Housing for an electric battery module of a vehicle and method for assembling said module

Abstract

A housing (2) for a battery module (1) of a motor vehicle, comprising a base (3) having a plurality of walls, a cover (4) comprising at least a main flank (41) configured to be mounted on the base (3) so as to close the housing (2), and a fastening device (5) comprising at least one opening (43), positioned in the main flank (41), and at least one deformable tab (33), connected to at least one of the walls and configured to be positioned in the at least one opening (43) and to be deformed.

Description

[0001] DESCRIPTION

[0002] TITLE: Housing for electric vehicle battery module and method of assembling said module

[0003] The present invention relates to a housing for an electric battery module of a vehicle. The invention also relates to an electric battery module comprising such a housing and a vehicle comprising such a housing and / or such a module. The invention finally relates to a method for assembling a battery module according to the invention.

[0004] In electric or hybrid vehicles, current electric powertrains rely on increasingly efficient electric battery systems to compete with combustion engines. Typically, these battery systems comprise a plurality of electrochemical cells arranged in one or more modules within at least one housing. These cells can be cylindrical, prismatic, or flexible.

[0005] The housing typically comprises a base open on one side, in which the electrochemical cells are arranged. Once the electrochemical cells are arranged, the housing can be closed by means of a cover arranged on the open side of the base. The cover is then secured to the base by a combination of fastening means such as screws, studs, clips, or even by welding. Such fastening means have the disadvantage of increasing the number of references required for assembling the battery module and, consequently, increasing its manufacturing cost. Furthermore, the implementation of such fastening means is time-consuming and tends to complicate the assembly of the battery module. The present invention falls within this context and aims to propose an alternative to known battery module housings allowing a reduction in the cost of the module and a simplification of its assembly.

[0006] To this end, the invention provides a housing for a motor vehicle battery module comprising a base open on one side having a plurality of walls, including at least one main wall and side walls connected to the main wall, and a cover, comprising at least one main flank configured to be mounted on the base so as to close the housing. The housing further comprises at least one fixing device comprising:

[0007] - at least one opening, arranged in the main flank;

[0008] - at least one deformable tab, connected to at least one of the side walls, configured to be arranged in the at least one opening and to be deformed between an insertion position, in which said tab extends along a first direction, in continuity with the at least one side wall and transverse to the main flank, and a position for securing the cover relative to the base in which said tab extends transversely to said wall.

[0009] In particular, the base is made of a metallic material, such as sheet steel and / or aluminum. Additionally or alternatively, the cover is optionally made of a plastic material, such as a filled or unfilled polymer, and / or of a metallic material, such as sheet steel and / or aluminum.

[0010] Preferably, at least one leg and at least one of the side walls of the base are made from one material.

[0011] Optionally, the at least one fixing device comprises at least one stop member, arranged in the cover and extending at the level of the at least one opening, said stop member being configured to form a stop for the at least one tab along at least one direction when the latter extends in the securing position.

[0012] Optionally, the at least one fastening device comprises at least one recess, disposed at the at least one opening, configured to receive the at least one tab when the latter extends into the securing position.

[0013] According to exemplary embodiments, the at least one leg has a dimension, along the first direction when said leg is in the insertion position, greater than or equal to 2 cm and / or the at least one leg has a dimension, along a second direction orthogonal to the first direction, greater than or equal to 1 cm, or even 2 cm.

[0014] Optionally, the housing according to the invention comprises a plurality of fixing devices such that the housing comprises a plurality of tabs and openings, each tab being configured to be arranged in one of the openings, the plurality of tabs being distributed into a plurality of sub-assemblies arranged such that:

[0015] - at least two subsets of legs are connected to two separate, opposite side walls; and / or

[0016] - at least two subsets of legs are connected to two separate, adjacent side walls; and / or

[0017] - at least two legs are arranged at the same side wall.

[0018] The invention also relates to a battery module comprising a housing according to the invention, delimiting an internal volume, and at least one electrochemical cell arranged in said volume.

[0019] The invention also relates to a motor vehicle with an electric or hybrid motor comprising a housing and / or at least one battery module according to the invention. The invention finally relates to a method for assembling a battery module according to the invention comprising:

[0020] - a step of positioning at least one electrochemical cell on the main wall of the base of the housing;

[0021] - a step of positioning the cover on the housing so as to arrange the at least one electrochemical cell in the interior volume and so as to close the housing, the at least one tab being arranged in the insertion position and extending through the at least one opening of the cover;

[0022] - a step of securing the cover to the base by moving the at least one tab from the insertion position to the securing position. In particular, such a movement is carried out by folding the at least one tab.

[0023] Other details, characteristics and advantages will emerge more clearly on reading the detailed description given below, for informational and non-limiting purposes, in relation to the various examples of embodiment illustrated in the following figures:

[0024] Figure 1 is a schematic representation of an embodiment of a battery module according to the invention.

[0025] Figure 2 is a representation of a portion of the battery module including a fastening device.

[0026] Figure 3 is a representation of a portion of the battery module including a fastening device.

[0027] Figure 4 is a schematic cross-sectional representation of the battery module.

[0028] Figure 5 is a schematic cross-sectional representation of a battery module housing.

[0029] Figure 6 is a schematic representation of an insertion position of a leg of the fixing device. Figure 7 is a schematic representation of a securing position of a leg of the fixing device.

[0030] Figures 1 to 7 represent an exemplary embodiment of an electric battery module 1, which may also be called a “battery” or “electric battery”. Such a battery module 1 is intended for a battery device, or electrical energy storage device, of a motor vehicle, particularly a vehicle with a hybrid or electric motor. For example, the battery device comprises at least one battery module 1 according to the invention or a plurality of said modules.

[0031] It is also understood that, throughout the figures, the dimensions and spacings separating the various components may be exaggerated for the sake of clarity. Furthermore, in the description below, the terms "first" and "second" are intended to distinguish the various elements of the invention and not to establish a hierarchy among them.

[0032] Generally, the battery module 1 comprises a housing 2, at least one electrochemical cell 11, arranged in said housing 2, in particular arranged in an internal volume 10 delimited by the housing 2. The following description is given with reference to a specific battery module 1 and to the housing 2 associated with it. It is nevertheless understood that the invention can extend to a plurality of battery modules 1 or housings 2.

[0033] In a known manner, the at least one electrochemical cell 11 may be of the prismatic, cylindrical or flexible type, in particular flexible prismatic, also known as the “pouch” type. “Prismatic” means that the electrochemical cell 11 may have a parallelepiped or substantially parallelepiped shape, in particular a rectangular or square parallelepiped, or even cubic. Each electrochemical cell 11 is capable of storing energy in chemical form and of restoring it in the form of an electric current. The electrochemical cells may, for example, be of the “lithium-ion” type, also called “Li-ion”. The battery module 1 comprises at least one electrochemical cell 11. It is nevertheless understood, as illustrated, that the battery module 1 may comprise a plurality of electrochemical cells, the number and dimensions of said cells being in no way limiting.

[0034] The housing 2 comprises a base 3, a cover 4, removable and attached relative to the base 3, and at least one device 5 for fixing the cover 4 to the base 3.

[0035] The base 3 comprises a plurality of walls and is open on one side so as to allow the insertion of the at least one electrochemical cell 11. Therefore, the term "open on one side" means here that one of the walls is missing and that the base does not form a closed structure. In particular, the plurality of walls comprises at least one main wall 31 and side walls 32, connected to the main wall 31 and extending transversely, or even orthogonally thereto. Also, the missing wall is, preferably, a wall opposite the main wall 31 or one of the side walls 32, adjacent to the main wall 31. For example, in a non-limiting manner, the base 3 has a parallelepiped shape in which opposite side walls 32 extend parallel to each other.The base 3 thus has a “U” or substantially “U” shaped profile, the main wall 31 forming a base of the “U” while the opposite side walls 32 form the branches.

[0036] For example, the base 3 is made of a metallic material, such as steel sheet or aluminum sheet, for example 3000 or 6000 series aluminum sheet. The cover 4 comprises at least one main flank 41 configured to be mounted on the base 3 so as to close the housing 2. The cover 4 is thus configured to be mounted at the open side of the base 3 so as to delimit the internal volume 10 of the housing 2 and to close the base 3. The main flank 41 of the cover 4 is thus opposite the main wall 31 along a first direction 100.

[0037] Optionally, the cover 4 also comprises a lateral flank 42 or a plurality of lateral flanks 42, connected to the main flank 41 and extending transversely, or even orthogonally to it. In this case, the cover 4 comprises a plurality of lateral flanks 42. In particular, the cover 4 is dimensioned and shaped so that the lateral flanks 42 extend into contact with at least a portion of the lateral walls 32 of the base 3 so as to limit, or even block, the movement of the cover 4 relative to the base 3 along at least one direction of a direction orthogonal to the first direction 100, for example along a second direction 200 or along a third direction 300, orthogonal to the first and second directions 200. Similar to the base 3, the cover 4 then has a “U” or substantially “U” shaped structure, the main flank 41 forming the base of said “U” and the lateral flanks 42 forming the branches.

[0038] For example, the cover 4 is made of a metallic material, such as steel sheet or aluminum sheet, or of a plastic material, such as a filled or unfilled polymer material or a composite, for example polypropylene with glass fiber (PPGF). Preferably, such a material is capable of withstanding a mechanical force exerted at at least a portion of the fixing device 5, as further explained below.

[0039] The fixing device 5 comprises at least one opening 43, arranged in the main flank 41, and at least one deformable tab 33, connected to at least one of the side walls 32. The at least one tab 33 is arranged at a free edge of the side wall 32 carrying it, that is to say at the open side. The opening 43 is through and extends in a thickness of the main flank 41 of the cover 4, between a first face 411 of the main flank 41, configured to be turned towards the internal volume 10, and a second face 412, opposite.

[0040] In general, the at least one deformable tab 33 is configured to be arranged in the at least one opening 43 of the cover 4 and to be deformed between an insertion position, visible in FIG. 6, and a position for securing the cover 4 relative to the base 3, visible in FIG. 7. In the insertion position, said tab 33 extends along the first direction 100, in the continuity of the at least one side wall 32 and transversely to the main flank 41 so as to be able to be inserted into the at least one opening 43, through the main flank 41 of the cover 4. The at least one tab 33 then extends projecting from the side wall 32 carrying it. In the secured position, the at least one tab 33 is folded back so as to extend transversely to the side wall 32 carrying it, for example parallel or substantially parallel to the main flank 41.In such a position, the cover 4 is interposed between at least a portion of the tab 33 and the internal volume 10 along the first direction 100. Optionally, when the at least one tab 33 is arranged in the securing position, it extends at least partly in contact with one of the faces of the cover 4 or at the level of one of the faces of the cover 4, in particular the second face 412 of the main flank 41 of the cover 4.

[0041] In particular, the at least one tab 33 is moved between the insertion position and the securing position, or vice versa, by deformation by folding, in an automated manner by means of a machine or manually, by human intervention. A bearing force is then exerted on at least a portion of the at least one tab 33. In particular, the cover 4, as indicated above, is made so as to resist such a bearing force applied to the at least one tab 33 and is made so as not to be deformed by any force likely to be exerted by said tab 33 on the cover 4 when the latter is arranged in the securing position.

[0042] According to an exemplary embodiment, the at least one tab 33 is folded into the securing position so that a free end 34 of said tab 33 extends towards a central zone of the housing 2, that is to say towards a zone furthest from the plurality of side walls 32. In this way, a single folding of the at least one tab 33 is required.

[0043] According to an alternative not shown, the at least one tab 33 is folded into the securing position so that its free end 34 extends towards one of the side walls 32 of the base 3. A first folding is then carried out so that an intermediate portion of the at least one tab 33 extends in contact with the main flank 41 of the cover 4, in particular parallel to the latter. A second folding is then carried out in order to move the free end 34 of the at least one tab 33 so that it extends transversely to the intermediate portion, for example parallel to one of the side walls 32 of the base 3. The at least one tab 33 is then folded into a “U” or substantially “U” shape. Such a more complex folding can help to optimize the holding of the base 3 relative to the cover 4 along at least one direction.

[0044] Optionally, as illustrated in Figures 1 to 3, the housing 2 comprises a plurality of fixing devices 5 for the cover 4 on the base 3 so that the housing 2 comprises a plurality of tabs 33 and openings 43, each tab 33 being configured to be inserted, as described previously, into one of the openings 43. The description below is made with reference to a tab 33 and an opening 43, it is nevertheless understood that the different characteristics relating to said tab 33 or said opening 43 may extend to all or part of the plurality of tabs 33 and to the plurality of openings 43.

[0045] Preferably, for ease of manufacture and reduction of manufacturing costs, the tab 33 and the side wall carrying it are made in one piece.

[0046] For example, the tab 33 has a polygonal shape. Preferably, the tab 33 has an elongated, rectilinear or substantially rectilinear shape, for example a rectangular or square tab shape. In particular, the tab 33 has a first dimension, along the first direction 100, greater than or equal to 2 cm when said tab 33 is in the insertion position. In particular, the first dimension 100 of the at least one tab 33 is adapted according to the dimensions of the cover 4 and the mass of the battery module 1. The first dimension here corresponds to a length of the tab 33.

[0047] Alternatively or additionally, the tab 33 has a dimension, along the third direction 300, greater than or equal to 1 cm, or even 2 cm. The second dimension here corresponds to a width of the tab 33 in the illustrated example. Optionally again, the tab 33 has a third dimension, corresponding to a thickness, defined along the second direction 200, between 1 mm and 10 mm, or even between 2 mm and 8 mm or even between 3 mm and 6 mm. As indicated above, the dimensions of the tab 33 are adapted according to the dimensions and the mass of the battery module 1 considered.

[0048] Optionally but preferably, the free end 34 of the tab 33 comprises at least one chamfer 35. Such a chamfer 35 aims to facilitate the insertion of the tab 33 into the opening 43. The opening 43 is configured to allow the passage of the tab 33 that it receives. In particular, the opening 43 is configured to allow the passage of a profile of the tab 33 that it receives, such a profile being defined in a plane orthogonal to the first direction 100. For example, the opening 43 has a shape complementary to at least a portion of the tab 33 that it is configured to receive. In particular, the opening 43 is complementary in shape to the profile of the tab 33 defined in the plane orthogonal to the first direction 100. For example, in a non-limiting manner, the opening 43 has the shape of a through slot, rectangular or substantially rectangular.

[0049] Optionally, the fixing device 5 comprises at least one recess 44 configured to receive all or part of the at least one tab 33 when the latter extends into the securing position. The recess 44 is included in the cover 4, in particular in the main flank 41, and arranged at the level of the at least one opening 43. In particular, the recess 44 opens onto the opening 43.

[0050] For example, the recess 44 can be obtained by cutting or removing material in the thickness of the main flank 41.

[0051] Preferably, a length of the recess 44, defined along the second direction 200, is strictly greater than a length of the end portion along this same direction so as to allow the positioning, manual or automated, of the tab 33 in the securing position but also in order to allow simple gripping of said tab 33 in the event of disassembly of the battery module 1.

[0052] Preferably, the recess 44 is shaped and dimensioned so that, when the tab 33 is in the securing position, it is at least partly in line with the cover 4, particularly the second face 412 of the cover 4. In other words, at least a portion of the tab 33 is then in a plane common to the second face 412 of the main flank 41. Such a principle advantageously makes it possible to limit the size generated by the tab 33 along the first direction 100. At least one end portion 45 of the tab 33, comprising its free end 34 and corresponding to the folded portion of said tab 33 in the securing position, then extends parallel or substantially parallel to the main flank 41 of the cover 4.

[0053] According to yet another alternative, a depth of the recess 44, defined along the first direction 100, is strictly greater than a thickness of the end part 45 of the tab 33 so as to be able to receive the entire end part 45, folded down, of said tab 33, when the latter is in the securing position.

[0054] Optionally, the fixing device 5 comprises at least one stop member 46, arranged in the cover 4 and extending at the level of the at least one opening 43. The stop member 46 is configured to form a stop for the tab 33 extending through the opening 43 along at least one direction when the latter extends in the securing position. In this case, the stop member 46 forms a stop for the tab 33 along a direction of the first direction 100 when the latter extends in the securing position. Also, the stop member 46 is capable of forming a stop for the tab 33 along the second direction 200.

[0055] According to an exemplary embodiment, not shown, the stop member 46 is formed by a part of the second face 412 of the main flank 41 of the cover 4. The tab 33 is then folded into the securing position so as to extend into contact with said face.

[0056] According to a preferred embodiment, shown in Figures 4 to 7, the stop member 46 is formed by a bottom of the recess 44 as explained above. The tab 33, when it is arranged in the securing position, then extends into the recess 44, in contact or substantially in contact with the bottom of said recess 44. The bottom of the recess 44 then forms a stop for the end portion 45 of the tab 33 along a direction of the first direction 100. Also, the bottom of the recess 44 forms a stop for the tab 33 along the second direction 200.

[0057] When the fixing device 5 comprises a plurality of tabs 33 and openings 43, as described previously, each tab 33 is configured to be arranged in one of the openings 43. The plurality of tabs 33 can then be distributed within the base 3 according to different alternative embodiments which can advantageously be combined with each other, the folding of said tabs 33 not presenting any specific constraints on the position or orientation thereof.

[0058] For example, the legs 33 may be distributed into a plurality of sub-assemblies arranged so that at least two sub-assemblies of legs 33 are connected to two separate, opposite side walls 32, as illustrated in the figures. Such an arrangement advantageously makes it possible to minimize the number of legs 33 required while optimizing the fixing of the cover 4 on the base 3.

[0059] Optionally and preferably, at least two tabs 33 are arranged at the level of the same side wall 32. In other words, a subassembly considered then also comprises a plurality of tabs 33. For example, said tabs 33 are regularly spaced within the side wall 32 considered.

[0060] Optionally still, additionally or alternatively, at least two sub-assemblies of legs 33 can be connected to two adjacent distinct side walls 32. It is understood that the position of the openings 43 within the cover 4, in particular the main flank 41, is then adapted accordingly and that the preceding description applies mutatis mutandis to all or part of the legs 33 and / or openings 43.

[0061] The invention finally extends to a method of assembling the battery module 1 according to the invention. Generally, such a method comprises a step of positioning at least one electrochemical cell 11 on the main wall 31 of the base 3 of the housing 2. The at least one electrochemical cell 11 is then arranged in the internal volume 10 of the housing 2. A similar principle applies when the battery module 1 comprises a plurality of electrochemical cells 11.

[0062] The method then comprises positioning the cover 4 on the housing 2, so as to close the housing 2 comprising the at least one electrochemical cell 11. The at least one tab 33 is then arranged in the insertion position, that is to say it extends along the first direction 100 as visible in FIG. 6, in the continuity of the side wall 32 carrying it, so that when the cover 4 is arranged on the base 3, the at least one tab 33 extends through the at least one opening 43 of the cover 4. It is understood that, when the fixing device 5 of the housing 2 comprises a plurality of tabs 33 and openings 43 as explained above, the different tabs 33 are arranged in the insertion position and extend along the first direction 100 so that each can be inserted into one of the openings 43 of the cover 4.

[0063] Once the cover 4 is positioned, that is to say once it is in contact with the base 3 and the at least one tab 33 is arranged through the at least one opening 43, the method comprises a step of securing the cover 4 to the base 3. Such a step is carried out by moving the end portion 45 of the at least one tab 33 from the insertion position to the securing position, that is to say by deformation of the at least one tab 33, in particular by folding. Such folding can be carried out according to the different orientation alternatives set out previously. Also, such folding can be carried out so that the at least one tab 33 extends into the recess 44 and / or in abutment with the abutment member 46 described above. Finally, the folding can advantageously be carried out automatically, by a machine, or manually.

[0064] To disassemble the battery module 1 according to the invention, for example in order to replace the at least one electrochemical cell 11 or one of the electrochemical cells, the reverse method is implemented.

[0065] The present invention thus provides a housing for a battery module making it possible to reduce the number of references required for assembling the housing. The manufacturing cost of a battery module comprising such a housing is thus advantageously reduced. The assembly and disassembly of the module are also simplified.

[0066] The present invention cannot, however, be limited to the means and configurations described and illustrated here and it also extends to any equivalent means or configuration and to any technically operative combination of such means insofar as they ultimately fulfill the functionalities described and illustrated in the present document.

Claims

CLAIMS 1. Housing (2) for a motor vehicle battery module (1) comprising a base (3) open on one side having a plurality of walls, including at least one main wall (31) and side walls (32) connected to the main wall (31), and a cover (4), comprising at least one main flank (41) configured to be mounted on the base (3) so as to close the housing (2), characterized in that the housing (2) further comprises at least one fixing device (5) comprising: - at least one opening (43), arranged in the main flank (41); - at least one deformable tab (33), connected to at least one of the side walls (32), configured to be arranged in the at least one opening (43) and to be deformed between an insertion position, in which said tab (33) extends along a first direction (100), in the continuity of the at least one side wall (32) and transverse to the main flank (41), and a position for securing the cover (4) relative to the base (3) in which said tab (33) extends transversely to said wall.

2. Housing (2) according to the preceding claim, in which: - the base (3) is made of a metallic material, such as sheet steel and / or aluminum; and / or - the cover (4) is made of a plastic material, such as a filled or unfilled polymer, and / or of a metallic material, such as sheet steel and / or aluminum.

3. Housing (2) according to one of the preceding claims, in which the at least one tab (33) and at least one of the side walls (32) of the base (3) are made in one piece.

4. Housing (2) according to one of the preceding claims, in which the at least one fixing device (5) comprises at least one stop member (46), arranged in the cover (4) and extending at the level of the at least one opening (43), said stop member (46) being configured to form a stop for the at least one tab (33) along at least one direction when the latter extends in the securing position.

5. Housing (2) according to one of the preceding claims, in which the at least one fixing device (5) comprises at least one recess (44), arranged at the level of the at least one opening (43), configured to receive the at least one tab (33) when the latter extends into the securing position.

6. Housing (2) according to one of the preceding claims, in which: - the at least one leg (33) has a dimension, along the first direction (100) when said leg (33) is in the insertion position, greater than or equal to 2 cm; and / or - the at least one leg (33) has a dimension, along a second direction orthogonal to the first direction (100), greater than or equal to 1 cm, or even 2 cm.

7. Housing (2) according to one of the preceding claims, comprising a plurality of fixing devices (5) such that the housing comprises a plurality of tabs (33) and openings (43), each tab (33) being configured to be arranged in one of the openings (43), the plurality of tabs (33) being distributed into a plurality of sub-assemblies arranged such that: - at least two subsets of legs (33) are connected to two separate, opposite side walls (32); and / or - at least two subsets of legs (33) are connected to two distinct, adjacent side walls (32); and / or - at least two legs (33) are arranged at the level of the same side wall (32).

8. Battery module (1) comprising a housing (2) according to one of the preceding claims, delimiting an internal volume (10), and at least one electrochemical cell (11) arranged in said volume.

9. Motor vehicle with electric or hybrid motorization comprising a housing (2) according to one of claims 1 to 7 and / or at least one battery module (1) according to claim 8.

10. Method of assembling a battery module (1) according to claim 8 comprising: - a step of positioning at least one electrochemical cell on the main wall (31) of the base (3) of the housing (2); - a step of positioning the cover (4) on the housing (2) so as to arrange the at least one electrochemical cell in the interior volume and so as to close the housing (2), the at least one tab (33) being arranged in the insertion position and extending through the at least one opening (43) of the cover (4); - a step of securing the cover (4) to the base (3) by moving the at least one tab (33) from the insertion position to the securing position.

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