limited to the examples and / or implementations provided in the drawings.DETAILED DESCRIPTION

[0010] Examples of the present application relate to a battery cell housing assembly for accommodating a plurality of cells in a module of a battery pack.

[0011] Electric vehicles rely on battery packs to power essential vehicle functions, including propulsion and support systems. A battery pack consists of multiple identical batteries or individual battery cells, such as lithium-ion batteries or those based on different chemistries. These battery cells are organized in various configurations, like series, parallel, or a combination, to meet specific voltage, capacity, or power density requirements. In addition to the individual battery cells, the battery pack also includes interconnects that enable electrical conductivity between the individual cells. Battery packs are particularly useful in electric vehicles, EV industries, power distribution, and home appliances where high-production cells or batteries are combined to provide efficient power solutions.

[0012] A cell housing is an integral part of a battery pack designed to accommodate different types of individual cells in a specific configuration.Typically, the housing consists of multiple compartments arranged at different heights to accommodate the cells securely. The assembly of the housing ensures electrical contact with the cell terminals. In some cases, the housing may be a plastic case with molded top and bottom compartments to house the cells effectively. The housing not only provides support and protection for each cell but also includes structures that help in structurally stiffening the housing when holding the cells.

[0013] Conventional housing designs include additional cross beams or members in a bottom enclosure of the housing to provide structural stiffness for housing the cells securely. Moreover, modern battery packs require efficient cooling mechanisms to maintain optimal power delivery and prevent thermal events that may damage the battery pack or the vehicle. To achieve this, cooling channels or cooling pads are integrated between the cells, allowing coolant to flow through passages of the cooling channels to cool the adjacent battery cells. Coolant pipes with connectors control the flow of the coolant in the cooling channels.

[0014] The conventional battery pack housing design comprises separate support and cooling components, leading to the use of numerous individual parts, such as coolant pipes, connectors, and cross beams, during assembly. The use of multiple components may add to the complexity of the battery pack housing assembly process. More components may occupy additional space, limiting the available area for other components or systems in the battery pack or the overall device it powers. Also, with more parts involved, there is an increased likelihood of components failing or malfunctioning, thereby reducing the overall reliability of the battery pack. The presence of additional components also contributes to increased weight, which may be undesirable in applications where weight is a critical factor.

[0015] Moreover, assembling multiple individual parts may be timeconsuming, leading to a longer production time for the battery packs. Manufacturing and assembling multiple individual parts may increaseproduction costs. Additionally, the presence of connectors and coolant pipes may introduce points of failure, such as leaks or connectivity problems, that may compromise the battery pack's performance and safety. Having separate cooling components may also make it challenging to manage the battery pack's thermal conditions effectively.

[0016] Accordingly, there is a requirement to provide a support structure and cooling mechanism, which may reduce the number of components, and manufacturing costs, and improve the durability, reliability, and efficiency of the battery pack housing.

[0017] Aspects in relation to a housing assembly configured to house battery cells of a battery pack are described. In an example implementation of the present subject matter, the housing assembly comprises a base plate that is bordered by side panels extending upwardly from the base plate to form an enclosure of the housing assembly. The enclosure is a bottom enclosure of the housing assembly and is designed to vertically receive one end of the battery cells. The housing assembly further comprises a first manifold and a second manifold. Each manifold comprises a front wall, a rear wall opposite to the front wall, opposed side walls located between either side of the front wall and rear wall, a bottom wall along a base of the front wall, rear wall and side walls, and a top wall along a top of the front wall, rear wall and side walls. Each of the front wall, the rear wall, the opposed side walls, the bottom wall, and the top wall are interconnected to form a reservoir for storing a coolant fluid.

[0018] The first manifold is coupled to a side panel and the second manifold is coupled to a side panel opposite to the side panel to which the first manifold is coupled. The coupling of each manifold to the respective opposite side panel is through the rear wall. The front wall of the manifold is provided with a plurality of openings for inlet or outlet of the coolant fluid. The housing assembly also comprises a cooling channel. The cooling channel has a flow passage within it to allow the coolant fluid to flow therein. The cooling channel has a first end and an opposing second end. The firstend of the cooling channel is connected to a corresponding opening on the front wall of the first manifold and the opposing second end of the cooling channel is connected to a corresponding opening on the front wall of the second manifold.

[0019] Thus, the housing assembly of the present subject matter combines the support and cooling channel functions into a unified component formed by the manifold and the cooling channels, reducing the reliance on numerous individual parts. For instance, the cooling channels are directly integrated to the manifolds that contain the coolant fluid and therefore there is no need to use the coolant pipes and the connectors for connecting the cooling channels with the source of the coolant fluid. Also, separate cross beams that provide structural strength to the battery cells in the conventional housing assemblies are not needed as cooling channels directly work as a cross-structural member for the battery pack while performing the function of cooling the battery cells.

[0020] Hence, integrating the manifolds with the cooling channels and directly securing the combined structure formed by the integration of the manifolds and the cooling channels in the bottom enclosure provides structural strength to the assembly along with a provision for better cell cooling. Since the cooling channels are directly integrated with the manifolds and the manifold is secured directly to the bottom enclosure, numerous individual parts, such as the coolant pipes, the connectors, and the cross beams, which are used to provide separate cooling and support structures in the conventional housing assembly are not needed anymore. Also, integrating the manifold and the cooling channels help reduce the weight of the battery pack, which is crucial for applications like electric vehicles to improve their range and performance. Additionally, with fewer parts to assemble, the time required for battery pack housing production may be reduced. An integrated design may also free up space, allowing for more efficient packaging of other components within the housing assembly.

[0021] While embodiments of the present invention have been described in the context of an electrical device, it will be understood that the same is only to provide an example of implementation of the present invention and is not to be construed as a limitation. The teachings of the present invention may be applied to an electronic instrument, an electric vehicle, an automobile, an electric power system, or the like, without deviating from the scope of the present subject matter.

[0022] The above and other features, aspects, and advantages of the subject matter will be better explained with regard to the following description and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter along with examples described herein and should not be construed as a limitation to the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and examples thereof, are intended to encompass equivalents thereof. Further, for the sake of simplicity, and without limitation, the same numbers are used throughout the drawings to reference like features and components.

[0023] Figure 1 illustrates an exploded view of a housing assembly 100 (hereinafter referred to as assembly) for battery cells (not illustrated) of a battery pack, according to an embodiment of the present subject matter. As depicted in Figure 1 , the assembly 100 comprises a base plate 102. The base plate 102 is bordered by side panels 104-1 , 104-2, 104-3, and 104-4 that extend upwardly from the base plate 102 to form an enclosure 106 of the assembly 100. The enclosure 106 is to vertically receive one end of the battery cells. In an example, the enclosure 106 is a bottom enclosure of the assembly that is to be coupled with a top enclosure (not illustrated) to complete the assembly. The enclosure 106 may be made of plastic, metal, or any other material that may be fashioned for this purpose, in an example. Although the enclosure 106 in the present example has been shown toinclude four side panels 104-1 , 104-2, 104-3, and 104-4, in an alternative embodiment, the enclosure 106 may have less or more than four sides depending upon design specifications of a unit in which the assembly 100 is to be fitted. For instance, in an electric vehicle, the enclosure 106 of the assembly 100 may include a hexagonal shape, comprising six side panels to optimize space utilization. In another alternative embodiment, the enclosure 106 may have curved side panels 104-1 , 104-2, 104-3, and 104- 4.

[0024] Further, the assembly 100 includes a first manifold and a second manifold shown collectively as manifold 108 in Figure 1. The first manifold and the second manifold may be separately provided on either of opposite two side panels 104-1 and 104-3 or 104-2 and 104-4 of the enclosure 106. Furthermore, as shown in Figure 1 , a plurality of cooling channels 1 10 is provided between the first manifold and the second manifold. Opposing side ends 1 12-1 , 112-2 of each of the plurality of cooling channels 1 10 are respectively fluidically connected to the corresponding manifold 108. The manifold 108 and the cooling channels 1 10 will be explained in detail with reference to Figures 2-4.

[0025] Thus, the manifolds 108 that are integrated into the enclosure 106 with the cooling channels 110 that are fluidically connected to the manifolds 108 form a rigid connection with the enclosure 106, thereby contributing to the stiffness and structural stability of the assembly 100. Also, the assembly 100 of the present invention does away with the need for the conventional battery housing that uses additional structural members to achieve stiffness, thereby making the assembly process easy, less time-consuming, and cost- effective.

[0026] Figure 2a illustrates a connection between the manifold 108 and the cooling channel 1 10, according to an embodiment of the present subject matter. Figure 2b illustrates a connection between the manifold 108 and enclosure 106 of the assembly 100, according to an embodiment of thepresent subject matter. Figure 2c illustrates a cross-sectional view of the assembly 100 according to an embodiment of the present subject matter.

[0027] Since Figures 2a and 2b illustrate an arrangement relationship of elements constituting the assembly 100, for the sake of ease of explanation, Figures 2a and 2b are explained together.

[0028] As shown in Figure 2a, the manifold 108 comprises a front wall 202, and a rear wall 204 opposite the front wall 202. The manifold 108 further comprises opposed side walls 206 that are located between either side of the front wall 202 and the rear wall 202. Furthermore, the manifold 108 has a bottom wall 208 along a base of the front wall 202, rear wall 204, and side walls 206. The manifold 108 also has a top wall 210 along a top of the front wall 202, rear wall 204, and side walls 206. The front wall 202, rear wall 204, opposed side walls 206, bottom wall 208, and top wall 210 are interconnected with each other to form sealed space therebetween. The sealed space between the front wall 202, rear wall 204, opposed side walls 206, bottom wall 208, and top wall 210 serves as a reservoir 214 for storing coolant fluid. Although, in the present example embodiment, the manifold 108 is shown in a tapered squared shape, any other shape such as oval, hexagonal, or circular, or any other such shape is also possible as required by the intended use of the manifold 108.

[0029] Further, as explained previously, the first manifold and the second manifold are separately secured on two opposite side panels 104-2 and 104-4 of the enclosure 106, as shown in Figure 1 . In particular, the rear wall 204 of each of the manifold 108 is affixed to interior surfaces of the opposite two side panels 104-2, 104-4 of the enclosure 106. For instance, as shown in Figure 2b, the rear wall 204 of the sidewall 108 is affixed or bonded to the interior surface of the side panel 104-4 of the enclosure 106. In an example, the manifold 108 may be affixed to the side panels 104-1 , 104-3, 104-2, 104- 4 of the enclosure 106 by means of a screw, heat-resistant adhesive, welding, or otherwise.

[0030] Furthermore, as shown in Figure 2c, the front wall 202 of each manifold 108 includes a plurality of identical openings 212 for inlet or outlet of the coolant fluid. Each of the plurality of openings 212 provided on the front wall 202 of the manifold 108 may be equidistant from one another along a length direction of the manifold 108. However, in an alternative embodiment, each of the plurality of openings 212 may not be equidistant from one another to provide any number of symmetric or asymmetric arrangement configurations. In an example embodiment, each of the plurality of openings 212 of the manifold 108 that is affixed to the interior surfaces of either of the opposite two side panels of the enclosure 106, such as the side panels 104-2, 104-4, as shown in Figure 1 , is adapted to receive the respective ends 112-1 , 112-2 of the cooling channel 1 10.

[0031] In an example, the cooling channel 1 10 may be a two-walled structure, with a width in between the walls that extends from the first end 1 12-1 to the second end 1 12-2, thereby forming a flow passage (not illustrated). The flow passage allows the coolant fluid that is stored in the reservoir 214 to flow through the channel 1 10. The flow passage runs within the cooling channel 110 connecting both ends 1 12-1 and 1 12-2 of the channel 1 10 and provides a continuous path for the circulation of coolant fluid. The coolant fluid flows through this passage, starting from one end of the cooling channel, and travels along the space between the channel's walls until it reaches the opposing end. Additionally, the opening 212 on the front wall 202 of the manifold 108 is connected to the cooling channel 1 10 through this flow passage. This connection allows for a flow of coolant fluid between the first and the second manifold 108 and the cooling channel 110, ensuring efficient cooling of the system. In an embodiment, the opening 212 on the front wall 202 of the manifold 108 may coincide with opening of the flow passage of the channel 1 10. In an example, the coolant fluid may be at least one of synthetic oil, water and ethylene glycol (WEG), poly-alpha-olefin (or poly-a-olefin, also abbreviated as PAO) oil, liquid dielectric cooling based on phase change, and the like.

[0032] In an example embodiment, as shown in Figures 1 , 2a, and 2b, the cooling channel 1 10 may have a serpentine configuration such that curvature of the cooling channel 1 10 corresponds to curvature of the battery cells along a direction in which the battery cells are to be stacked in the enclosure 106. This ensures that each battery cell is directly adjacent to the at least one cooling channel 110, thereby forming a thermal contact. Due to this thermal contact, the serpentine flow path of the cooling channel 1 10 provides uniform dissipation of heat from the individual battery cells by allowing the transfer of heat from the battery cells to the coolant fluid circulating through the cooling channels 1 10. In some embodiments, the cooling channels 1 10 may be structured into a shape other than the serpentine shape shown in Figures 1 , 2a, and 2b. For example, in some embodiments, the cooling channels 110 may be structured to include a spiral type of pattern.

[0033] In an example embodiment, the openings 212 formed on the front wall 202 of the manifold 108 for receiving corresponding ends 112-1 , 1 12-2 of the cooling channel 1 10 may be a vertical opening along Y-axis as shown in Figure 2c. The openings 212 extend perpendicular to the base plate 102 of the enclosure 106. In an example, height of the openings 212 may vary corresponding to a height of the cooling channel 1 10. The more heighted the cooling channel 1 10, the longer the opening 212 may be, for example. In an example, the cooling channel 1 10 may have a predefined height that lies in a range of 60-95% of height of the battery cells. In operation, the cooling channels 1 10 and the manifolds 108 may be made up of aluminum and brazed together and placed inside of the enclosure 106. The manifold 108 may then be screwed or welded or brazed with the enclosure 106, thereby making the structure rigid.

[0034] Figure 3a illustrates inlet ports 302-1 , 302-2 in the enclosure 106 of the assembly 100, according to an embodiment of the present subject matter. Figure 3b illustrates outlet ports 304-1 , 304-2 in the enclosure 106 of the assembly 100, according to an embodiment of the present subjectmatter. Since Figures 3a-3b illustrate an arrangement relationship of elements constituting the assembly 100, for the sake of ease of explanation, Figures 3a-3b are explained together.

[0035] In an embodiment, each of the opposite side panels of the enclosure 106 may include one or more access ports, such as the inlet ports 302-1 , 302-2 and the outlet ports 304-1 , 304-2. For instance, as shown in Figure 3a, the inlet ports 302-1 , 302-2 may be provided towards the side panel 104-2. Similarly, the outlet ports 304-1 , 304-2 may be provided towards the side panel 104-4 that opposite to the side panel side panel 104- 2 having the inlet ports 302-1 , 302-2. The rear wall 204 of the manifold 108 may be fluidically connected to the corresponding inlet ports 302-1 , 302-2, and the outlet ports 304-1 , 304-2. In an example, the inlet ports 302-1 , 302- 2 are to be used to introduce the coolant fluid in the manifold 108. Similarly, the outlet ports 304-1 , 304-2 may be used to flush out the coolant fluid from the manifold 108. In the alternative embodiment, inlet ports 302-1 , 302-2 and the outlet ports 304-1 , 304-2 may be used interchangeably to flush out the coolant fluid from the manifold 108 and introduce the coolant fluid in the manifold 108, respectively.

[0036] The core advantage of the battery cell housing assembly of the present subject matter is that the bottom enclosure has been given more attention as it not only collects all the parts of the battery pack but also gives structural strength to the whole battery pack. The use of the cooling structure, which includes manifolds and the cooling channels, to provide structural strength to the assembly omits the need to use additional structural members of the battery packs to provide strength to the assembly. Thus, the cooling channels integrated into the enclosure with the help of manifolds work additionally as a structural part of the battery pack, making the assembly rigid without requiring additional supporting structure.

[0037] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible. As such, the present disclosure should notbe considered limited to the description of the preferred examples and implementations contained therein.

Claims

I / We Claim:1 . A housing assembly (100) for battery cells, comprising: a base plate (102) bordered by side panels (104-1 , 104-2, 104-3, 104-4) extending upwardly from the base plate (102) to form a housing, the housing is to vertically receive one end of the battery cells; a first manifold and a second manifold with each manifold (108) comprising a front wall (202), a rear wall (204) opposite to the front wall (202), opposed side walls (206) located between either side of the front wall (202) and rear wall (204), a bottom wall (208) along a base of the front wall (202), rear wall (104) and side walls (206), and a top wall (210) along a top of the front wall (202), rear wall (204) and side walls (206), interconnected to form a reservoir (214) for storing a coolant fluid, the first manifold (108) and the second manifold (108) being coupled to a respective opposite side panel (104-2, 104-4) through the rear wall (204), wherein the front wall (202) comprises a plurality of openings (212) for inlet or outlet of the coolant fluid; and a cooling channel (1 10) having a flow passage to allow the coolant fluid to flow therein, wherein a first end (112-1 ) of the cooling channel (1 10) is connected to a corresponding opening (212) on the front wall (202) of the first manifold (108) and an opposing second end (112-2) of the cooling channel (110) is connected to a corresponding opening (212) on the front wall (202) of the second manifold (108).

2. The housing assembly (100) as claimed in claim 1 , wherein the cooling channel (1 10) is configured to be in thermal contact with the battery cells.

3. The housing assembly (100) as claimed in claim 1 , wherein the flow passage forms a continuous flow path for circulation of the coolant fluid between the first end (1 12-1 ) and the opposing second end (1 12-2).

4. The housing assembly (100) as claimed in claim 1 , wherein the rear wall (204) of the manifold (108) is coupled to the side panel (104-2, 104-4) of the housing via being at least one of screwed, soldered, welded.

5. The housing assembly (100) as claimed in claim 1 , wherein the rear wall (204) of the manifold (108) is bonded to the side panel (104-2, 104-4) by an adhesive, the adhesive being heat resistant.

6. The housing assembly (100) as claimed in claim 1 , wherein each of the opposite side panels (104-2, 104-4) includes one or more access ports (302-1 , 302-2, 304-1 , 304-2), the rear wall (204) of the manifold (108) is fluidly coupled to the one or more access ports (302-1 , 302-2, 304-1 , 304- 2).

7. The housing assembly (100) as claimed in claim 1 , wherein a height of the opening (212) on the front wall (202) and a height of the cooling channel (1 10) correspond to each other.

8. The housing assembly (100) as claimed in claim 1 , wherein a shape of the cooling channel (1 10) corresponds to a profile of outer surface of the battery cells.

9. The housing assembly (100) as claimed in claim 8, wherein the shape of the cooling channel (1 10) is serpentine.

10. The housing assembly (100) as claimed in claim 1 , wherein the cooling channel (1 10) has a predefined height that lies in a range of 60-95% of height of battery cells.

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