Member in a battery case

Abstract

The present invention relates to a battery case of an automotive vehicle that accommodates multiple battery modules or cells and that comprises a frame, with at least two opposite walls and at least one member that extends between two opposite walls, that separates two adjacent battery modules or cells and that is made of a polymer material.

Description

[0001] Member in a battery Case

[0002] The present invention relates to a battery case of an automotive vehicle that accommodates multiple battery modules or cells and that comprises a frame, with at least two opposite walls and at least one member that extends between two opposite walls, that separates two adjacent battery modules or cells or cells and that is made of a polymer material.

[0003] Such battery cases are for example known from DE 102023 123 390 A1 , US 2024 / 0075819 A1 and US 2024 / 0075802 and are a part of an electric driven vehicle, for example an automotive. The battery case comprises a frame which can be the body in white of the vehicle or a separate frame. The battery case may further comprise a bottom-plate and / or a cover. The frame is reinforced by one or more members, for example bars, which can extend longitudinally; i.e. parallel to the longitudinal axis of the vehicle or can be a cross-member; i.e. extend perpendicular to the longitudinal direction of the vehicle. There is a constant need to improve the such battery cases in terms of producibility, safety, lightweighting and / or functionality, including management of assembly tolerances.

[0004] It is therefore the problem of the present invention to improve existing battery cases.

[0005] The problem is attained with a battery case of an automotive vehicle that accommodates multiple battery modules or cells or cells and that comprises a frame, with at least two opposite walls and at least one member that extends between two opposite walls, that separates two adjacent battery modules or cells and that is made of a polymer material, wherein at least two battery modules or cells are connected by at least one busbar and that the member comprises at least one electrical connector to connect elements of the busbar.

[0006] The disclosure made regarding this embodiment of the present invention also applies to the other embodiment and vice versa. Subject matters disclosed in connection with this embodiment can be incorporated into the other embodiment and vice versa.

[0007] The present invention deals with a battery case for an automotive vehicle, that accommodates multiple battery modules or cells or cells. Commonly, these batteries modules or cells are at least partially connected by one or more busbar(s). In conventional designs, the electrical connectors need to be isolated from the carrying-metallic elements. Using an organic material to realize the crossmembers, this isolation is not required, as the organic material is not electrically and / or neither thermally conductive. This allows smaller devices to be realized, allowing a maximal usage of the space to include cells and modules. The battery case comprises a frame, which conventionally has a square or rectangular shape and is made from a metal material. The battery frame can be part of the body in white or a structure connected to the body in white. The Battery case preferably comprises a plate, preferably a bottom plate and / or a cover. Besides carrying the battery modules or cells, the bottom may comprise additional features, for example safety features, such as cooling.

[0008] Between to opposite walls, one or more members are provided, which divide the inner volume of the frame into compartments, wherein each compartment preferably houses a battery module. The members are preferably parallel and / or orthogonal to each other and even more preferably form a grid of compartments. Preferably, a member is connected to the frame, for example by welding, adhesion and / or a mechanical connection.

[0009] Each member is made partially or entirely from an electrically non-conductive polymer material. Preferably, the member is an extruded or pultruded part and / or moulded, preferably over-molded. Preferably, the member is at least partially hollow with more preferably one or more ribs. Preferably, the cross-section of the member is rectangular.

[0010] According to the invention, at least two battery modules or cells are connected by at least one busbar and that the member comprises at least one electrical connector to connect elements of the busbar. This embodiment allows a simple connection of two battery modules or cells or cells via the electrical connector elements in the member. Shorter busbar segments can be used. The busbar segments may even fasten the battery module in the compartment. The electrical connector can be plate, a hollow structure or the like, preferably made from an electrically conductive material, more preferably a metal material. The electrical connector can be connected to the member by a mechanical- and / or an adhesive connection. The electrical connector can be over molded. Preferably, the electrical connector comprises means to connect the busbar to the electrical connector. Such means can for example be a screw. Alternatively, the busbar is welded to the electrical connector.

[0011] According to a preferred embodiment of the present invention, the busbar is supported, preferably only supported, by the member, preferably without a fastening means or the like. Preferably, a form- and / or force-fit-means is provided to improve the support of the busbar on the member. More preferably, the form- and / or force-fit limits a movement of the busbar relative to the member, but even more preferably can be removed from the member without a tool. Preferably, the electrical connector is provided in a groove and / or a cavity in the member. This embodiment of the present invention has the advantage that the electrical connector and / or the busbar attached to it, is protected. Even more preferably, the electrical connector is covered with an electrical insulator, for example to avoid short cuts and further protect the connector and / or the connection.

[0012] The problem is also attained with a battery case comprising one or more member(s) which is / are provided as modular structure comprising a profile and / or a center element.

[0013] The disclosure made regarding this embodiment of the present invention also applies to the other embodiment and vice versa. Subject matters disclosed in connection with this embodiment can be incorporated into the other embodiment and vice versa.

[0014] According to this embodiment, the member comprises multiple modular profiles and / or elements, which are connected to form the member. The profiles / elements are preferably extruded or pultruded. The profiles and / or elements can be combined to form the member needed. Each member of the battery case can be assembled individually. The connection between the profiles and / or the elements and / or between a profile and an element is preferably an adhesive and / or a form-fit-connection.

[0015] An member is for example formed by a center profile, that has an additional profile at one longitudinal end and / or a profile at the opposite longitudinal end. The center profile can be formed by a multitude of separate elements.

[0016] The profile has preferably a groove and / or a cavity, preferably to accommodate an adhesive and / or the electrical connector. This adhesive can for example be used to connect the member to the plate and / or to the cover. The electrical connector has the functionality described above.

[0017] Preferably, each member is connected with the frame, preferably at its longitudinal ends. Preferred is a weld- or an adhesive- or a mechanical-connection.

[0018] Preferably at each end of the member, an endcap is provided. The endcap can be made of the same of a different material than the member itself. The end-cap material can be made from a metallic- and / or organic-material, with preference in this case, of a thermopolymer material. This preferred embodiment allows complex shapes than can adapt to the shape of the member. According to a preferred embodiment of the present invention, the member comprises a length compensation element, to reduce or eliminate gaps between the member and the frame. Preferably, the length compensation element is an expandable material, that is provided between the center profile of the member and the endcap. The expansion of the expandable material closes a potential gap between the member and the frames

[0019] Alternatively or additionally, the length compensation element is a sloped part. Due to, for example a height adjustment of the member, a gap is closed.

[0020] The inventions are now further disclosed according to the Figures. This disclosure is only exemplary and does not limit the scope of protection. The disclosure applies to all inventions likewise.

[0021] Fig. 1 shows the inventive battery case.

[0022] Fig. 2 shows a modularly built member 7.

[0023] Figs. 3a - 3d show features of the member 7.

[0024] Figs. 4a - 4c show another embodiment of the member 7.

[0025] Figs. 5a - 6b show electrical connector.

[0026] Fig. 7 shows an embodiment with an endcap.

[0027] Figs. 8 - 9 show an embodiment with length compensation.

[0028] Figs. 10a - c show another embodiment of the member 7.

[0029] Fig. 11 show an embodiment with attachment means.

[0030] Figure 1 shows the inventive battery case 1 with a frame 5, that comprises in the present case four sidewalls. In the present case, the frame 5 is provided inside the body in white 2, but the person skilled in the art understands that the battery case can also be part of the body in white. The frame is preferably made from a metal material. The battery case may comprise a plate 4, specifically a bottom plate and / or a cover 6. The bottom and / or the cover may comprise safety features, like cooling. The battery case accommodates a multitude of battery modules or cells 3, which are at least partially connected by a busbar 9. The battery case 1 comprises one or more member(s) 7, which here separate two adjacent battery modules or cells 3. In the present case, the members are arranged in a transverse direction to the longest extension of the battery case 1. The member is preferably made of a electrically non-conductive material. Preferably, the member 7 is ex- or pultrude. In the present case it is hollow and / or comprises a rectangular cross-section. Preferably one or more ribs are provided to increase the stability of the member 7 and / or to provide separated compartments, which can be used to accommodate for example a cable or for a gas- or fluidflow. At both of its ends, the member 7 is connected to the frame 5, for example by an adhesive connection. The member 7 comprises an electrical connector 10 to which elements of the busbar 9 can be permanently or reversibly connected. The electrical connector 10 is for example a metal plate, that is attached to the member 7 by adhesion or which has been over-moulded by the polymer material from which the member is made.

[0031] Figure 2 shows an embodiment of the member 7, which has in the present case a modular structure with a center profile 13 to which one or more, here two profiles are added, for example by an adhesive layer 11. The member 7 can be connected to plate or the cover by one or more optional adhesive layers 11 , here at the bottom and the top. The member comprises here two endcaps to connect the member 7 to the frame 5. The endcaps can be made of metal and welded to the frame.

[0032] Figures 3a - 3d each depict a different embodiment of a profile 12 that can be added to the center profile 13. The embodiment according to Figure 3a has a groove at the top that can accommodate for example an adhesive and / or the electrical connector or that can provide a form fit for another part being connected to the member 7. Form-fit-means 14 can be provided to connect the profile 12 to the center profile 13. The profile 12 is preferably pultruded. Regarding Figure 3b reference can be made to the elaborations according to Figure 3a. In the present case a cavity15 for example for a fluid or an electrical connector is provided. Figure 3c shows that an adhesive can also be provided in a groove 15 or as depicted in Figure 3d an electrical connector 10, which is depicted on the right hand side of Figure 3d.

[0033] Figures 4a - c show that the member can be made from to profiles 12 at the bottom and top, between which center elements 17 are provided and connected to the profiles 12, here by a form fit. As can be seen from Figure 4c, the center elements 17 can be different to provide different mechanical properties and / or different functionalities. Figures 5a - b show an electrical connector 10 provided in the member 7, here in a groove 15 of the member, which here has here indentations in its sidewalls to accommodate the busbar elements 9, which are here screwed to the electrical connector. A cover 18 can be added to protect the electrical connection.

[0034] According to the embodiment of Figures 6a - b, the electrical connector 10 is integrated in a cavity 15 and busbar elements can be connected to the electrical connector for example via openings 30.

[0035] Figure 7 shows an embodiment of a member 7 with an endcap 20, to connect the member to the frame 5, in the present case with an adhesive layer 8. In the present case, the member 7 also comprises a length compensation 8, here in the form of an expandable layer, which expands, for example under the influence of heat. The expanded material preferably solidifies in the expanded position. Alternatively or additionally, the length compensation can be rubber like. The length compensation 8 can also comprise adhesive properties to connect the endcap with the member 7.

[0036] Another embodiment for a length compensation 8 is a wedge-shaped length compensation element 21, as depicted in Figure 8. Due to a relative movement between the member 7 and the element 21 , potential gaps between the member 7 and the frame 5 can be compensated.

[0037] A member 7 with length compensation is also depicted in Figure 9. At the ends and here also in the middle, a carrier with an expandable layer 22 is included in the member 7. The expandable layer(s) expand and thus change the length of the member 7. The expanded material preferably solidifies in the expanded position. A preferred reference element 23 maintains the center of the member 7 in a certain position relative to the frame. The reference element is preferably inserted into an indentation for example in the plate 4 of the battery case.

[0038] Figures 10 a - c show another embodiment of the member 7, wwhich is in the present case pultruded, has a rectangular hollow shape and form-fit means which connect a dove-tailed electrical connector element 10 to the member 7. Busbar elements can be connected to the electrical connector, for example by welding. At the bottom preferably a form-fit means is provided which connects an element to the member 7, that can be utilized to connect the member with the plate 4. At both ends endcaps are inserted into the cavity of member 7 slidingly, so that an expandable material upon expansion closes a potential gap between the an endcap and the frame. The expanded material preferably solidifies in the expanded position.

[0039] Figure 11 shoes an embodiment of the member 7 with a form-fit-means at one sidewall to slidingly fasten attachment means 24 for cables or the like.

[0040] List of reference signs:

[0041] 1 Battery case

[0042] 2 Body in white, rocker

[0043] 3 Battery Module

[0044] 4 Plate, protective plate, cooling plate

[0045] 5 Frame

[0046] 6 Cover

[0047] 7 Member

[0048] 8 Connection of the member 7 to the battery frame 5

[0049] 9 Busbar

[0050] 10 Electrical connector

[0051] 11 Connecting layer, adhesive connection

[0052] 12 profile

[0053] 13 Center profile

[0054] 14 Form-fit-means

[0055] 15 Groove, Cavity, for example for an adhesive and / or an electrical connector

[0056] 16 Adhesive, expandable Adhesive

[0057] 17 Center element

[0058] 18 Insulator

[0059] 19 Window

[0060] 20 Endcap

[0061] 21 Length compensation element

[0062] 22 Expandable part

[0063] 23 Reference element

[0064] 24 Attachment means

Claims

Claims:

1. Battery case (1) of an automotive vehicle that accommodates multiple battery modules or cells (3) and that comprises a frame (5), with at least two opposite walls and at least one member (7) that extends between two opposite walls, that separates two adjacent battery modules or cells (3) and that is made of a polymer material, characterized in, that at least two battery modules or cells are connected by at least one busbar (9) and that the member (7) comprises at least one electrical connector (10) to connect elements of the busbar (9).

2. Battery case (1) according to claim 1 , wherein the electrical connector (10) is provided in a groove and / or a cavity (15) in the member (7).

3. Battery case (1) according to claims 1 or 2, wherein the electrical connector (10) is covered with an electrical insulator (18).

4. Battery case (1 ) according to one of the preceding claims or the preamble of claim 1 , characterized in, that the member (7) is provided as modular structure comprising a profile (12, 13) and / or a center element (17).

5. Battery case (1) according to claim 4, wherein two profiles (12, 13) and / or the center element(s) (17) and / or the center element (17) and the profile are connected, preferably by an adhesive or form-fit-connection.

6. Battery case (1) according to claims 4 or 5, wherein the profile (12) has a groove and / or a cavity (15), preferably to accommodate an adhesive (16) and / or the electrical connector (10).

7. Battery case (1) according to one of the preceding claims, wherein each member (7) is connected with the frame (5).

8. Battery case (1) according to one of the preceding claims, wherein at each end of the member (7), an endcap (20) is provided.

9. Battery case (1) according to one of the preceding claims, wherein the member (7) comprises a length compensation element (21).

10. Battery case (1) according to claim 9, wherein the length compensation element (21) is an expandable material.

11. Battery case (1) according to claim 9, wherein the length compensation element (21) is a sloped part.

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