GB2588768A - A battery pack housing member and a distribution means - Google Patents

A battery pack housing member and a distribution means Download PDF

Info

Publication number
GB2588768A
GB2588768A GB1915997.9A GB201915997A GB2588768A GB 2588768 A GB2588768 A GB 2588768A GB 201915997 A GB201915997 A GB 201915997A GB 2588768 A GB2588768 A GB 2588768A
Authority
GB
United Kingdom
Prior art keywords
battery pack
pack housing
housing member
duct
reinforcement
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1915997.9A
Other versions
GB201915997D0 (en
Inventor
Flannery Barry
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Xerotech Ltd
Original Assignee
Xerotech Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Xerotech Ltd filed Critical Xerotech Ltd
Priority to GB1915997.9A priority Critical patent/GB2588768A/en
Publication of GB201915997D0 publication Critical patent/GB201915997D0/en
Publication of GB2588768A publication Critical patent/GB2588768A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/64—Heating or cooling; Temperature control characterised by the shape of the cells
    • H01M10/643—Cylindrical cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/653—Means for temperature control structurally associated with the cells characterised by electrically insulating or thermally conductive materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6556—Solid parts with flow channel passages or pipes for heat exchange
    • H01M10/6557—Solid parts with flow channel passages or pipes for heat exchange arranged between the cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6567—Liquids
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/60—Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/60—Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
    • H01M50/609—Arrangements or processes for filling with liquid, e.g. electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/60—Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
    • H01M50/609—Arrangements or processes for filling with liquid, e.g. electrolytes
    • H01M50/627—Filling ports
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

A battery pack housing member 3a comprises at least one passage 20 wherein reinforcement material is able to pass through the battery pack housing member via the at least one passage. Preferably the battery pack housing member is a wall of the battery pack housing 1 and the reinforcement material is a fluid such as epoxy resin, a silicone potting compound or an expandable foam, which is introduced through an inlet 21 into the battery pack housing member before passing into the interior of the battery pack housing through one or more outlets 7a-c. After being set, cured or hardened the reinforcing material provides mechanical support to the components within the battery pack, especially the individual cells 5 and a thermal management duct (8, figs 1 & 6). The thermal management duct is preferably an inflatable flexible serpentine conduit which conforms to the outer surface of the cells between which it interleaves. A distribution manifold for the reinforcement material and a method of manufacturing the battery pack are also claimed.

Description

A BATTERY PACK HOUSING MEMBER AND A DISTRIBUTION MEANS
The present invention relates to inserting reinforcement means such as a potting material into a battery pack housing.
Thermal management systems in state-of-the-art battery packs typically include a heat exchanger in the form of a duct The duct provides a conduit through which a thermal management fluid can pass through the pack to cool or warm the cells therein. Ducts can be rigid or flexible. Rigid ducts tend to be constructed from high thermal conductivity materials such as copper or aluminium, providing excellent thermal transfer between the thermal management fluid within the duct and the cells which are to be thermally managed. However, rigid ducts must be carefully designed and accurately machined to ensure that they can provide good thermal contact with the cells. In contrast flexible ducts in a pressurised or inflated state can closely conform to the shape of the cells, although such ducts may be liable to bursting. A build-up of pressure within an inflatable duct causes the duct wall(s) to stretch and thin, reducing the strength of the walls and potentially leading to leakage of thermal management fluid within the pack. While the risk of bursting can be mitigated by increasing the wall thickness of the duct doing so also increases the thermal resistance ofthe duct and therefore the effectiveness of the thermal management system. There exists a need for a way to reliably strengthen a variety of ducts within battery packs.
While ducts can be reinforced using individual reinforcing members within the pack, doing so complicates the pack design and the manufacturing process required to produce the pack, increasing manufacturing costs. There exists a need for a way to reinforce ducts within a battery pack which is both simple and easy to implement during battery pack manufacture.
A further problem with state-of-the-art battery packs is their propensity to catch fire. The risk of fire within a battery pack is increased when the cells are exposed to high temperatures, when short circuits develop and/or when the internal structure of the cells are compromised. For example, lithium plating and/or crystal formation within a cell can puncture internal cell dielectric membranes, resulting in potentially catastrophic short circuits and explosion of the cell. Such an event can spread throughout the pack causing all of the cells to catch fire. There exists a need for a way of stopping or reducing the spread of excessive heat from a localised region within a battery pack.
It is an object of the invention to obviate or mitigate the problems outlined above. In particular, it is an object of the invention to provide a way to reliably and effectively reinforce 35 internal components within a battery pack.
It is a further object of the invention to provide a reinforcement means which can be used throughout the interior space of the entire pack.
It is a further object of the invention to improve the ease of manufacture of a battery pack.
It is a further object of the invention to provide a battery pack which is inherently fire-retardant.
According to a first aspect of the invention there is provided a battery pack housing member comprising at least one passage means wherein a reinforcement means is able to pass through the battery pack housing member via the at least one passage means. Advantageously, the passage means allows the reinforcement means to be passed into the battery pack housing during manufacturing of the pack.
Preferably the battery pack housing member comprises a plurality of passage means.
Advantageously, there being a plurality of passage means allows reinforcement means to be inserted into the pack at a plurality of locations at the same time. Beneficially this helps to ensure that there is an even distribution of reinforcement means throughout the battery pack.
Ideally the reinforcement means is able to pass into the interior of a battery pack housing 15 via the at least one passage means.
Ideally the passage means is located within the body of the battery pack housing member. Optionally the passage means is located at the peripheral edge of the body of the battery pack housing member.
Ideally the battery pack housing comprises at least two passage means.
Preferably the or each passage means comprises at least one inlet channel.
Preferably the or each passage means comprises one inlet channel.
Preferably the or each passage means comprises a plurality of inlet channels. Preferably the or each passage means comprises at least one outlet channel. Preferably the or each passage means comprises one outlet channel.
Preferably the or each passage means comprises a plurality of outlet channels.
Preferably the or each inlet channel is operably connected to at least one outlet channel. Preferably the or each inlet channel is operably connected to a plurality of outlet channels. Preferably the or each outlet channel is operably connected to a plurality of inlet channels. Preferably the reinforcement means can pass from the or each inlet channel into at least one outlet channel.
Preferably the reinforcement means can pass from the or each inlet channel into a plurality of outlet channels.
Preferably the reinforcement means flows along a straight path through the passage means.
Preferably the reinforcement means flows along a curved or non-sVaight path through the passage means.
Optionally the reinforcement means flows along a path through the passage means having one or more bends.
Optionally the reinforcement means flows along a path through the passage means having one or more 906 bends.
Preferably one or more inlet channel(s) are substantially parallel to one or more outlet channel(s).
Preferably the direction of flow of the reinforcement means through one or more inlet channel(s) is substantially parallel to the direction of flow of the reinforcement means through one or more outlet channels.
Optionally one or more inlet channel(s) are substantially perpendicular to one or more outlet channel(s).
Optionally the direction of flow of the reinforcement means through one or more inlet channel(s) is substantially perpendicular to the direction of flow of the reinforcement means through one or more outlet channels.
Preferably the battery pack housing member comprises at least one inlet aperture.
Preferably the or each inlet aperture provides an entrance to the passage means.
Preferably the battery pack housing member comprises at least one outlet aperture.
Preferably the or each outlet aperture provides an exit from the passage means. Preferably the or each inlet aperture and/or outlet aperture are symmetrical.
Preferably the or each inlet aperture and/or outlet aperture are circular.
Preferably the or each inlet aperture and/or outlet aperture provides a flared opening into 20 and/or out of the battery pack housing member.
Preferably the or each inlet aperture and/or outlet aperture provides a flared opening into and/or out of the passage means.
Ideally the reinforcement means is a flowable reinforcement means. Advantageously, the reinforcement means being flowable allows the reinforcement means to be easily inserted into 25 the battery pack housing.
Ideally the reinforcement means comprises a potting material. Advantageously, potting material can help to reduce the spread of thermal events such as fires within the pack. Preferably the reinforcement means comprises epoxy resin.
Preferably the reinforcement means comprises silicone potting compound.
Preferably the reinforcement means comprises expandable foam.
Preferably the reinforcement means comprises intumescent foam.
Preferably the reinforcement means comprises polyurethane foam.
Ideally the battery pack housing member forms part of a battery pack housing.
Ideally the battery pack housing comprises a plurality of battery pack housing members.
Preferably the battery pack housing includes an upper clamshell, a lower clamshell, one or more side walls and/or one or more end walls.
Preferably the battery pack housing member is an upper clamshell. Preferably the battery pack housing member is a lower clamshell.
Preferably the battery pack housing member is a side wall.
Preferably the battery pack housing member is an end wall.
Preferably the battery pack housing further includes an upper clamshell cover.
Preferably the battery pack housing further includes a lower clamshell cover.
Preferably the battery pack housing further includes one or more busbars connected to the one or more c ells.
Preferably one or more busbars are located between the lower clamshell and the lower clamshell cover.
Preferably one or more busbars are located between the upper clamshell and the upper 10 clamshell cover.
Preferably the battery pack housing member comprises a plurality of faces.
Preferably the battery pack housing member comprises two end faces.
Preferably the battery pack housing member comprises a top face and a bottom face. Preferably the battery pack housing member comprises an interior face and an exterior face.
Preferably the or each inlet aperture and/or outlet aperture is/are located on a face of the battery pack housing member.
Preferably at least one inlet aperture is located on the top face of the battery pack housing member.
Preferably at least one inlet aperture is located on the exterior face of the battery pack housing member.
Preferably at least one outlet aperture is located on the interior face of the battery pack housing member.
Ideally one or more cells are located within the battery pack housing.
Preferably the cells are cylindrical cells.
Optionally the cells are prismatic or pouch cells.
Preferably the cells are arranged in a regular array.
Preferably the cells are located within recesses in the upper and/or lower clamshells.
Preferably the cells are spaced apart from the battery pack side walls.
Preferably the cells are arranged in a regular array comprising a plurality of rows of aligned cells.
Preferably the or each outlet aperture is positioned such that, in use, the or each outlet aperture is located adjacent to the peripheral edge of the array of cells.
Preferably the or each outlet aperture is positioned such that, in use, the or each outlet 35 aperture is located between neighbouring cells. Advantageously, the outlet aperture(s) being between cells means that as reinforcement means passes through outlet aperture(s) its path is not obstructed by cells within the battery pack.
Ideally one or more ducts are located within the battery pack housing.
S
Preferably the or each duct is a thermal management duct Optionally the battery pack comprises a plurality of ducts. Preferably the one or more ducts are serpentine ducts. Optionally the one or more ducts are manifold ducts.
Optionally the battery pack comprises one or more substantially straight ducts.
Optionally the battery pack comprises one or more parallel ducts.
Preferably the or each duct comprises one or more substantially straight sections.
Preferably the or each duct is configured to carry a thermal management fluid. Preferably the or each duct is configured to carry air, water or a water-glycol mixture.
Ideally the duct is a flexible duct Preferably the flexible duct is formed from a polymer-based material.
Preferably the flexible duct is formed from an inflatable plastics material. An inflatable plastics material is advantageous as the material is intrinsically electrically insulating, lightweight and does not corrode or chemically interact with a thermal management fluid such as a glycol 15 water mix.
Preferably the inflatable plastics material is polyester, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE) or high-density polyethylene (H DP E).
Ideally the walls of the flexible duct are between 10 qn a nd 150 qn thick. Advantageously, the inflatable plastics material may be made very thin which allows for good thermal transfer 20 properties between the or each duct and the cells.
Optionally the duct is a rigid duct Optionally the duct is a metallic duct such as an aluminium or copper duct Advantageously, a metallic duct provides good thermal conduction between the duct and the cells. Preferably the duct is a single-lumen duct Optionally the duct is a multi-lumen duct A multi-lumen duct may be used in large battery packs where a single lumen duct is not capable of promoting an even temperature distribution.
Ideally the multi-lumen duct comprises two or more lumens along which thermal management fluid may flow.
Preferably the duct has an outer surface.
Preferably at least a part of the outer surface of the duct is in thermal contact with one or more cells. Advantageously, thermal contact between the duct and cells allows heat to be transferred to/from the cells for thermal management purposes.
Preferably at least a part of the outer surface of the duct is in physical contact with one or more cells.
Preferably the or each duct is inflatable.
Preferably the or each duct comprises a fluid inlet nozzle for allowing a thermal management fluid to pass into the or each duct Preferably the or each duct comprises a fluid outlet nozzle for allowing a thermal management fluid to pass out of the or each duct Preferably the duct is filled with a thermal management fluid.
Preferably the or each duct is pressurised by the thermal management fluid to an inflated state.
Preferably the thermal management fluid is air, water or a water-glycol mixture. Preferably the duct is inflated such that at least part of the duct conforms to at least part of the surface shape of at least one cell.
Preferably the or each outlet aperture is positioned such that in use, the path of 10 reinforcement means out of the or each outlet aperture is not obstructed by a duct within the battery pack housing. Advantageously as reinforcement means passes through outlet aperture(s) its path is not obstructed by e.g. serpentine sections of the duct within the battery pack.
According to a second aspect of the invention there is provided a distibution means for distributing reinforcement means to a battery pack housing, the distribution means comprising a conduit means adapted to allow transport of reinforcement means towards the interior of the battery pack housing. Advantageously, the distribution means allows a controlled flow of reinforcement means into the battery pack housing in order to support components therein.
Ideally the reinforcement means is a flowable reinforcement means. Advantageously, the reinforcement means being flowable allows the reinforcement means to be easily inserted into the battery pack housing.
Ideally the reinforcement means comprises a potting material.
Preferably the reinforcement means comprises epoxy resin.
Preferably the reinforcement means comprises silicone potting compound.
Preferably the reinforcement means comprises expandable foam. Preferably the reinforcement means comprises intumescent foam. Preferably the reinforcement means comprises polyurethane foam. Preferably the conduit means comprises at least one inlet flow path.
Ideally the or each inlet flow path is in fluid communication with a receiving port Advantageously, the or each receiving port allows reinforcement means to flow into the distribution means.
Preferably the reinforcement means is operable to pass into the distribution means via the or each receiving port Preferably the conduit means comprises at least one outlet flow path.
Preferably the distribution means comprises a plurality of outlet flow paths. Advantageously, the distribution means allows reinforcement means to be inserted into the pack in multiple positions at once.
Preferably the distribution means comprises two or three outlet flow paths.
Preferably the reinforcement means is operable to pass out of the distribution means via the or each injection nozzle.
Preferably the or each inlet flow path is in fluid communication with the or each outlet flow path.
Ideally the reinforcement means is operable to pass through the inlet flow path(s) and outlet flow path(s).
Ideally each outlet flow path is of a substantially equal hydraulic resistance. Advantageously, there being an equal hydraulic resistance for each outlet flow path means that in use, the flow of reinforcement means through each flow path will be substantially equal. In cases where two or more outlet flow paths are of different lengths the cross-sectional area is varied. For example, shorter outlet flow paths have smaller cross-sectional areas to restrict the flowrate and ensure balanced flow through each outlet flow path.
Ideally each outlet flow path is of a substantially equal length.
Preferably the distribution means comprises a body.
Preferably the distribution means comprises a substantially rigid body.
Preferably the or each flow path is located within the body.
Preferably the body comprises one or more distribution arms.
Preferably the or each outlet flow path is located within a distribution arm.
Ideally the or each outlet flow path terminates in an injection nozzle.
Ideally the or each injection nozzle is integrally formed with the body.
Optionally the or each injection nozzle is connected to the body.
Optionally the or each injection nozzle is substantially cylindrical.
Ideally the or each injection nozzle is located at the distal end of a distribution arm.
Ideally the or each injection nozzle is operable to fit within an inlet aperture within a battery pack housing member.
Ideally the distribution means comprises a plurality of injection nozzles and distribution arms spaced such that they can be in fluid communication with a plurality with receiving apertures in a battery pack housing simultaneously.
Ideally the distribution means comprises a plurality of injection nozzles and distribution arms spaced such that they can be in fluid communication with a plurality with receiving apertures in a battery pack housing member simultaneously.
Ideally the distribution means comprises a plurality of injection nozzles and distribution arms spaced such that they can be in fluid communication with a plurality with receiving apertures 35 in a plurality of battery pack housing members simultaneously.
Ideally the injection nozzles and/or distribution arms are spaced according to a spacing that is commensurate with receiving apertures in a battery pack housing member.
Preferably the distribution means comprises a support means.
Preferably the support means comprises one or more support members.
Preferably the support means comprises two support members. Advantageously the support members are operable to support the body such that the body is at an appropriate height for inserting reinforcement means into the battery pack housing.
Preferably the or each support member comprises a base.
Preferably the or each support member comprises a support post.
Preferably the or each support post is connected to a base at a first end thereof and the body of the distribution means at a second end thereof.
According to a third aspect of the invention there is provided a method of manufacturing a battery pack having a battery pack housing, the method comprising inserting a reinforcement means through at least one passage means in the battery pack housing. Advantageously, the reinforcement means can be easily inserted into the battery pack after the housing has been constructed in order to reinforce and support the internal components such as cells and/or ducts within the pack.
Preferably the method comprises constructing the battery pack housing.
Preferably the method comprises attaching a plurality of battery pack housing members to one another using fastening means.
Preferably the method comprises attaching one or more side walls and/or end walls to a lower clamshell.
Preferably the method comprises inserting one or more cells into recesses in a lower clamshell of the battery pack housing.
Preferably the method comprises installing one or more ducts between and/or around the 25 one or more cells.
Preferably the method comprises positioning one or more support means on the lower clamshell.
Preferably the method comprises positioning one or more support means on the lower clamshell at the peripheral edge of the array of cells.
Preferably the method comprises locating a portion of a flexible duct within a support means to provide support to at least a portion of the duct Locating the flexible duct in a support means is advantageous as it prevents the duct from kinking as the duct is expanded, particularly at the corners of a serpentine duct where kinking and/or collapse of the duct is most likely. Preferably the method comprises attaching the or each duct to a delivery means for 35 thermal management fluid.
Preferably the method comprises attaching the or each duct to a thermal management fluid feed line.
Preferably the method comprises connecting the or each duct to a thermal management system.
Preferably the method comprises attaching an upper clamshell to the one or more side walls and end walls of the battery pack housing.
Preferably the method comprises passing a thermal management fluid into the or each duct.
Preferably the method comprises passing a thermal management fluid into the or each duct via fluid inlet nozzle(s).
Preferably the method comprises inflating the or each duct Preferably the method comprises inflating the or each duct using a pressurised fluid such as air, water or a water-glycol mixture.
Preferably the method comprises inflating the duct such that the duct contacts at least a part of the one or more cells.
Preferably the method comprises inflating the or each duct such that at least part of the 15 duct conforms to at least part of the surface shape of at least one cell.
Preferably the method comprises mixing the reinforcement means using a mixer nozzle. Preferably the method comprises inserting the reinforcement means using a distribution means and/or a dispensing means.
Preferably the method comprises inserting the reinforcement means using a plurality of 20 distribution means and/or dispensing means.
Preferably the method comprises inserting reinforcement means into the battery pack housing using a plurality of distribution means and/or dispensing means.
Preferably the method comprises inserting reinforcement means into the battery pack housing via a plurality of passage means simultaneously.
Preferably the method comprises inserting reinforcement means into the battery pack housing via at least tvvo passage means simultaneously.
Preferably the method comprises inserting reinforcement means into the battery pack housing using a distribution means and/or dispensing means mounted on a robotic arm. Preferably the method comprises mating a distribution means and/or dispensing means 30 with the or each passage means.
Preferably the method comprises mating at least one distribution means nozzle with an inlet channel.
Preferably the method comprises passing reinforcement means into the distribution means and/or dispensing means.
Preferably the method comprises creating a flow of reinforcement means through the distribution means and/or dispensing means.
Preferably the method comprises creating a flow of reinforcement means into the or each passage means.
Preferably the method comprises passing reinforcement means into at least one inlet channel.
Preferably the method comprises inserting reinforcement means into the battery pack housing via at least one side wall and/or end wall of the battery pack housing.
Preferably the method comprises inserting reinforcement means into the battery pack housing via an upper clamshell of the battery pack housing.
Preferably the method comprises inserting reinforcement means into the battery pack housing via a lower clamshell of the battery pack housing.
Preferably the method comprises reinforcing at least part of the duct with the 10 reinforcement means.
Preferably the method comprises at least partially surrounding the duct and/or cells within the battery pack housing with a reinforcement means. Advantageously, the reinforcement means provides strength to the walls of the duct in order prevent the duct over-inflating and/or bursting.
Preferably the method comprises inserting a flowable potting material into the battery pack housing.
Preferably the method comprises inserting a fixed volume of flowable potting material into the battery pack housing.
Preferably the method comprises inserting an epoxy resin into the battery pack housing. Preferably the method comprises inserting a silicone potting compound into the battery 20 pack housing.
Preferably the method comprises inserting an expandable foam into the battery pack housing.
Preferably the method comprises inserting an intumescent foam into the battery pack housing.
Preferably the method comprises inserting a polyurethane foam into the battery pack housing.
Preferably the method comprises expanding the reinforcement means. Advantageously, the reinforcement means can expand to fills the space within the pack.
Preferably the method comprises curing or hardening the reinforcement means.
Preferably the method comprises tilting the battery pack housing prior to inserting the reinforcement means into the battery pack housing. Advantageously, tilting the battery pack housing allows the force of gravity to encourage a flow of the reinforcement means through the battery pack housing.
Preferably the method comprises inserting the reinforcement means while the battery 35 pack is tilted at an angle to the horizontal.
Preferably the method includes electrically connecting the cells to busbars of the battery pack.
Preferably the method includes electrically connecting the cells to the busbars using ultrasonic bonding, laser welding, ultrasonic welding or resistance welding.
Preferably the method includes electrically connecting the cells to the busbars while the cells are held in place by the flexible duct Preferably the method includes electrically connecting the cells to the busbars before the potdng material is inserted into the battery pack.
Preferably the method includes inserting the potting means into the battery pack after electrically connecting the cells to the busbars. Advantageously, the potting means serves to protect the aluminium ultrasonic wire bonds from external moisture thereby preventing galvanic 10 corrosion of the wire bonds.
It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.
The invention will now be described with reference to the accompanying drawings which show, by way of example only, embodiments in accordance with the invention.
Figure 1 is a perspective view of a battery pack comprising a battery pack housing member in accordance with the invention.
Figure 2 is an alternative perspective view of the battery pack of Figure 1.
Figure 3a is a top view of a battery pack end wall and two side walls.
Figure 3b is a side view of the battery pack end wall and two side walls of Figure 3a.
Figure 4 is a perspective view of the battery pack of Figure 1 while reinforcement material is being inserted into the pack using a dispenser.
Figure 5 is a side view of a tilted battery pack while reinforcement material is being inserted into the pack by a dispenser via the top surface of a sidewall.
Figure 6 is a top view of the internal components within a battery pack housing.
Figure 7 is a perspective view of an alternative battery pack comprising a battery pack housing member in accordance with the invention.
Figure 8 is a side view of a tilted battery pack while reinforcement material is being inserted into the pack by a dispenser via the exterior side surface of a sidewall of the pack.
Figure 9 is a perspective view of a distribution arrangement according to an aspect of the invention.
Figure 10 is a cross sectional perspective view of the distribution arrangement of Figure 9.
Figure 11 is a perspective view of the distribution arrangement of Figure 9 mated with a battery pack housing.
Figure 12 is a perspective view of the distribution arrangement of Figure 9 mated with a battery pack housing and connected to a dispenser for reinforcement material.
Figure 13 is a perspective view of an alternative distribution arrangement mated with a battery pack housing.
Figure 14 is a perspective view of the distribution arrangement of Figure 13 mated with a battery pack housing and connected to a dispenser for reinforcement material.
Figure 15 is a perspective view and a detailed view of the interior surface of clamshell of 10 a battery pack.
Figure 16 is a perspective view and a detailed view of the exterior surface of the clamshell of Figure 15.
Figure 17 is a perspective view of the clamshell of Figures 15 and 16 electrically connected to a plurality of cells.
Figure 18 is a perspective view showing reinforcing material being inserted into a battery pack housing through the upper clamshell of the battery pack.
Figure 19 is a closeup perspective view of Figure 18.
Figure 20 is a perspective view of a clamshell and a clamshell cover.
Figure 21 is another perspective view of the clamshell and clamshell cover of Figure 20.
Figure 22 is a perspective view showing reinforcing material being inserted into a battery pack housing through the clamshell cover of Figure 20.
Figures 1 and 2 show a battery pack indicated generally by the numeral 1. The battery pack 1 comprises a plurality of cylindrical cells 5 located within a housing having a plurality of housing members. The housing members include an upper clamshell (not shown), a lower clamshell 10, sidewalls 2a,2b and end walls 3a,3b. The cells 5 are arranged in a regular close-packed array comprising a plurality of rows of aligned cells 5. The cells 5 are spaced apart from the side walls 2a,2b and end walls 3a,3b.
Construction of the battery pack housing includes attaching the battery pack housing members to one another using fastening arrangements such as screws, adhesives etc. Side walls 2a,2b and end walls 3a,3b are attached to the lower clamshell 10 and upper clamshell 11. Once the cells 5 are properly positioned within the battery pack housing, and a thermal management duct 8 is properly installed between and around the array of cells 5, the housing is completed by attaching the upper clamshell 11 (shown in figure 4) to the side walls 2a,2b and end walls 3a,3b using fastenings and/or adhesives. As is explained in further detail below, the cells 5 are retained within recesses in the lower clamshell 10 and upper clamshell 11.
A serpentine thermal management duct 8 is located within the battery pack housing between and around the cells 5 in the array. The duct 8 is configured to carry a thermal management fluid such as air, water or a water-glycol mixture. The duct 8 comprises several substantially straight sections and several bends. In use, at least a part of the outer surface of the ducts is in thermal contact with the cells 5. Thermal contact between the duct 8 and cells 5 allows heat to be transferred to/from the cells 5 for thermal management purposes i.e. to maintain the cells 5 within an appropriate temperature envelope e.g. 20-30 EC.
The duct 8 shown in figure 1 is inflatable and flexible. In figure 1, the duct 8 is shown in the pre-inflated state. The duct 8 is inflated via filling with a thermal management fluid such as air, water or a water-glycol mixture. Once inflated, parts of the outer surface of the duct 8 make physical contact with individual cells 5 in the array. The duct 8 is inflated and pressurised such that at least part of the duct 8 conforms to the surface shape of the cells S. Inflation of the duct 8 ensures good thermal contact between the cells Sand duct 8. The ducts comprises a fluid inlet nozzle (not shown) for allowing thermal management fluid to pass into the duct 8 and a fluid outlet nozzle (not shown) for allowing the thermal management fluid to pass out of the duct 8. S upport structures 9 are provided on the lower clamshell at the periphery of the array of cells 5 in order to support and guide the flexible duct 8 at bends where the duct 8 is liable to kinking and collapse.
In preferred embodiments, the ducts is formed from a polymer-based material, particularly an inflatable plastics material such as polyester, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE) or high-density polyethylene (H DP E). An inflatable plastics material is advantageous since it is intrinsically electrically insulating, lightweight and does not corrode or chemically interact with the thermal management fluid. The walls of the duct 8 are between 10 R-n and 150 R-n thick, allowing for good thermal transfer properties between the ducts and the cells S. In use, the duct 8 is attached to a thermal management fluid feed line in order to supply thermal management fluid to the duct 8. The thermal management fluid feed line forms part of a thermal management system for the battery pack 1. Thermal management fluid is passed into the or each duct via a fluid inlet nozzle and the duct 8 is maintained in an inflated state by the pressurised fluid such as air, water or a water-glycol mixture. The duct 8 contacts the sidewalls of cells 5 and partially conforms to the surface shape thereof End wall 3a, shown in Figures 1 and 2, comprises two end faces which contact side walls 2a and 2b. End wall 3a further includes a top face 4a, a bottom face (not shown), an interior face 4c adjacent to the cells 5 and ducts, and an exterior face 4b which is located on the outside of the battery pack 1. An inlet aperture 6 is located on the top face 4a of the end wall 3a and outlet apertures 7a-c are located on the interior face 4c of the end wall 3a. Each outlet aperture 7 is located adjacent to the peripheral edge of the array of cells 5.
As shown schematically in Figures 3a and 3b, end wall 3a comprises a passage arrangement 20 through which a reinforcement material is able to pass through the end wall 3a and into the into the interior of the battery pack housing during manufacturing of the battery pack 1. The reinforcement material is a flowable reinforcement material. In preferred embodiments the reinforcement material comprises a potting material such as epoxy resin, silicone potting compound or foam such as expandable, intumescent or polyurethane foam.
After the reinforcement material has been inserted into the battery pack housing and has set cured or hardened, it provides mechanical supportto the components within the battery pack, 5 particularly the duct 8 and cells 5. In its set cured or hardened state, the reinforcement material is substantially rigid such that it secures the cells 5 and the duct 8 in position within the battery pack 1. This is advantageous as it reduces the effects of vibrations on component within the battery pack 1, provides strength to the walls of the duct in order prevent the duct from over-inflating and/or bursting, and provides thermal insulation within the pack to prevents the 10 propagation of high temperature events such as fires therein.
The passage arrangement 20 comprises an inlet channel 21 and a plurality of outlet channels 22a-c. The inlet channel 21 is operably connected to the outlet channels 22a-c such that reinforcement material can pass from the inlet channel 21 into the outlet channels 22a-c along a non-straight path having one 906 bend. The principal axis of the inlet channel 21 is substantially perpendicular to that of the outlet channels 22a-c and, in use, the direction offlow of reinforcement material through the inlet channel 21 is substantially perpendicular to the direction of flow of reinforcement material through the outlet channels 22a-c. In preferred embodiments the cross-sectional areas of the outlet channels 22a-c are chosen so that the hydraulic resistance of the outlet channels 22a-c is substantially equal. For example, shorter outlet flow path 22b can have a smaller cross-sectional area than the longer outlet flow paths 22a and 22c. This restricts the flowrate through the outlet flow paths and ensures balanced flow through each outlet flow path 22a-c.
As shown in figures 3a and 3b, end wall 3a comprises an inlet aperture 6 which provides an entrance to the passage arrangement 20. The inlet aperture 6 includes a flared opening 23 into end wall 3a, particularly into the passage arrangement 20 and inlet channel 21. The flared opening allows e.g. a dispensing nozzle to be easily located within the inlet channel 21. End wall 3a comprises three outlet apertures 7a-c which each provide an exit from the passage arrangement 20. The inlet aperture 6 and outlet apertures 7a-c are circular and symmetrical.
During manufacture of the battery pack 1, reinforcement material is inserted into the pack 1 after the battery pack housing has been constructed and after the duct 8 has been inflated (in cases where the duct 8 is inflatable). Once the reinforcement material has cured or hardened around the duct 8 and cells 5, the reinforcement material provides a cavity within which the duct 8 is supported. The walls of this cavity prevent over-inflation and bursting of the duct 8. Furthermore, the duct 8 is maintained in its open and cell-contacting configuration via adhesion to the reinforcement material. This means that the working fluid may be removed from the interior of the duct 8 and the duct would still be in its open configuration.
The passage arrangement 20 allows reinforcement material to enter the interior of the battery pack housing in several locations at once. This can ensure that the reinforcement material is evenly distributed within the battery pack 1. Ensuring that the reinforcement material is evenly distributed within the battery pack 1 means that the duct 8 and cells 5 are adequately supported at locations throughout the pack 1. Furthermore, even distribution of the reinforcement material also provides consistent the rma I characteristics throughout the pack 1.
The reinforcement material can be inserted into the battery pack housing/passage arrangement 20 using a dispenser 50. The dispenser 50 is mountable on a robotic arm to automate the process of filling the battery pack housing with the reinforcement material. The dispenser 50 is mated with the passage arrangement 20, particularly the inlet aperture 6 via a hole in the upper clamshell 11, as shown in figure 4. The dispenser 50 has a nozzle which passes through the upper clamshell 11. Reinforcement material is passed into the dispenser 50 and flows from the dispenser 50 into the passage arrangement 20 via the inlet channel 21. Once a sufficient amount of reinforcement material has been inserted into the battery pack 1, a fixing means such as a screw can be used to close the inlet aperture 6.
The reinforcement material flows into the interior of the battery pack housing towards the duct 8 and cells 5 via the outlet channels 22a-c and outlet apertures 7a-c. A fixed volume of flowable reinforcement material (e.g. epoxy resin, silicone potting compound or expandable foam such as intumescent polyurethane foam) is inserted into the battery pack housing while the reinforcement material it is in its liquid state. In the case of expandable foam, the foam is allowed to expand inside the pack 1 to fill gaps around the interior components. In the case of epoxy resin and silicone potting compound, the pack is filled with reinfocement material until the gaps around the interior components are sufficiently filled. Once a sufficient amount of the reinforcement material is inserted into the pack 1, the reinforcement material is allowed to set, cure or harden.
As shown in Figure 5, the battery pack 1 can be tilted at an angle to the horizontal while the reinforcement material is inserted through the upper clamshell 11 and inlet aperture 6. One end of the battery pack rests on surface 60. Tilting the pack 1 means that the force of gravity encourages a flow of the reinforcement material through the battery pack housing between the cells Sand duct 8. The reinforcement material moves from the end of the battery pack 1 where it is inserted towards the other end of the battery pack, helping to ensure an even distribution of reinforcement material throughout the pack 1. The tilt may be adjusted and/or reversed to encourage reinforcement material towards any appropriate position within the pack 1. The tilt may be reversed before reinforcement material is passed through a passage arrangement in the opposite end wall 3b.
As shown in figure 6, the duct 8 is a serpentine duct having four generally straight sections 8a connected by three bend sections 8b. Outlet apertures 7a-e in the end walls 3a,3b are positioned such that the reinforcement material is able to flow into the interior of the battery pack 1 without being obstructed by the duct 8, specifically the bend sections 8b. Neighbouring straight sections 8a of the duct 8 are separated by two rows of cells 5. This means that each row of cells 5 has one side which is adjacent to (and thermally contacts) a straight section 8a of the duct 8 and an opposing side which is directly adjacent to a neighbouring row of cells 5. The outlet apertures 7a-e, through which reinforcement material passes into the pack, are positioned such that the reinforcement material can pass between neighbouring rows of cells 5 where there is no straight section 8a of the duct 8, and between the peripheral straight sections and inner surface of the battery pack housing. In other words, the outlet apertures 7a-e are located at positions away from the bend sections 8b of the duct 8. As such, the path of reinforcement material into the battery pack 1 is not obstructed by the duct 8 and can easily pass throughout the pack 1 to reinforce and support the components therein, particularly the duct S and cells 8.
Figure 7 shows an alternative embodiment of a battery pack 101 having three passage arrangements 120 in the end wall 103a. The three passage arrangements 120 each comprise a channel connected to an inlet aperture and an outlet aperture. Reinforcement material can pass through the passage arrangements 120 towards the interior of the battery pack housing. Figure 8 shows reinforcement material being dispensed using a dispenser SO to the battery pack housing 101 via a passage arrangement 120 while the battery pack 101 is tilted, one end of the battery pack resting on a surface 60.
A distribution arrangement such as the distribution arrangement 200 shown in Figure 9, can be used to distribute reinforcement material to the battery pack 101. The distribution arrangement 200 comprises a conduit arrangement adapted to allow transport of reinforcement material towards the interior of the battery pack housing. The distribution arrangement 200 allows a controlled and even flow of reinforcement material into the battery pack housing during manufacture of the battery pack 101.
The distribution arrangement 200 comprises a substantially rigid body 205 having three distribution arms 206a-c. Each flow path is located within the body 205. Each outlet flow path 202a-c is located within a respective distribution arm 206a-c and terminates in an injection nozzle 203a-c at the distal end of a distribution arm 206a-c. Each injection nozzle 203a-c is substantially cylindrical and is integrally formed with the body 205. The skilled person will appreciate that each nozzle may be a separate component attachable to the body 205 and can be of any suitable shape to fit within and/or mate with passage arrangement(s) 120, particularly the inlet apertures in the end wall 103a of the pack 101.
The distribution arrangement 200 comprises an inlet flow path in fluid communication with a receiving port 201. Reinforcement material is operable to pass into the distribution arrangement 200 via the receiving port 201. The distribution arrangement 200 comprises three outlet flow paths 202a-c shown in Figure 10. The inlet flow path is in fluid communication with each outlet flow path 203a-c. There being multiple outlet flow paths 202a-c allows reinforcement material to be inserted into the battery pack 101 at multiple positions at once, promoting an even distribution of reinforcement material within the pack. Each outlet flow path 202a-c terminates at an injection nozzle 203a-c. Reinforcement material is operable to pass out of the distribution arrangement 200 via the injection nozzles 203a-c.
Each outlet flow path 202a-c is of a substantially equal hydraulic resistance so that, in use, the flow of reinforcement material through each flow path 202a-c is substantially equal. Each outlet flow path may be of a substantially equal length, or where a path is s horter than other paths it may have a reduced cross sectional area. For example, shorter outlet flow path 202b can have a smaller cross-sectional area than the longer outlet flow paths 202a and 202c. This restricts the flowrate through the outlet flow paths and ensures balanced flow through each outlet flow path 202a-c.
The distribution arrangement 200 includes a support arrangement The support arrangement comprises two support members 210. The support members 210 are operable to support the body 205 such that the body 205 is at an appropriate he ight for inserting reinforcement material into the battery pack housing 201. When the battery pack 101 and distribution arrangement 200 are on a flat surface, the support arrangement ensures that the distribution nozzles 203a-c are at the same height as the passage arrangements 120. Each support member 210 comprises a base 211 and a support post 212. Each support post 212 is connected to the respective base 211 at a first end thereof and the body 205 of the distribution arrangement 200 at a second end thereof.
The injection nozzles 203a-c and distribution arms 206a-c are spaced such that they can be in simultaneous fluid communication with the receiving apertures in end wall 3a of the battery pack housing 101. The distance between the injection nozzles 203a-c is commensurate with the distance between the passage arrangements 120. In use, the distribution arrangement 200 is mated with the passage arrangements 120, as shown in figure 11. A dispenser SO is connected to the receiving port 201, as shown in figure 12. Reinforcement material is operable to pass from the dispenser 50 through the inlet flow path and outlet flow paths 203a-c and into the battery pack 101 Figure 13 shows a further distribution arrangement 300 which is mated with two passage arrangements on the other end wall 3b of the battery pack 101. The other end wall 3b comprises two holes through which inlet and outlet nozzles for the inflatable duct 8 pass. A dispenser 50 can be connected to the receiving port of the further distribution arrangement 300, as shown in figure 14, to dispense reinforcement material into the battery pack 101 at the other end thereof.
Reinforcement material is operable to pass through the inlet flow path and two outlet flow paths of the further distribution arrangement 300 and into the battery pack 101.
Figures 15 and 16 show views of a clamshell 400 for use with a battery pack 1,101. The lower clamshell 10 and/or an upper clamshell 11 of battery pack 1,101 can take the form of the clamshell 400. Figure 15 shows the interior face of the clamshell 400 comprising a plurality of recesses 401 which are sized and shaped to receive and retain cells 5, particularly the ends of the cells 5. The recesses 401 are arranged in rows in a close-packed hexagonal pattern. Neighbouring recesses 401 in different rows are separated by parts of the body of clamshell 400. Neighbouring recesses 401 in the same row are separated by either bridges 402 or breaks 403.
In the example of Figure 15, each recess 401 is connected to one neighbouring recess in the same row by a bridge 402 and another neighbouring recess in the same row by a break 403. The breaks 403 provide passages for reinforcement means to pass into the battery pack via the clamshells and the ridges 402 provide added strength to the clamshell 400.
As shown in the detail of Figure 15, each recess 401 in the clamshell 400 is a stopped recess 401 passing part of the way through the body of the clamshell 400. On the opposite side of the clamshell 400 are a plurality of slots 405 (see figure 16). Slots 405 pass part way through the opposite side of the body of the clamshell 400 to the recesses 401. At places where the slots 405 and recesses 401 coincide, there is a channel passing through the body of the clamshell 400 which provides access for e.g. electrical contacts to be made between cells 5 within the housing and busbars located on the outer side of the clamshell 400. At places where the slots 405 and breaks 403 coincide, there is a passage through which reinforcement material can be passed through the clamshell 400.
Figure 16 shows the exterior face of clamshell 400 i.e. the face which is on the exterior-side ofthe pack. The battery pack 1,101 includes one or more busbars 410 attached to the exterior faces of either or both clamshells 10,11. Busbar spacers 409 for securing and separating the busbars 410 pass through the slots 405 in the clamshell 400. The busbars 410 are connected to the one or more cells 5 via electrical connectors. Figure 17 shows cells 5 which are electrically connected to busbars 410 via aluminium wires using ultrasonic bonding, laser welding, ultrasonic welding or resistance welding. The busbars 410 are located on the slot-side of the clamshell 400. The cells 5 can be connected to the busbars 410 while they are held in place within the pack 1,101 by the duct 8 and before the reinforcement material is inserted into the battery pack 1,101. The reinforcement material can protect the aluminium ultrasonic wire bonds from external moisture thereby preventing galvanic corrosion.
Figures 18 and 19 show reinforcement material being inserted into the battery pack housing via the upper clamshell 11 using a dispenser 50. The reinforcement material is inserted at places where the slots 405 and breaks 403 in the upper clamshell coincide i.e. in places between the cells 5. Inserting reinforcement material into the top of the battery pack 1,101 near the centre of the array of cells ensures that battery pack housing is evenly filled with the reinforcement material. Inserting reinforcement material via the upper clamshell 11 can be repeated at a plurality of locations to ensure an even spread of reinforcement means throughout the pack 1,101.
Figures 20 and 21 show views of a clamshell cover 420 which is used to cover and protect each clamshell 400, as well as the electrical contacts between the cells 5 and busbars. The busbars 410 are located between the clamshe11400 and clamshell cover 420. The clamshell cover 420 is attached to each clamshell afterthe electrical contacts are provided and after reinforcement material has been inserted into the battery pack 1,101. As shown in figure 22, reinforcement material may be passed into the battery pack housing via the clamshell cover 420.
As will be understood by the skilled person, the example embodiments presented above can be modified in a number of ways without departing from the scope of the invention. For example, the cells can be prismatic or pouch cells. Any battery pack housing member may include one or more passage arrangements 20,120 including the upper clamshell, lower clamshell, a side wall or end wall. The or each passage arrangement 20,120 may comprise a plurality of inlet channels and/or one outlet channel.
The battery pack 1,101 may comprise any number of ducts. The ducts may be manifold ducts, substantially straight ducts and/or parallel ducts. The battery pack may include one or more rigid ducts such as aluminium or copper ducts. A metallic duct provides good thermal coupling with the cells. The or each duct can be a single-lumen or a multi-lumen duct Multi-lumen duct(s) may be used in large battery packs where a single lumen duct is not capable of promoting an even temperature distribution. A multi-lumen duct comprises two or more lumens along which thermal management fluid may flow.
The or each passage arrangement 20,120 may be designed so that reinforcement material flows along a straight or curved path through the passage arrangement 20,120. Each passage arrangement 20,120 may include any number of bends. One or more inlet channel(s) in each passage arrangement 20,120 may be substantially parallel to one or more outlet channel(s) and the direction of flow of the reinforcement material through one or more inlet channel(s) may be substantially parallel to the direction of flow of the reinforcement material through one or more outlet channels. Each outlet aperture may provide a flared opening out of a battery pack housing member. Passage arrangement(s) 20,120 can be located within the body of any battery pack housing member or at a peripheral edge of the body of any battery pack housing member.
The reinforcement material may be mixed using a mixer nozzle prior to being inserted into the battery pack 1,101. Reinforcement material may be inserted into the battery pack 1,101 using a plurality of distribution arrangements 200,300 and/or dispensers 50 simultaneously. Reinforcement material may be inserted into the battery pack housing via a plurality of passage arrangements 20,120 simultaneously.
In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of the parameter, lying between the more preferred and the less preferred of the alternatives, is itself preferred to the less preferred value and also to each value lying between the less preferred value and the intermediate value.
The features disclosed in the foregoing description or the following drawings, expressed 35 in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of 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

Claims (25)

  1. CLAIMS1. A battery pack housing member comprising at least one passage means wherein a reinforcement means is able to pass through the battery pack housing member via the at least one passage means.
  2. 2. A battery pack housing member to claim 1 wherein the reinforcement means is a flowable reinforcement means.
  3. 3. A battery pack housing member according to claim 1 or claim 2 wherein the reinforcement means comprises epoxy resin, a silicone potting compound or an expandable foam.
  4. 4. A battery pack housing member according to any preceding claim wherein the or each passage means comprises at least one inlet channel operably connected to at least one outlet channel.
  5. 5. A battery pack housing member according to claim 4 wherein the or each passage means comprises one inlet channel and a plurality of outlet channels.
  6. 6. A battery pack housing member according to claim 4 or claims wherein the direction of flow of the reinforcement means through the inlet channel(s) is substantially perpendicular to the direction of flow of the reinforcement means through the outlet channel(s).
  7. 7. A battery pack housing member according to any preceding claim wherein the battery pack housing member forms part of a battery pack housing.
  8. 8. A battery pack housing member according to claim 7 wherein the battery pack housing member is a side wall or end wall of the battery pack housing.
  9. 9. A battery pack housing member according to claim 7 or claim 8 wherein one or more cells are located within the battery pack housing.
  10. 10. A battery pack housing member according to any one of claims 7 to 9 wherein one or more ducts are located within the battery pack housing.
  11. 11.A battery pack housing member according to claim 10 wherein the one or more ducts are inflatable serpentine ducts.
  12. 12. A distribution means for distributing reinforcement means to a battery pack housing, the distribution means comprising a conduit means adapted to allow transport of reinforcement means towards the interior of the battery pack housing.
  13. 13.A distribution means according to claim 12 wherein the reinforcement means is a flowable reinforcement means.
  14. 14.A distribution means according to claim 13 wherein the reinforcement means comprises epoxy resin, a silicone potting compound or expandable foam.
  15. 15.A distribution means according to any one of claims 12 to 14 wherein the conduit means comprises at least one inlet flow path in fluid communication with a receiving port and a plurality of outlet flow paths.
  16. 16.A distribution means according to any claim 15 wherein each outlet flow path is of a substantially equal hydraulic resistance.
  17. 17. A distribution means according to claim 15 or claim 16 wherein the or each outlet flow path terminates in an injection nozzle operable to fit within an inlet aperture within a battery pack housing member.
  18. 18.A distribution means according to claim 17 wherein the distribution means comprises a plurality of injection nozzles spaced such that they can be in fluid communication with a plurality with receiving apertures in a battery pack housing simultaneously.
  19. 19.A method of manufacturing a battery pack having a battery pack housing, the method comprising inserting a reinforcement means through at least one passage means in the battery pack housing.
  20. 20. A method according to claim 19 wherein the method comprises inserting a flowable potting material into the battery pack housing.
  21. 21. A method according to claim 20 wherein the method comprises inserting an epoxy resin, silicone potting compound or an expandable foam into the battery pack housing.
  22. 22.A method according to any one of claims 19 to 21 wherein the method comprises, prior to the step of inserting the reinforcement means, installing one or more ducts between and/or around the one or more cells within the battery pack housing.
  23. 23.A method according to claim 22 wherein the method comprises, prior to the step of inserting the reinforcement means, inflating the or each duct such thatthe or each duct contacts at least a part of at least one of the one or more cells.
  24. 24.A method according to any one of claims 19 to 23 wherein the method comprises inserting reinforcement means into the battery pack housing via a plurality of passage means simultaneously.
  25. 25.A method according to any one of claims 20 to 24 wherein the method comprises inserting the reinforcement means while the battery pack is tilted at an angle to the horizontal.
GB1915997.9A 2019-11-04 2019-11-04 A battery pack housing member and a distribution means Withdrawn GB2588768A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1915997.9A GB2588768A (en) 2019-11-04 2019-11-04 A battery pack housing member and a distribution means

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1915997.9A GB2588768A (en) 2019-11-04 2019-11-04 A battery pack housing member and a distribution means

Publications (2)

Publication Number Publication Date
GB201915997D0 GB201915997D0 (en) 2019-12-18
GB2588768A true GB2588768A (en) 2021-05-12

Family

ID=68988049

Family Applications (1)

Application Number Title Priority Date Filing Date
GB1915997.9A Withdrawn GB2588768A (en) 2019-11-04 2019-11-04 A battery pack housing member and a distribution means

Country Status (1)

Country Link
GB (1) GB2588768A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220131211A1 (en) * 2020-10-27 2022-04-28 Dr. Ing. H.C. F. Porsche Aktiengesellschaft High-voltage battery having a plurality of battery modules and heat sinks

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070259258A1 (en) * 2006-05-04 2007-11-08 Derrick Scott Buck Battery assembly with temperature control device
US20160197386A1 (en) * 2013-08-28 2016-07-07 Lg Chem Ltd. Module housing of unit module having heat dissipation structure and battery module including the same
KR20170045481A (en) * 2015-10-19 2017-04-27 주식회사 엘지화학 Apparatus Having Injection Molding Machine and Mold Capable of Simultaneously Manufacturing Injection Molding Articles Having Different Shapes
US20170162922A1 (en) * 2013-10-17 2017-06-08 Tesla, Inc. Energy storage pack
KR20190092835A (en) * 2018-01-31 2019-08-08 주식회사 엘지화학 Top cover, battery module using the same, and battery pack and vehicle including the same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070259258A1 (en) * 2006-05-04 2007-11-08 Derrick Scott Buck Battery assembly with temperature control device
US20160197386A1 (en) * 2013-08-28 2016-07-07 Lg Chem Ltd. Module housing of unit module having heat dissipation structure and battery module including the same
US20170162922A1 (en) * 2013-10-17 2017-06-08 Tesla, Inc. Energy storage pack
KR20170045481A (en) * 2015-10-19 2017-04-27 주식회사 엘지화학 Apparatus Having Injection Molding Machine and Mold Capable of Simultaneously Manufacturing Injection Molding Articles Having Different Shapes
KR20190092835A (en) * 2018-01-31 2019-08-08 주식회사 엘지화학 Top cover, battery module using the same, and battery pack and vehicle including the same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220131211A1 (en) * 2020-10-27 2022-04-28 Dr. Ing. H.C. F. Porsche Aktiengesellschaft High-voltage battery having a plurality of battery modules and heat sinks
US11888137B2 (en) * 2020-10-27 2024-01-30 Dr. Ing. H.C. F. Porsche Aktiengesellschaft High-voltage battery having a plurality of battery modules and heat sinks

Also Published As

Publication number Publication date
GB201915997D0 (en) 2019-12-18

Similar Documents

Publication Publication Date Title
ES2961036T3 (en) Battery block and manufacturing method of a battery block
US10020550B2 (en) Energy storage pack
CN108701791B (en) Battery module assembly
GB2588768A (en) A battery pack housing member and a distribution means
JP7078719B2 (en) Battery housing for drive battery
ES2239945T3 (en) VALVE PROVISION.
KR102292216B1 (en) Energy storage pack
KR20180083140A (en) Battery pack housing and battery pack including the same
CN111033875A (en) Battery cooling system
CN213782096U (en) Battery pack box and battery pack
JP2008543557A (en) dispenser
CA2444375C (en) Apparatus for use of single point watering system with monobloc lead-acid batteries
EP4334995A1 (en) Thermal management of a liquid cooled module
KR20230129349A (en) Battery pack
CN114530643A (en) Battery pack box and battery pack
CN217934077U (en) Supporting component and electric equipment
CN116525920A (en) Battery pack potting apparatus and method
KR20210005943A (en) Sealing segments to control the temperature of fluid cooled batteries
CN115149197A (en) Battery pack
CN110573368A (en) accumulator device
CN107017482A (en) Discharge electric terminal block
PL177858B1 (en) Conduit for carrying pressurised fluids
CN114204742B (en) Sheath structure and sheath monomer thereof
CN217903339U (en) Battery pack
EP3726641A1 (en) Battery module

Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)