An enclosure for a battery module, a battery module comprising the same, and a method of assembling a battery module

Abstract

An enclosure for a battery module, the enclosure comprising first and second plates and a panel, which extends between the first and second plates, wherein the first and second plates each comprise one or more attachment lugs, which project therefrom, the lugs being received by corresponding attachment openings in the panel for attaching the panel to the first and second plates.

Description

[0001] An enclosure for a battery module, a battery module comprising the same, and a method of assembling a battery module

[0002] The present disclosure relates to an enclosure for a battery module, which allows for simplified assembly, to a battery module comprising the same, and to a method of assembling the battery module.

[0003] Battery modules are generally self-contained units within larger battery systems, typically containing multiple individual cells and associated components. The battery modules comprise enclosures for containing the individual cells and holding them in a suitable position relative to one another.

[0004] Between adjacent cells there is typically provided a compressive insulating material, which aids in minimising heat transfer between components, reduces the transmission of vibrations to the cells, and ensures even contact between components. The insulating material, as well as the cells, is under a degree of compression once the battery module is assembled. This complicates assembly of the battery module, particularly the construction of the enclosure, which is generally formed from a number of separate metal parts. Complex jigs are required.

[0005] The present invention arose in a bid to provide an improved battery module enclosure that would allow for a simplified structure and easier assembly.

[0006] Representative features are set out in the following clauses, which stand alone or may be combined, in any combination, with one or more features disclosed in the text and / or drawings of the specification.

[0007] According to the present invention in a first aspect, there is provided an enclosure for a battery module, the enclosure comprising first and second plates and a panel, which extends between the first and second plates, wherein the first and second plates each comprise one or more attachment lugs, which project therefrom, the lugs being received by corresponding attachment openings in the panel for attaching the panel to the first and second plates.

[0008] By virtue of such an arrangement, assembly of a battery module is greatly simplified. A self-aligning / self-retaining assembly is possible.

[0009] The lugs may be unitarily formed with the first and second plates. The lugs may otherwise be separately formed to the plates and fixed thereto. The lugs may be detachably fixed to the first and second plates.

[0010] The lugs may remain in place following attachment of the panel to the first and second plates and form part of the final enclosure. They may alternatively, be used during assembly only and removed once the panel has been fixed in place, such that they do not form part of the final enclosure.

[0011] Preferably, the first and second plates comprise end plates and the attachment openings are provided in first and second end portions of the panel.

[0012] The attachment lugs and attachment openings may have profiles that are substantially congruent. Alternatively, the attachment openings may have larger profiles than the attachment lugs. The attachment openings may comprise slots having a width substantially equal to a width of the attachment lugs but a greater length.

[0013] The one or more attachment lugs may each comprise a neck and an enlarged head.

[0014] By virtue of the provision of enlarged heads, retention may occur in multiple dimensions / planes.

[0015] Preferably, each attachment opening has a first portion having a first width and a second portion having a second width, wherein the second width is smaller than the first width, and the enlarged head has a greater width than the second width. By such arrangement, the attachment lugs and attachment openings will function in the manner of keyhole fasteners, the enlarged heads passing through the enlarged first portions and being trapped by the second portions.

[0016] The second portion of each attachment opening is preferably adjacent to an end of the panel, such that a force urging the plates away from each other will urge the lug towards the first portion.

[0017] Preferably, the attachment openings and the lugs have complimentary profiles in regions where they engage one another. When the complimentary profiles are tapered, a particularly beneficial self-jigging effect is achieved.

[0018] Preferably, each attachment opening is tapered between the first portion and the second portion. Each attachment opening may be trapezoidal or wedge shaped. The neck portion of each lug may have a tapered profile in section, wherein tapered faces of the neck engage tapered edges of the attachment opening.

[0019] Such an arrangement provides an effective spread of loads and reduces risks that the lugs may tear through the material of the panel. However, it is to be noted that the openings and / or neck portions may take alternative forms, including curved, rounded or square forms.

[0020] Preferably, the neck of each attachment lug projects from the plate by a distance that is substantially equal to the thickness of the panel in a region of the respective attachment opening.

[0021] By such an arrangement, the enlarged heads of the lugs will act to hold the panel tight against the plates, which is particularly useful for closing gaps for welding, etc.

[0022] The panel is preferably unitarily formed from a sheet. The panel may be folded around an outer end face of each of the plates. The folded portions may be welded to the plates.

[0023] The panel may be substantially planar. It may alternatively be non-planar. It may comprise one or more flanges. It may be substantially L-shaped or C-shaped in section.

[0024] The panel may provide a side and a base of the enclosure, with a lower folded portion forming a base useful for supporting the cells within the enclosure from below.

[0025] The enclosure preferably comprises two of the panels. The enclosure may be substantially rectangular in form with the panels parallel to one another to define opposed sides of the enclosure.

[0026] According to the present invention in a further aspect, there is provided a battery module comprising an enclosure as defined in any of the above paragraphs and a plurality of battery cells. Preferably, the battery cells are arranged between the plates and between each adjacent pair of battery cells there is provided a compressive material.

[0027] According to the present invention in a yet further aspect, there is provided a method of assembling a battery module as defined above, the method comprising: arranging the plurality of battery cells and the compressive material between the plates; applying a compressive force to the end plates to move them towards one another by compression of the compressive material; inserting the lugs in the attachment openings; and releasing the compressive force to allow the compressive material to resile, thereby urging the plates apart from each other, and attaching the panel to the first and second plates.

[0028] The method may comprise a step of welding the panel to the first and second plates. The method may comprise a step of detaching the one or more attachment lugs.

[0029] Further, preferable, features will be apparent from the dependent claims and / or from the description that follows.

[0030] As will be apparent, by virtue of the unique design of the enclosure an arrangement is provided that exhibits numerous advantages over the prior art, including but not limited to: releasing to a set length as opposed to a set pressure thereby ensuring further assembly uniformity; aligning without the aid of additional tooling; aligning the parts with respect to each other automatically; closing the gap between the metals to allow for welding without further tooling; and being sufficiently structural to be handled and moved during assembly without further clamps or tooling.

[0031] Non-limiting embodiments of the invention will now be discussed with reference to the following drawings:

[0032] Figure 1 shows a perspective view of a battery module according to a first arrangement;

[0033] Figure 2 shows a perspective view of a battery module according to a second arrangement;

[0034] Figure 3 shows a perspective view of a first plate and panel of an enclosure for a battery module attached to one another;

[0035] Figure 4a and 4b show end and side views, respectively, of the first plate of Figure 3;

[0036] Figure 5 shows a partial side view of the panel of Figure 3;

[0037] Figure 6 shows a partial side view of the first plate and panel of Figure 3 attached to one another;

[0038] Figure 7 shows an end view of an alternative first plate and panel of an enclosure for a battery module attached to one another; and

[0039] Figure 8 shows a partial side view of the first plate and panel of Figure 7. With reference to Figure 1 , there is shown a non-limiting, exemplary, battery module 100, which comprises an enclosure 1 and a plurality of battery cells 10 housed within the enclosure. The enclosure 1 comprises first and second plates 2, 3 and a panel 4, which extends between the first and second plates 2, 3. The first and second plates 2, 3 each comprise one or more attachment lugs 5, which project therefrom. The lugs 5 are received by corresponding attachment openings 6 in the panel 4 for attaching the panel to the first and second plates 2, 3. The battery cells 10 are arranged between the plates 2, 3, and between each adjacent pair of battery cells 10 there is provided a compressive material 7. The compressive material may comprise cork or other suitable material.

[0040] The first and second plates 2, 3 preferably comprise end plates of the enclosure 1 , as shown. The attachment openings 6 are preferably provided in end portions of the panel 4. The enclosure 1 preferably comprises two of the panels 4, as shown. The panels 4 preferably comprise side panels. It should be appreciated, however, that in alternative arrangements a single panel 4 only may be provided, which could, for example, comprise a bottom panel, or additional panels 4 could be provided, such that there are more than two panels 4.

[0041] Figure 2 shows an alternative non-limiting, exemplary, battery module 101 , which has an enclosure of similar construction to the battery module 100 of Figure 1 . The primary differences are in the profiles of the panels 4, and the provision of a single attachment lug 5 on each side of each of the plates 2, 3 rather than of a pair of attachment lugs 5 on each side of each of the plates 2, 3 in the arrangement of Figure 1 .

[0042] As mentioned, and will be readily appreciated by those skilled in the art, numerous variations will be possible in respect of the number and form of panels 4. Additionally or alternatively, numerous variations in the number, location and form of the lugs 5 will be possible.

[0043] Further consideration will now be given to the construction of the enclosures 1 , with particular reference to Figures 3 to 8. The first and second plates 2, 3 are not particularly limited in their structure. They are preferably metal. They are preferably unitarily formed but may be formed in multiple pieces. They may be machined, extruded or die cast.

[0044] Notably, whilst the attachment lugs 5 are shown to project from side edges of the first and second plates 2, 3, their location is not limited as such. It will depend on the arrangement of the panel(s) 4, as will be readily appreciated.

[0045] Whilst it need not be the case, it is preferable that the attachment lugs 5 each comprise a neck 5b and an enlarged head 5a. Where the attachment lugs 5 do not comprise enlarged heads then they will be suitable for retention substantially in the plane of the panel 4 only, which is of itself very helpful for assembly in the manner discussed further below. With enlarged heads, however, the panel can be locked in place, with retention out of the plane of the panel 4 also, as also further discussed below.

[0046] In either case, as noted above, the lugs 5 may be a permanent feature, included in the final enclosure, or may be removable once the enclosure is assembled. In the latter case, the panel 4 will be fixed to the plates 2, 3 using alternative fixing means, such as welding, and once suitably attached, the lugs may be removed.

[0047] The lugs 5 may be unitarily formed with the plates 2, 3 or may be separately formed and attached thereto, permanently, or removably. For example, removable lugs 5 could be threaded and received by suitable threaded holes.

[0048] Preferably, each attachment opening 6 has a first portion having a first width and a second portion having a second width, wherein the second width is smaller than the first width, and the enlarged head 5a has a greater width than the second portion, as is clearly seen in Figures 3, 6 and 8. The second portion with the smaller width is preferably adjacent to an end of the panel 4. The specific form of the lugs 5 and the attachment openings 6 is not particularly limited. By virtue of the stated general form, the attachment lugs 5 and attachment openings 6 will function in the manner of keyhole fasteners, the enlarged heads 5a passing through the enlarged first portions and being trapped by the second portions.

[0049] Regardless of whether they comprise enlarged heads or not, the attachment openings 6 and the lugs 5 may have complimentary profiles in regions where they engage one another. The complimentary profiles may take various forms, and may for example be curved, round, square or tapered. Complimentary profiles may be useful for spreading load.

[0050] Notably, where the attachment lugs 5 omit enlarged heads, it is possible that the lugs 5 and attachment openings 6 are substantially congruent. The attachment openings 6 will, however, more preferably be larger, and may comprise slots that have widths substantially equal to the widths of the attachment lugs 5.

[0051] Considering the depicted arrangements, it is preferable that each attachment opening 6 is tapered. In particular, each attachment opening 6 may be trapezoidal or wedge shaped. In the depicted arrangements, the attachment openings 6 are trapezoidal, as best seen in Figures 5, 6 and 8. Each attachment opening 6 may be tapered between the first portion and the second portion, as shown. As noted, where the attachment openings 6 have a tapered profile, it is preferable that the necks 5b of the attachment lugs 5 also have a tapered profile in section, wherein the tapered faces of the neck 5b engage tapered edges of the attachment opening 6, as is further evident from the figures.

[0052] It is preferable that the neck 5b of each attachment lug 5 projects from the respective plate 2, 3 by a distance that is substantially equal to the thickness of the panel 4 in a region of the respective attachment opening, as best seen in Figure 7. By such an arrangement, the enlarged heads 5a of the lugs will act to hold the panel 4 tight against the plates 2,3, which is particularly useful for closing gaps for welding, etc.

[0053] The panels 4 are preferably each unitarily formed from a sheet. The panels 4 are preferably metal. The panels 4 may be substantially planar or may be non- planar. When non-planar they may comprise one or more flanges, formed by bending the panel out of plane. In the depicted arrangements, the panels 4 are non- planar, which is typically preferred for increased rigidity and enhanced utility of the panels for the support of and / or connection to other components within the battery module.

[0054] The panels 4 may, for example, be folded around an outer end face of each of the plates 2, 3, as shown in Figure 1 .

[0055] The panels 4 may be substantially L-shaped or C-shaped or Z-shaped in section. The panels may be folded around upper and / or lower edges of the end plates 2, 3 or alternatively folded out from the plates 2, 3.

[0056] By way of non-limiting example only, the panels 4 in the arrangement of Figure 1 are substantially L-shaped and folded around lower edges of the plates 2, 3 such that they may support the cells 10 from below. They could otherwise be substantially planar, C-shaped, Z-shaped, or otherwise non-planar. Moreover, they need not wrap around the plates 2, 3. Any flanges could be directed away from the plates 2, 3.

[0057] By way of an alternative non-limiting example only, the panels 4 in the arrangement of Figure 2 are substantially C-shaped. The panel 4 shown in Figures 3, 5, 6, 7 and 8 has the same form as the panels of Figure 2. The panels 4 do not wrap around the plates 2, 3, rather they are directed away from the plates 2, 3. They could otherwise be substantially planar or L-shaped, or otherwise non-planar.

[0058] Consideration will now be given to the assembly of a battery module 100, 101 according to the principles of the present disclosure. The method comprises:

[0059] - arranging the plurality of battery cells 10 and the compressive material 7 between the plates 2, 3,

[0060] - applying a compressive force to the end plates 2, 3 to move them towards one another by compression of the compressive material 7 (and the cells 10),

[0061] - inserting the lugs 5 in the attachment openings 6, and releasing the compressive force to allow the compressive material 7 (and the cells 10) to resile, thereby urging the plates 2, 3 apart from each other, and attaching the panels 4 to the first and second plates 2, 3.

[0062] Such a method, uniquely possible by virtue of an enclosure formed in accordance with the principles of the disclosure, is greatly simplified over the prior art methods. In particular, no complex jigs are required. Significant savings in respect of both time and cost are possible.

[0063] Following assembly, as above, there may be a fixing step for fixing the panel 4 to the first and second plates 2, 3. The panel may, for example, be fixed by welding.

[0064] Whilst the lugs 5 may be a permanent feature, present in the finished enclosure, as discussed, the lugs may be detachable following assembly. In such case, following fixing of the end plate, the lugs may be removed.

[0065] Numerous alternative arrangements and modifications to the embodiments as described herein will be readily appreciated by those skilled in the art within the scope of the appended claims. In particular, features of the described embodiments may be readily combined.

[0066] When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

[0067] The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

[0068] Although certain example embodiments of the invention have been described, the scope of the appended claims is not intended to be limited solely to these embodiments. The claims are to be construed literally, purposively, and / or to encompass equivalents.

[0069] REPRESENTATIVE FEATURES

[0070] 1 . An enclosure for a battery module, the enclosure comprising first and second plates and a panel, which extends between the first and second plates, wherein the first and second plates each comprise one or more attachment lugs, which project therefrom, the lugs being received by corresponding attachment openings in the panel for attaching the panel to the first and second plates.

[0071] 2. An enclosure according to Clause 1 , wherein the first and second plates comprise end plates and the attachment openings are provided in end portions of the panel.

[0072] 3. An enclosure according to Clause 1 or 2, wherein the attachment openings and the lugs have complimentary profiles in regions where they engage one another.

[0073] 4. An enclosure according to any preceding clause, wherein the one or more attachment lugs each comprise a neck and an enlarged head.

[0074] 5. An enclosure according to Clause 4, wherein each attachment opening has a first portion having a first width and a second portion having a second width, wherein the second width is smaller than the first width, and the enlarged head has a greater width than the second portion.

[0075] 6. An enclosure according to Clause 5 wherein the second portion is adjacent to an end of the panel.

[0076] 7. An enclosure according to Clause 5 or 6, wherein each attachment opening is tapered between the first portion and the second portion.

[0077] 8. An enclosure according to any of Clauses 5 to 7, wherein each attachment opening is trapezoidal or wedge shaped. 9. An enclosure according to Clause 7 or 8, wherein, the neck portion has a tapered profile in section, and tapered faces of the neck engage tapered edges of the attachment opening.

[0078] 10. An enclosure according to any preceding clause, wherein the neck of each attachment lug projects from the plate by a distance that is substantially equal to the thickness of the panel in a region of the respective attachment opening.

[0079] 11. An enclosure according to any preceding clause, wherein the panel is unitarily formed from a sheet.

[0080] 12. An enclosure according to any preceding clause, wherein the panel comprises one or more flanges.

[0081] 13. An enclosure according to any preceding clause, wherein the panel is folded around an outer end face of each of the plates.

[0082] 14. An enclosure according to any preceding clause, wherein the panel is substantially L-shaped in section, substantially C-shaped in section, or substantially Z-shaped in section.

[0083] 15. An enclosure according to any preceding clause, wherein the one or more attachment lugs are permanently attached to the first and second plates or are detachable therefrom.

[0084] 16. An enclosure according to any preceding clause comprising two, three or more of the panels.

[0085] 17. A battery module comprising an enclosure according to any preceding clause and a plurality of battery cells. 18. A battery module according to Clause 17, wherein the battery cells are arranged between the plates, and between each adjacent pair of battery cells there is provided a compressive material.

[0086] 19. A method of assembling a battery module according to Clause 18, the method comprising: arranging the plurality of battery cells and the compressive material between the plates, applying a compressive force to the end plates to move them towards one another by compression of the compressive material, inserting the lugs in the attachment openings, releasing the compressive force to allow the compressive material to resile, thereby urging the plates apart from each other, and attaching the panel to the first and second plates.

[0087] 20. A method according to Clause 19 further comprising a step of welding the panel to the first and second plates.

[0088] 21 . A method according to Clause 19 or 20 further comprising a step of detaching the one or more attachment lugs.

Claims

Claims1 . An enclosure for a battery module, the enclosure comprising first and second plates and a panel, which extends between the first and second plates, wherein the first and second plates each comprise one or more attachment lugs, which project therefrom, the lugs being received by corresponding attachment openings in the panel for attaching the panel to the first and second plates, wherein the attachment openings and the lugs have complimentary tapered profiles in regions where they engage one another.

2. An enclosure as claimed in Claim 1 , wherein the first and second plates comprise end plates and the attachment openings are provided in end portions of the panel.

3. An enclosure as claimed in any preceding claim, wherein the one or more attachment lugs each comprise a neck and an enlarged head.

4. An enclosure as claimed in Claim 3, wherein each attachment opening has a first portion having a first width and a second portion having a second width, wherein the second width is smaller than the first width, and the enlarged head has a greater width than the second portion.

5. An enclosure as claimed in Claim 4 wherein the second portion is adjacent to an end of the panel.

6. An enclosure as claimed in Claim 4 or 5, wherein each attachment opening is tapered between the first portion and the second portion.

7. An enclosure as claimed in any of Claims 4 to 6, wherein each attachment opening is trapezoidal or wedge shaped.

8. An enclosure as claimed in Claim 6 or 7, wherein, the neck portion has the tapered profile in section, and tapered faces of the neck engage tapered edges of the attachment opening.

9. An enclosure as claimed in Claim 3 or any claim dependent thereon, wherein the neck of each attachment lug projects from the plate by a distance that is substantially equal to the thickness of the panel in a region of the respective attachment opening.

10. An enclosure as claimed in any preceding claim, wherein the panel is unitarily formed from a sheet.

11. An enclosure as claimed in any preceding claim, wherein the panel comprises one or more flanges.

12. An enclosure as claimed in any preceding claim, wherein the panel is folded around an outer end face of each of the plates.

13. An enclosure as claimed in any preceding claim, wherein the panel is substantially L-shaped in section, substantially C-shaped in section, or substantially Z-shaped in section.

14. An enclosure as claimed in any preceding claim, wherein the one or more attachment lugs are permanently attached to the first and second plates or are detachable therefrom.

15. An enclosure as claimed in any preceding claim comprising two, three or more of the panels.

16. A battery module comprising an enclosure as claimed in any preceding claim and a plurality of battery cells.

17. A battery module as claimed in Claim 16, wherein the battery cells are arranged between the plates, and between each adjacent pair of battery cells there is provided a compressive material.

18. A method of assembling a battery module as claimed in Claim 17, the method comprising: arranging the plurality of battery cells and the compressive material between the plates, applying a compressive force to the end plates to move them towards one another by compression of the compressive material, inserting the lugs in the attachment openings, releasing the compressive force to allow the compressive material to resile, thereby urging the plates apart from each other, and attaching the panel to the first and second plates.

19. A method as claimed in Claim 18 further comprising a step of welding the panel to the first and second plates.

20. A method as claimed in Claim 18 or 19 further comprising a step of detaching the one or more attachment lugs.

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