Cellular battery assembly of simplified architecture facilitating replacement of internal elements, for a system

Abstract

According to the invention, a system is equipped with a cellular battery assembly (EB) comprising modules (MC) that contain cells for storing electrical energy and that are secured by first screws (V1) to crossbars (TB) separating them and under which a cooling device (DR) is installed, the cooling device being placed above a protective plate (PP). Each module (MC) comprises two ends each provided with two connection terminals (BOC) connected to corresponding connection terminals (BOC) of neighbouring modules (MC) via inter-module conductive lines (LC) that are fixedly secured by second screws (V2), and a power board to which the cells are coupled and generating, when not in operation, a zero voltage difference between the connection terminals (BOC), the heads of the first and second screws (V1, V2) being accessible from beneath the cellular battery assembly in order to allow the module (MC) to be uninstalled by unscrewing these screws, after movement of the cooling device (DR) and protective plate (PP).

Description

DESCRIPTION TITLE: CELLULAR BATTERY ASSEMBLY WITH SIMPLIFIED ARCHITECTURE FACILITATING THE REPLACEMENT OF INTERNAL ELEMENTS, FOR A SYSTEM The present invention claims priority from French application No. 2309446 filed on 08.09.2024, the content of which (text, drawings and claims) is incorporated herein by reference. Technical field of the invention

[0001] The invention relates to cellular battery assemblies (or "packs") which are suitable for equipping systems, and more precisely to the architectures of such assemblies (or packs). State of the art

[0002] Certain systems, such as for example certain vehicles (possibly of the automobile or railway type or even all-terrain (or "off-road")) or certain mobile machines (or devices) (possibly lifting), comprise at least one set (or pack) of cellular battery comprising at least three modules each comprising at least two electrical energy storage cells.

[0003] Here, the term "electrical energy storage cell" means a rechargeable and possibly electrochemical cell (for example, lithium-ion (or Li-ion) or Ni-Mh or Ni-Cd type).

[0004] In some of these assemblies, the (cellular) modules are fixedly secured by first screws to crosspieces which separate them and under which a cooling device is installed (such as for example plates between which a cooling circuit is defined in which a refrigerant fluid circulates), placed above a protective plate.

[0005] Currently, the electrical architectures of the aforementioned systems, and in particular of vehicles, include a set of electronic power boxes making it possible to adapt the direct current / voltage pair delivered by the cellular battery to the specificities of the electrical power components of the system and to the on-board network of the latter, as well as possibly ensuring compatibility with an electrical network external to the system.

[0006] For example, in a vehicle when the cellular battery is of the 450 V type, it delivers to its terminals a direct voltage of between approximately 260 V and 450 V depending on its state of charge. When the vehicle is stationary, the cellular battery is isolated from the vehicle's so-called "power" electrical network by opening the relay. Currently inside the cellular battery assembly (or pack), when the vehicle is not in operation, there remains at the terminals of its cellular battery a voltage which is always between approximately 260 V and 450 V, which makes any intervention within the assembly very delicate and therefore requires a qualified and authorized technician. It should be noted that the higher the voltage of the cellular battery, the more potentially dangerous the intervention will be.

[0007] Currently, the aforementioned technicians are rare and generally present in specialized establishments which are themselves rare. Consequently, when a module is faulty it is necessary, for safety reasons, to remove the cell battery assembly of which it is a part, then transport it to a specialized establishment which will intervene on it by opening it and replacing the faulty module (at least). It will be understood that the time required for this removal combined with this transport and this intervention, then all the operations in the opposite direction, is long (typically one month) and requires suitable logistics (sometimes over long distances and therefore with a significant carbon footprint). In addition, the overall cost of the repair is high.Furthermore, in the case of a vehicle, the latter is immobilized in a garage and therefore, in order not to penalize its user, it must be replaced by a courtesy vehicle, which requires having enough available and causes additional costs.

[0008] The invention therefore aims in particular to improve the situation. Presentation of the invention

[0009] For this purpose, it proposes in particular a set of cellular batteries suitable for equipping a system and comprising at least three modules, each comprising at least two electrical energy storage cells, and fixedly secured by first screws to crosspieces separating them and under which is installed a cooling device placed above a protective plate.

[0010] This battery pack is characterized by the fact that each module has two opposite ends, each equipped with:

[0011] - two connection terminals respectively connected to corresponding connection terminals of neighboring modules via inter-module conductive lines fixedly secured by second screws, and

[0012] - a power board to which the cells are coupled and capable of establishing, when not in operation, a zero voltage difference between the connection terminals, the heads of the first and second screws being accessible from below the cell battery assembly in order to allow disassembly of the module by unscrewing the corresponding first and second screws, after moving the cooling device and protective plate.

[0013] Thanks to this new and original architecture, a faulty module can now be replaced quickly by a technician (without any particular specialization or special authorization), without having to completely remove the entire cell battery assembly and without having to plan for suitable logistics or the loan of a courtesy vehicle.

[0014] The battery assembly according to the invention may include other characteristics which may be taken separately or in combination, and in particular:

[0015] - it may comprise a structure to which the cooling device is fixedly secured by third screws and to which the crosspieces are coupled;

[0016] - in the presence of the first option, it may comprise a rotation drive mechanism fixedly secured to the structure and to which the cooling device is coupled in order to allow it to be driven in rotation relative to the structure after unscrewing the third screws, to dismantle at least one module;

[0017] - in the presence of the last sub-option, the rotation drive mechanism can be arranged in the form of at least one hinge;

[0018] - also in the presence of the first option, the protective plate can be fixedly secured to the structure;

[0019] - it may comprise clamping parts in a number equal to a number of first screws and each placed below a crosspiece located between two neighboring modules, each being crossed by a corresponding first screw to clamp these modules on this crosspiece;

[0020] - in the presence of the last option, the modules and the clamping parts can be placed against the cooling device;

[0021] - each power board can define a so-called H-bridge which is placed in a state suitable for establishing the zero voltage difference, when it is not operating. In this case, the power boards can together define a distributed multilevel inverter;

[0022] - the cooling device may comprise an upper face facing the modules and the crosspieces and provided with a heat transfer layer;

[0023] - it may include an electrical insulation plate placed above the modules and inter-module conductive lines.

[0024] The invention also proposes a system comprising at least one cellular battery assembly of the type presented above.

[0025] For example, this system can constitute a vehicle, possibly of the automobile or railway type or even all-terrain (or off-road), or a mobile machine (or device). Brief description of the figures

[0026] Other characteristics and advantages of the invention will appear on examining the detailed description below, and the appended drawings, in which:

[0027] [Fig. 1] schematically and functionally illustrates, in a side view, an example of a vehicle comprising an example of embodiment of a cellular battery assembly according to the invention,

[0028] [Fig. 2] schematically illustrates, in a perspective view from above, an exemplary embodiment of a cellular battery assembly according to the invention,

[0029] [Fig. 3] schematically and functionally illustrates, in a perspective view from above, a portion of the cell battery assembly of Figure 2, without the inter-module cross members,

[0030] [Fig. 4] schematically and functionally illustrates, in a sectional view in a longitudinal and vertical plane, a portion of the cellular battery assembly of Fig. 2, and

[0031] [Fig. 5] schematically and functionally illustrates, in a side view, the vehicle of Figure 1 after removal of the protective wall from its cellular battery assembly and rotation of the latter's cooling device. Detailed description of the invention

[0032] The invention aims in particular to propose an EB cellular battery assembly intended to equip a system S and having a simplified architecture facilitating the replacement of internal elements (and in particular of (cellular) MC modules).

[0033] In the following, it is considered, by way of non-limiting example, that the system S is a vehicle of the automobile type, such as for example a car (as illustrated non-limitingly in Figures 1 and 5). But the invention is not limited to this type of system. It indeed concerns any system comprising at least one set of cellular batteries. Thus, it concerns all vehicles (land (including rail or all-terrain (or off-road), and in particular construction machinery and trucks), maritime (or river), or air), mobile machinery (including those which provide a lifting function), devices (possibly general public and / or possibly mobile), installations (possibly industrial), and buildings (public or private).

[0034] Figure 1 schematically illustrates an example of a system S (here a vehicle) comprising an example of an embodiment of a cellular battery assembly EB according to the invention, installed on the lower face of its body (under the passenger compartment).

[0035] As illustrated at least partially in Figures 1 to 5, a cell battery assembly EB, according to the invention, comprises at least three (cell) modules MC, crosspieces TB, inter-module conductive lines LC, first V1 and second V2 screws, a cooling device DR and a protective plate PP.

[0036] The DR cooling device is installed below the MC modules and TB crosspieces and above the PP protection plate. For example, this DR cooling device may comprise plates between which a cooling circuit is defined in which a refrigerant circulates which is not necessarily dedicated to the cooling of the EB cell battery assembly (and in particular its cells).

[0037] The MC modules each comprise at least two electrical energy storage cells. It is recalled that the term "electrical energy storage cell" here means a rechargeable and possibly electrochemical cell (for example, lithium-ion (or Li-ion) or Ni-Mh or Ni-Cd type).

[0038] For example, MC modules can enable the EB cell battery pack to deliver a low voltage (typically 450V for illustration purposes) to its terminals. But it could deliver a medium voltage or a high voltage.

[0039] As illustrated at least partially in Figures 2 and 4, the MC modules are fixedly secured by first screws V1 to crosspieces TB which separate them. It will therefore be understood that two neighboring MC modules are secured to the same crosspiece TB in at least one location, and preferably several (at least two). The heads of the first screws V1 are accessible from below the cellular battery assembly EB, once the cooling device DR and protective plate PP have been moved (see Figure 5).

[0040] It will be noted, as illustrated non-limitingly in Figure 3, that each MC module can be equipped with at least (or associated with at least) one CE electronic card responsible for controlling and supervising the operation of the cells, and in particular for determining operating parameters such as, for example, the internal current and the internal temperature. In the example illustrated non-limitingly in Figure 3, the CE electronic cards are installed on the upper face of the MC modules between the two pairs of BOC connection terminals. But this is not an obligation.

[0041] Furthermore, and as illustrated at least partially in Figures 2 to 4, each MC module has two opposite ends, each provided with two BOC connection terminals and a CP power board.

[0042] The two BOC connection terminals of each end of an MC module are respectively connected to corresponding BOC connection terminals of neighboring MC modules via inter-module conductive lines LC. In other words, the first BOC connection terminal of a first end of an nth MC module is connected to the second BOC connection terminal of a first end of an (n-1)th MC module, and the second BOC connection terminal of this first end of the nth MC module is connected to the first BOC connection terminal of the first end of the (n+1)th MC module. Similarly, the first terminal BOC connection terminal of a second end of an nth MC module is connected to the second BOC connection terminal of a second end of an (n-1)th MC module, and the second BOC connection terminal of this second end of the nth MC module is connected to the first BOC connection terminal of the second end of the (n+1)th MC module.

[0043] The MC modules are therefore connected in series and the inter-module LC conductive lines, which interconnect them, define a current line which starts at the level of the MC module located furthest "upstream" and extends to the MC module located furthest "downstream" and then from the latter to the MC module located furthest upstream.

[0044] It will be noted that within an EB cell battery assembly, there may be several (at least two) groups of modules within each of which the MC modules are mounted in series and associated with a current line (there are then several (at least two) current lines). This is particularly the case in the example illustrated non-limitingly in Figure 2 (indeed there are three groups of eight MC modules respectively providing three current lines).

[0045] As shown in Figure 4, the inter-module conductive lines LC are fixedly secured to the MC modules by second screws V2. The heads of the second screws V2 are accessible from below the EB cell battery assembly, once the DR cooling device and PP protection plate have been moved (see Figure 5)-

[0046] The cells of an MC module are coupled to the CP power boards installed respectively at the two opposite ends of this MC module.

[0047] The power board CP of one end of an MC module is arranged so as to establish, when not in operation, a zero voltage difference between the connection terminals BOC of this end. This very advantageously allows disassembly of this MC module by unscrewing the first V1 and second V2 corresponding screws, after moving the DR cooling device and the PP protection plate (see figure 5).

[0048] It will be understood that when the system S (here a vehicle) is no longer in operation, the voltage between the BOC connection terminals at each end of each MC module is zero, and therefore a technician can intervene to remove without electrical risk any faulty MC module from the EB cellular battery assembly, once he has moved the DR cooling device and the PP protection plate.

[0049] This new and original architecture is particularly advantageous, because a faulty MC module can now be replaced quickly by a technician (without any particular specialization or special authorization), without having to completely remove the EB cellular battery assembly and without having to plan for suitable logistics or the loan of a courtesy vehicle. This results in a very significant reduction in the downtime of a vehicle and in repair costs for the after-sales service and / or the vehicle user.

[0050] For example, and as illustrated non-limitingly in Figure 2, the cellular battery assembly EB may comprise a structure SB to which the cooling device DR is fixedly secured by third screws (not shown) and to which the crossbars TB which support the modules MC are coupled. It will be understood that when replacing a module, moving the cooling device DR requires first completely unscrewing all the third screws. In order to allow work on the modules MC, the structure SB may be in the form of a frame surrounding the modules MC and on an internal face of which the opposite ends of the crossbars TB are installed and supported, for example.

[0051] This SB structure is fixedly attached to a part of the S system, such as the lower face of the body when it constitutes a motor vehicle.

[0052] In the presence of such a structure SB, the cellular battery assembly EB may also comprise a rotational drive mechanism MER fixedly secured to this structure SB (for example on its lower face facing outwards), as illustrated non-limitingly in figures 1 and 5. In this case, the cooling device DR is coupled to this rotation drive mechanism MER so that it can be rotated relative to the structure SB after unscrewing the third screws, to allow a technician to dismantle at least one module MC.

[0053] For example, this MER rotation drive mechanism can be arranged in the form of at least one hinge. But other types of MER rotation drive mechanism can be used.

[0054] The use of a MER rotary drive mechanism is advantageous because it eliminates the need to disconnect the DR cooling device from its refrigerant supply system before storing it during the intervention. However, the MER rotary drive mechanism can be dispensed with, but in this case, the DR cooling device and its refrigerant supply system must be purged, unless quick couplings are provided.

[0055] Also for example, and as illustrated non-limitingly in Figure 1, the PP protection plate can be fixedly secured to the SB structure. But in an alternative embodiment not illustrated, the PP protection plate could be fixedly secured to the S system, such as for example the lower face of the body when it constitutes a motor vehicle. It will be noted that the PP protection plate could also be fixedly secured to the S system and to the SB structure. In all cases, the fixed fastening can be done by screwing and / or clipping.

[0056] Also for example, and as illustrated non-limitingly in Figure 4, the cellular battery assembly EB may also comprise clamping parts PB in a number equal to the number of first screws V1. In this case, each clamping part PB is placed below a crosspiece TB, located between two neighboring MC modules, being crossed by a corresponding first screw V1 to clamp these MC modules on this crosspiece TB.

[0057] Thanks to these PB clamping parts, the MC modules are fixedly secured in pairs to (and supported by) the TB crosspieces, which makes it possible to reduce the number of first V1 screws used. By unscrewing the first V1 screws which fixedly secure the PB clamping parts of a faulty MC module, these PB clamping parts and then the faulty MC module can be removed axially without the two neighboring MC modules (upstream and downstream) falling since they are still held by other PB clamping parts with their other respective neighbors.

[0058] Also for example, and as illustrated non-limitingly in Figure 4, the MC modules and the PB clamping parts are preferentially placed against the DR cooling device. This in fact makes it possible to improve the cooling of the elements located inside the EB cell battery assembly (and in particular the MC modules).

[0059] Also for example, each CP power board can define a so-called H-bridge which is placed in a state suitable for establishing the zero voltage difference between the two BOC connection terminals of its MC module end, when it is not operating. In this case, the CP power boards together define what can be called a distributed multilevel inverter.

[0060] It is recalled that an H-bridge is an electronic device which is used to control the polarity at the terminals of a dipole, and which for this purpose comprises four switching elements generally arranged in an H and which may be, for example, relays or transistors. Such an H-bridge is generally controlled by means of signals which are pulse-width modulated, and can be switched so as to cyclically vary the polarity of the load voltage in order to constitute an inverter.

[0061] It should be noted that the state which is suitable for establishing the zero voltage difference between the two BOC connection terminals may, for example, be an open, non-conducting state. But this is not an obligation. Thus, as a variant this state could generate a bypass, for example and not limited to.

[0062] But other types of CP power card can be used as long as they allow, when not in operation, the establishment of a zero voltage difference between the two BOC connection terminals at one end of the MC module.

[0063] Also for example, and as illustrated non-limitingly in Figure 4, the cooling device DR may comprise an upper face FS which is oriented towards the modules MC and the crosspieces TB and which is provided with a heat transfer layer (or "thermal pad") CT. It is recalled that such a heat transfer layer CT makes it possible to homogenize the transfer of calories between two surfaces, and therefore to improve the cooling of the elements located inside the cellular battery assembly EB (and in particular the modules MC).

[0064] Also for example, and as illustrated non-limitingly in Figure 4, the EB cell battery assembly may also comprise an electrical insulation plate PIE placed above the MC modules and the inter-module conductive lines LC. This makes it possible to avoid the generation of short circuits and possible discharges of MC modules, for example by capacitive effect.

[0065] In the presence of such a PIE electrical insulation plate, the CE electronic cards are preferably inserted between the upper face of the MC modules and the PIE electrical insulation plate.

[0066] The procedure for replacing an MC module can therefore take place as follows.

[0067] In the first step, a technician separates the PP protection plate in order to move it (see figure 5).

[0068] In a second step, the technician unscrews the third screws which secure the DR cooling device (here to the SB structure).

[0069] In a third step, the technician moves the DR cooling device, for example by rotating it downwards, when such rotation is permitted by the arrangement of the EB cell battery assembly.

[0070] In a fourth step, the technician can, for example, carry out a safety check to ensure that there is no voltage at the MC modules. To this end, a light diode can be added to each CP power board, for example, to generate photons in the presence of voltage.

[0071] In a fifth step, the technician unscrews the second V2 screws securing the inter-module LC conductive lines to the faulty MC module that is to be removed.

[0072] In a sixth step, the technician unscrews the first V1 screws ensuring the attachment to the TB crosspieces framing the faulty MC module of the PB clamping parts concerned, then removes the latter (PB) in order to remove the faulty MC module.

[0073] To install a replacement MC module, perform the steps described above in reverse order.

Claims

CLAIMS

1. Cellular battery assembly (EB) suitable for equipping a system (S) and comprising at least three modules (MC) each comprising at least two electrical energy storage cells, and fixedly secured by first screws (V1) to crosspieces (TB) separating them and under which is installed a cooling device (DR) placed above a protection plate (PP), characterized in that each module (MC) has two opposite ends and each provided with i) two connection terminals (BOC) respectively connected to corresponding connection terminals (BOC) of neighboring modules (MC) via inter-module conductive lines (LC) fixedly secured by second screws (V2), and ii) a power card (CP) to which said cells are coupled and suitable for establishing, when not in operation, a zero voltage difference between said connection terminals (BOC), the heads of the first and second screws (V1,V2) being accessible from below the cellular battery assembly (EB) in order to allow disassembly of said module (MC) by unscrewing the first (V1) and second (V2) corresponding screws, after moving said cooling device (DR) and protection plate (PP).,

2. Cellular battery assembly according to claim 1, characterized in that it comprises a structure (SB) to which said cooling device (DR) is fixedly secured by third screws and to which said crosspieces (TB) are coupled.

3. Cellular battery assembly according to claim 2, characterized in that it comprises a rotational drive mechanism (MER) fixedly secured to said structure (SB) and to which said cooling device (DR) is coupled in order to allow its rotational drive relative to said structure (SB) after unscrewing of said third screws, to dismantle at least one module (MC).

4. Cell battery assembly according to claim 3, characterized in that said rotational drive mechanism (MER) is arranged in the form of at least one hinge.

5. Cellular battery assembly according to one of claims 2 to 4, characterized in that said protective plate (PP) is fixedly secured to said structure (SB).

6. Cellular battery assembly according to one of claims 1 to 5, characterized in that it comprises clamping parts (PB) in a number equal to a number of first screws (V1) and each placed below a crosspiece (TB) located between two neighboring modules (MC), each being crossed by a corresponding first screw (V1) to clamp these modules (MC) on this crosspiece (TB).

7. Cellular battery assembly according to claim 6, characterized in that said modules (MC) and said clamping parts (PB) are placed against said cooling device (DR).

8. Cellular battery assembly according to one of claims 1 to 7, characterized in that each power card (CP) defines a so-called H-bridge placed in a state suitable for establishing said zero voltage difference, when it is not operating, and in that said power cards (CP) together define a distributed multilevel inverter.

9. System (S), characterized in that it comprises at least one cellular battery assembly (EB) according to one of claims 1 to 8.

10. System according to claim 9, characterized in that it constitutes a vehicle or a mobile machine.

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