GB2625266A - A vehicle traction battery pack subassembly, a vehicle traction battery pack and a vehicle - Google Patents

A vehicle traction battery pack subassembly, a vehicle traction battery pack and a vehicle Download PDF

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Publication number
GB2625266A
GB2625266A GB2218498.0A GB202218498A GB2625266A GB 2625266 A GB2625266 A GB 2625266A GB 202218498 A GB202218498 A GB 202218498A GB 2625266 A GB2625266 A GB 2625266A
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United Kingdom
Prior art keywords
battery pack
traction battery
vehicle traction
elongate
subassembly
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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.)
Pending
Application number
GB2218498.0A
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GB202218498D0 (en
Inventor
Godding Chris
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.)
Jaguar Land Rover Ltd
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Jaguar Land Rover 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 Jaguar Land Rover Ltd filed Critical Jaguar Land Rover Ltd
Priority to GB2218498.0A priority Critical patent/GB2625266A/en
Publication of GB202218498D0 publication Critical patent/GB202218498D0/en
Publication of GB2625266A publication Critical patent/GB2625266A/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for electric 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
    • H01M10/62—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
    • H01M10/647—Prismatic or flat cells, e.g. pouch 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
    • H01M50/204—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
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular 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
    • H01M50/249—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
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • H01M50/51—Connection only in series
    • 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

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Power Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

A vehicle traction battery pack subassembly (100 fig 1A), a vehicle traction battery pack (900 fig 20) and a vehicle (2100 fig 21) are provided. The battery pack (100) comprises: plural electrical cells 110 in a casing (120 fig 1A) elongated in a lengthways direction 130. Each cell 110 comprises front and back faces (111,112 figs 1B,C), and ends (113,114 figs 1B,C), between which the faces (111,112) extend. Terminals (115,116 figs 1B,C) are provided for the cell 110 at the respective ends (113,114). At least one line 140 of end-to-end cells 110 is provided in the lengthways direction 130. Several subassemblies (100) may be provided side by side. Each casing (120) may include overlapping C-section open profile elongate sections (350,360 fig 3) forming lips (31,320 fig 3) which meet respective indents in casings of adjacent subassemblies. The invention is aimed at providing suitable structural strength and energy density without excess bulk or weight or undue reliance on other structural components for strength.

Description

A VEHICLE TRACTION BATTERY PACK SUBASSEMBLY, A VEHICLE TRACTION BATTERY PACK AND A VEHICLE
TECHNICAL FIELD
The present disclosure relates to a vehicle traction battery pack subassembly, a vehicle traction battery pack and a vehicle. Aspects of the invention relate to a vehicle traction battery pack subassembly, to a vehicle traction battery pack, and to a vehicle.
BACKGROUND
It is known to provide a vehicle traction battery pack for use in a vehicle. Previous vehicle traction battery packs have comparatively low energy density due to the arrangement of electrical cells in the pack. The structural strength of previous battery packs tends to be provided by means of additional structural components rather than being integrated into the form of the battery pack itself. Previous vehicle battery packs therefore provide excess bulk and weight, as structural components for the vehicle must be fitted around and/or to the battery pack.
It is an aim of the present invention to address one or more of the disadvantages associated with the prior art.
SUMMARY OF THE INVENTION
Aspects and embodiments of the invention provide a vehicle traction battery pack subassembly, a vehicle traction battery pack and a vehicle as claimed in the appended claims According to an aspect of the present invention there is provided a vehicle traction battery pack subassembly, comprising: a plurality of electrical cells; an elongate casing containing the plurality of electrical cells, wherein the elongate casing is elongate in a lengthways direction; wherein each electrical cell comprises a front face, a back face, a first end and a second end, wherein the front face and the back face extend between the first end and the second end, wherein a first terminal of the electrical cell is provided at the first end and a second terminal of the electrical cell is provided at the second end; wherein the plurality of electrical cells are arranged within the elongate casing to form at least one line of electrical cells arranged endto-end, wherein the at least one line of electrical cells extends in the lengthways direction.
According to another aspect of the invention, there is provided a battery pack comprising a plurality of vehicle traction battery pack subassemblies.
According to a further aspect of the invention, there is provided a vehicle comprising a vehicle traction battery pack.
Advantageously, this provides subassemblies and a vehicle traction battery pack that has high energy density and can provide part of the structural strength of the vehicle, i.e. contributes towards the rigidity of the vehicle. The high energy density is provided by the arrangement of the electrical cells in lines, and the elongate casing of each subassembly provides structural strength to the vehicle.
Optionally, the elongate casing comprises a hollow profile.
Optionally, the elongate casing comprises: a first lip extending at least partially along the lengthways direction, said first lip protruding in a first direction away from the hollow profile; a second lip extending at least partially along the lengthways direction, said second lip protruding in a second direction opposite the first direction.
Optionally the elongate casing comprises multiple first lips, each of the multiple first lips extending partially along the lengthways direction and joined to be continuous; multiple second lips, each of the multiple second lips extending partially along the lengthways direction and joined to be continuous.
Optionally, the elongate casing comprises: a first indent suitable for receiving, in use, the first lip of an elongate casing of a first adjacent vehicle traction battery pack subassembly on one side of the vehicle traction battery pack subassembly, the first indent extending at least partially along the lengthways direction; and a second indent suitable for receiving, in use, the second lip of an elongate casing of a second adjacent vehicle traction battery pack subassembly on the other side of the vehicle traction battery pack subassembly, the second indent extending at least partially along the lengthways direction.
Advantageously, the lips, and optionally the indents, provide the benefit of enabling tessellation of the subassemblies for packaging in the battery pack. This ensures the subassemblies are tightly packed for high energy density, and also provides an efficient way to assemble the subassemblies into the battery pack. Additionally, by adhering/gluing/welding the lips to the indents, the battery pack will have increased stiffness in the lengthways direction and in a direction extending perpendicularly to the lengthways direction Optionally the elongate casing comprises two open-profile elongate sections joined together.
Optionally the cross section of each of the two sections comprises a top face, a bottom face and a side face configured as a C-section.
Optionally, for a first one of the two elongate sections the top face protrudes further from the side face than the bottom face, and for a second one of the two elongate sections the bottom face protrudes further from the side face than the top face.
Optionally, the two sections are arranged so that the top faces of each of the two sections contact and substantially overlap one another, and the bottom faces of each of the two sections contact and substantially overlap one another.
Optionally, the two elongate sections are rotationally substantially symmetrical to one another in cross section.
Advantageously, this means the elongate sections provide an efficient way to assemble the elongate casing, as they are very similar in structure and can therefore be made using the same manufacturing process, and providing the casing in two section allows for insertion of the electrical cells and other components into the casing before joining the two sections together.
Optionally, the first lip is provided by one of the top face and bottom face of one of the two sections and the second lip is provided by an opposite one of the top face and bottom face of the other of the two sections.
Optionally, the first indent is provided by one of the top face and bottom face of the two sections and the second indent is provided by an opposite one of the top face and bottom face of the other of the two sections.
Optionally, the elongate casing comprises at least two chambers arranged in a line end-toend, the line extending in the lengthways direction, and at least one bulkhead disposed between and separating adjacent chambers, wherein each of the at least two chambers contains at least one of the plurality of electrical cells.
Advantageously, the chambers with bulkheads can prevent hot gases from a venting event in one chamber from entering other adjacent chambers, whilst also contributing to the structural strength of the vehicle.
Optionally, each bulkhead comprises a cell connector.
Advantageously this means the bulkheads can separate chambers whilst also electrically connecting electrical cells in adjacent chambers.
Optionally, each one of the at least two chambers contains at least two of the plurality of electrical cells, wherein the electrical cells in each chamber are stacked in a direction extending perpendicular to the lengthways direction.
Optionally, the vehicle traction battery pack subassembly comprises adhesive material arranged to secure the plurality of electrical cells within the elongate casing.
Optionally, some of the adhesive material is located between electrical cells in the same chamber.
Advantageously, the adhesive material can secure the electrical cells within the elongate casing whilst also being a thermal interface material.
Optionally, the vehicle traction battery pack subassembly comprises an electrical harness, wherein the electrical harness is contained within the elongate casing and runs the length of the elongate casing.
Optionally, the plurality of electrical cells are pouch cells.
Optionally, the vehicle traction battery pack subassemblies are arranged in a stack in a direction extending perpendicular to a lengthways direction.
Advantageously, the stack provides a high energy density, structural battery pack.
Optionally the elongate casing of each vehicle traction battery pack subassembly is fastened to an elongate casing of an adjacent vehicle traction battery pack subassembly.
Optionally, the first lip of the subassembly is mounted to a first adjacent one of the plurality of vehicle traction battery pack subassemblies, and the second lip is mounted to a second adjacent one Optionally, for at least one of the plurality of vehicle traction battery pack subassemblies, the first indent of the elongate casing has received the first lip of a first adjacent one of the plurality of vehicle traction battery pack subassemblies, and the second indent of the elongate casing has received the second lip of a second adjacent one of the plurality of vehicle traction battery pack subassemblies.
Advantageously, the stack of subassemblies with lips and optionally indents provides a tight packing of electrical cells for high energy density, whilst also providing a rigid, high strength, structural battery pack Aspects and embodiments of the invention provide a vehicle traction battery pack and a vehicle as claimed in the appended claims According to an aspect of the present invention there is provided a vehicle traction battery pack, comprising: a plurality of vehicle traction battery pack subassemblies, each vehicle traction battery pack subassembly comprising: a plurality of electrical cells, an elongate casing containing the plurality of electrical cells, wherein the elongate casing is elongate in a lengthways direction, wherein the elongate casing comprises a casing base comprising a plurality of casing openings; and a baseplate comprising a plurality of elongate galleries, wherein each one of the plurality of elongate galleries comprises two gallery sidewalls, a gallery base, and a gallery opening opposite the gallery base, wherein the plurality of vehicle traction battery pack subassemblies are mounted on the baseplate in alignment with the plurality of elongate galleries such that the plurality of casing openings of each vehicle traction battery pack subassembly face an aligned said gallery opening.
According to another aspect of the invention, there is provided a vehicle comprising a vehicle traction battery pack.
Advantageously, the baseplate comprising galleries, also referred to as a bashplate, provides part of the structural strength of the vehicle, whilst also functioning as a venting volume for the electrical cells.
Optionally, the plurality of elongate galleries extend in a lengthways direction, and the plurality of vehicle traction battery pack subassemblies are stacked in a direction perpendicular to a lengthways direction.
Optionally, each elongate casing of the plurality of vehicle traction battery pack subassemblies straddles the gallery opening of one elongate gallery.
Optionally, each elongate casing of the plurality of vehicle traction battery pack subassemblies straddles and extends along the gallery openings of multiple elongate galleries arranged in a line end-to-end, wherein the line extends in the lengthways direction.
Advantageously, arranging the subassemblies to straddle one or more galleries provides a venting space directly below the casing openings where hot gases may be emitted in a venting event.
Optionally, each elongate casing of the plurality of vehicle traction battery pack subassemblies contains at least two chambers arranged in a line end-to-end extending in the lengthways direction, and at least one bulkhead, wherein each one of the at least two chambers is separated from an adjacent chamber by one of the at least one bulkhead, wherein each one of the at least two chambers contains at least one of the plurality of electrical cells.
Advantageously, the chambers and the bulkheads can prevent hot gases from a venting event in one chamber entering adjacent chambers, whilst also contributing to the structural strength of the vehicle.
Optionally each one of the at least two chambers is aligned with a corresponding one gallery of said multiple galleries.
Optionally each one of the at least two chambers corresponds to one or more of the plurality of casing openings.
Optionally the casing base comprises one or more interval portions without any of the plurality of casing openings, wherein each interval portion spans across two chambers.
Optionally, the vehicle traction battery pack comprises one or more insulating sheets arranged to cover the plurality of casing openings.
Optionally, the one or more insulating sheets are Mica sheets.
Advantageously, the one or more insulating sheets can allow hot gases to be emitted from a chamber due to the parts of the sheet over the casing openings of the chamber rupturing during a venting event in the chamber. For other chambers, the one or more insulating sheets can prevent the hot gases, which may have expanded and cooled in the galleries, from entering the chamber Optionally, the baseplate comprises a corrugated sheet, wherein the corrugated sheet comprises peaks and troughs, wherein the troughs of the corrugation provide the plurality of galleries.
Optionally, the corrugated sheet comprises one or more ridges extending in a direction perpendicular to a lengthways direction, wherein each ridge spans across multiple peaks and troughs, wherein each ridge has a maximum height below a height of the peaks and above the gallery bases provided by the troughs.
Optionally, for each pair of adjacent galleries arranged in one of the lines of multiple galleries, a portion of one of the one or more ridges provides an end of one gallery and an end of the adjacent gallery.
Advantageously, the ridges contribute to the structural strength of the vehicle whilst also separating galleries.
Optionally, each interval portion in a vehicle battery pack subassembly substantially aligns in a direction parallel to a lengthways direction with a corresponding interval portion in an adjacent vehicle battery pack subassembly to form at least one line of aligned interval portions, each one of the at least one line of aligned interval portions extending in the direction parallel to the lengthways direction, wherein each one of the at least one line of aligned interval portions overlies one of the one or more ridges.
Advantageously, the bulkheads and the ridges are aligned, which both contribute to the structural strength of the vehicle.
Aspects and embodiments of the invention provide a vehicle traction battery pack and a vehicle as claimed in the appended claims According to an aspect of the present invention there is provided a vehicle traction battery pack, comprising: a plurality of vehicle traction battery pack subassemblies, each vehicle traction battery pack subassembly comprising a plurality of electrical cells and an elongate casing containing the plurality of electrical cells, the elongate casing being elongate in a lengthways direction and comprising at least two chambers arranged in a line end-to-end in the lengthways direction, and at least one bulkhead, wherein each chamber is separated from an adjacent chamber by one of the at least one bulkhead, and wherein each chamber contains at least one of the plurality of electrical cells; wherein the plurality of vehicle traction battery pack subassemblies are stacked adjacent to one another in a direction perpendicular to the lengthways direction; wherein the bulkheads in adjacent vehicle traction battery pack subassemblies substantially align with one another to provide at least one line of bulkheads, the at least one line of bulkheads extending perpendicular to the lengthways direction.
According to another aspect of the invention, there is provided a vehicle comprising a vehicle traction battery pack.
Advantageously, the bulkheads separate chambers whilst also contribute to the structural strength of the vehicle.
Optionally, each bulkhead comprises a cell connector.
Advantageously, this means the bulkhead separates chambers whilst also providing electrical connection between electrical cells in different chambers.
Optionally, each electrical cell comprises a first terminal at a first end, a second terminal at a second end, wherein at least one of the first terminal and second terminal of each electrical cell is connected to the cell connector of one of the at least one bulkheads by a flexible connector.
Advantageously, the flexible connectors can flex in a side-pole impact to an extent without breaking their connection to the cell and the bulkhead.
Optionally, each bulkhead comprises a bulkhead insulating material surrounding the cell connector.
Optionally, the bulkhead insulating material comprises a plastics material.
Optionally, the bulkhead insulating material comprises a ceramic material.
Optionally, the bulkhead insulating material comprises an intumescent material.
Advantageously, this means that the bulkhead will swell when hot gases are emitted in a chamber, and further prevent hot gases in a venting event from entering adjacent chambers.
Optionally each bulkhead comprises four flanges, wherein each of the four flanges is provided at one of four corners of the bulkhead.
Advantageously this provides bulkheads with high structural strength.
Optionally, the vehicle traction battery pack comprises one or more load transfer structures, wherein each of the one or more load transfer structures is arranged at a first end or a second end of one of the at least one line of bulkheads and extends therefrom along the at least one line Optionally, one of the one or more load transfer structures is provided at the first end of one of the at least one line of bulkheads and another of the one or more load transfer structures is provided at the second end of the one of the at least one line of bulkheads.
Advantageously, this means that in a side-pole impact, the bulkheads and the load transfer structures are aligned to minimise damage to other components with less structural strength.
Optionally the vehicle traction battery comprises one or more beams extending in a lengthways direction, wherein each of the one or more beams is mounted adjacent to the elongate casing of at least one of the plurality of vehicle traction battery pack subassemblies.
Optionally, each one of the plurality of vehicle traction battery pack subassemblies comprises an electrical harness, wherein the harness is contained within the elongate casing of each one of the vehicle traction battery pack subassemblies and runs the length of the elongate casing, wherein each one of the at least one bulkhead comprises a harness passage which the harness passes through.
Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1A shows a vehicle traction battery pack subassembly; Figure 1B shows part of a vehicle traction battery pack subassembly; Figure 1C shows part of a vehicle traction battery pack subassembly; Figure 1D shows part of a vehicle traction battery pack subassembly; Figure 2 shows a vehicle traction battery pack subassembly; Figure 3 shows part of an elongate casing; Figure 4 shows a cross section of a bulkhead and four electrical cells of a vehicle traction battery pack subassembly; Figure 5 shows a cross section of an end portion of a vehicle traction battery pack subassembly and two electrical cells; Figure 6 shows part of a vehicle traction battery pack subassembly; Figure 7 shows part of a vehicle traction battery pack subassembly; Figure 8 shows part of a vehicle traction battery pack subassembly; Figure 9 show a vehicle traction battery pack; Figure 10 shows part of a vehicle traction battery pack; Figure 11 shows a lid of a battery pack; Figure 12A shows a baseplate of a battery pack; Figure 12B shows part of a baseplate of a battery pack; Figure 13 shows a vehicle traction battery pack subassembly; Figure 14 shows a cross section of part of a vehicle traction battery pack; Figure 15 shows a vehicle traction battery pack; Figure 16 shows a vehicle traction battery pack; Figure 17 shows part of a vehicle traction battery pack subassembly; Figure 18A shows part of a vehicle traction battery pack; Figure 18B shows part of a vehicle traction battery pack; Figure 19 shows a bulkhead; Figure 20 shows a cross section of part of a vehicle traction battery pack; Figure 21 shows a vehicle.
DETAILED DESCRIPTION
A vehicle traction battery pack subassembly according to the present invention is described herein with reference to the accompanying Figure 1A, Figure 1B, Figure 1C, Figure 1D. The vehicle traction battery pack subassembly 100 comprises a plurality of electrical cells 110, an elongate casing 120 containing the plurality of electrical cells. The elongate casing 120 is elongate in a lengthways direction 130.
As shown in Figure 1B and Figure 10, each electrical cell 110 comprises a front face 111, a back face 112, a first end 113 and a second end 114. Figure 1B illustrates two electrical cells 110 and Figure 1C illustrates one electrical cell 110 with its back face 112 showing. The front face 111 and the back face 112 extend between the first end 113 and the second end 114. A first terminal 115 of the electrical cell 110 is provided at the first end 113 and a second terminal 116 of the electrical cell is provided at the second end 114.
As shown in Figure 1D, which shows the subassembly 100 without the elongate casing 120, the plurality of electrical cells 110 are arranged within the elongate casing 120 to form at least one line 140 of electrical cells 110 arranged end-to-end. The at least one line 140 of electrical cells 110 extends in the lengthways direction 130. The electrical cells 110 in the line 140 are arranged end-to-end so that a second end 114 of one electrical cell 110 is proximate to a first end 113 of the electrical cell 110 next in the line 140. For clarity not all electrical cells 110 are labelled in Figure 1D.
Figure 1D also shows a second line 141 of electrical cells 110 arranged end-to-end extending in the lengthways direction 130. The subassembly 100 also comprises at least one bulkhead 150. Figure 1D shows four bulkheads 150.
Figure 2 illustrates a vehicle traction battery pack subassembly 100 according to the present invention. Figure 2 shows a subassembly 100 comprising chambers 200 arranged in a line 210 end-to-end, the line 210 extending in the lengthways direction 130.
Figure 2 shows the position of the bulkheads 150, although they are not visible due to being within the elongate casing 120. Each one of the chambers 200 is separated from an adjacent chamber 200 by one of the bulkheads 150. Within each chamber 200 is at least one electrical cell 110.
In Figure 2, each chamber 200 contains two of the plurality of electrical cells 110. The electrical cells 110 in each chamber 200 are stacked in a direction extending perpendicular to the lengthways direction 130, as illustrated in Figure 1D.
For each of the two lines 140, 141 of electrical cells 110 illustrated in Figure 1D, each electrical cell 110 is in a different chamber 200. Separating each chamber 200 by the bulkheads 150 has the benefit that, if one of the electrical cells 110 should undergo a venting event, hot gases from the venting event may be prevented from entering other chambers 200.
Figure 3 shows part of an elongate casing 120 of a vehicle traction battery pack subassembly 100 according to the present invention. As shown in Figure 3, the elongate casing 120 comprises a hollow profile 300. The elongate casing 120 comprises a first lip 310 extending at least partially along the lengthways direction 130. The first lip 310 protrudes in a first direction 311 away from the hollow profile. The elongate casing 120 also comprises a second lip 320 extending at least partially along the lengthways direction 130. The second lip 320 protrudes in a second direction 321 opposite the first direction 311.
The elongate casing 120 also comprises: a first indent 330 extending at least partially along the lengthways direction 130 and a second indent 340 extending at least partially along the lengthways direction 130. The first indent 330 is suitable for receiving, in use, the first lip 310 of an elongate casing 120 of a first adjacent vehicle traction battery pack subassembly 100. The second indent 340 is suitable for receiving, in use, the second lip 320 of an elongate casing 120 of a second adjacent vehicle traction battery pack subassembly 100.
As shown in Figure 3, the elongate casing 120 comprises two elongate open-profile sections 350, 360 joined together. The cross section of each of the two sections 350, 360 comprises a top face 351, 361, a side face 352, 362 and a bottom face 353, 363, configured as a C-section.
Figure 3 shows that a first one 360 of the two elongate sections 350, 360 has a top face 361 which protrudes further from its side face 362 than its bottom face 363. The second one 350 of the two elongate sections 350, 360 has a bottom face 353 which protrudes further from its side face 352 than its top face 351. The top face 361 and the bottom face 363 of the first one 360 of the elongate sections 350, 360 protrudes from its side face 362 in the same direction, and the top face 351 and the bottom face 353 of the second one 350 of the elongate sections 350, 360 protrudes from its side face 352 in the same direction.
The two elongate sections 350, 360 are arranged so that the top faces 351, 361 contact and substantially overlap one another and the bottom faces 353, 363 of each of the two sections 350, 360 contact and substantially overlap one another. Figure 3 shows the top face 361 of the first one 360 of the elongate sections 350, 360 overlapping the top face 351 of the second one 350 of the elongate sections 350, 360, and also shows the bottom face 363 of the first one 360 of the elongate sections 350, 360 overlapping the bottom face 353 of the second one 350 of the elongate sections 350, 360.
As shown in Figure 3, the two elongate sections 350, 360 are rotationally substantially symmetrical to one another in cross section. For example, the first one 360 of the two elongate sections 350, 360 could be rotated 180 degrees about an axis parallel to the lengthways direction of the elongate sections 350, 360 and the second one 350 of the two elongate sections 350, 360 could be rotated 180 degrees about the axis parallel to the lengthways direction and the cross section of the two elongate sections 350, 360 would appear substantially the same. The rotational symmetry of the two elongate sections 350, 360 enables the design process and any modifications made to the design to be done more efficiently, as only one section needs to be designed to form the basis for both elongate sections 350, 360.
Advantageously, at least some of the tooling and manufacturing process can be shared for the manufacture of both elongate sections 350, 360, providing a more efficient manufacturing process.
The first lip 310 is provided by one of the top face 351, 361 and bottom face 353, 363 of one of the two sections 350, 360 and the second lip 320 is provided by an opposite one of the top face 351, 361 and bottom face 353, 363 of the other of the two sections 350, 360. In Figure 3, the top face 361 of the first one 360 of the sections 350, 360 provides the first lip 310 and the bottom face 353 of the second one 350 of the sections 350, 360 provides the second lip 320.
The first indent 330 is provided by one of the top face 351, 361 and bottom face 353, 363 of one of the two sections 350, 360 and the second indent 340 is provided by an opposite one of the top face 351, 361 and bottom face 353, 363 of the other of the two sections 350, 360. In Figure 3, the top face 361 of the first one 360 of the sections 350, 360 provides the first indent 330 and the bottom face 353 of the second one 350 of the sections 350, 360 provides the second indent 340.
The first indent 330 can receive a first lip 310 of a second such vehicle traction battery pack subassembly 100, and the second indent 340 can receive a second lip 320 of a third such vehicle traction battery pack subassembly 100.
Figure 4 illustrates a cross section of a bulkhead 150 and four electrical cells 110 of a vehicle traction battery pack subassembly 100 according to the present invention. As shown in Figure 4, the bulkhead 150 comprises a cell connector 400, which electrically connects the electrical cells 110. In Figure 4, the two electrical cells on the left of the cell connector 400 (as viewed in Figure 4) are connected to the cell connector 400 with their second terminals 116, and their first terminals 115 are connected to another cell connector 400 not shown. The electrical cells 110 on the left of the cell connector 400 are connected in parallel with each other. Similarly the two electrical cells 110 on the right of the cell connector 400 are connected in parallel with each other, with their first terminals 115 connected to the cell connector 400 and their second terminals 116 connected at another cell connector 400 not shown. The cell connector 400 connects the electrical cells 110 on the left of the connector 400 in series with the electrical cells on the right of the connector 400. The electrical cells 110 on the left of the connector 400 are provided in a different chamber 200 to the electrical cells on the right of the connector 400, as shown in Figure 2, for example. Therefore the bulkhead 150 separates adjacent chambers 200 whilst also enabling electrical connection of electrical cells 110 in adjacent chambers 200.
Figure 4 also shows an adhesive material 410 between the electrical cells on the right of the cell connector 400. The adhesive material 410 is arranged to secure the electrical cells 110 within the elongate casing 120.
Figure 5 illustrates a cross section of a subassembly end portion 500 of the bulkhead 150 and two electrical cells 110 of a vehicle traction battery pack subassembly 100 according to the present invention. The subassembly 100 comprises the bulkhead 150 having an end portion 500 at each end of the subassembly 100. Figure 5 illustrates one of the bulkhead end portions 500, provided at first ends 113 of two of the electrical cells 110. The end portion 500 comprises the cell connector 400 which electrically connects the electrical cells 110 on the right of the connector 400 in parallel, via their first terminals 115 being connected to the cell connector 400. The end portion insulates the electrical connector 400 and may be constructed from plastics or ceramic material, and provides the structural support of the bulkhead 150 as discussed further below.
Figure 6 illustrates part of a vehicle traction battery pack subassembly 100 according to the present invention. As shown in Figure 6, part of the cell connector 400 is exposed to allow connection to a busbar connection. Figure 6 also shows a subassembly 100 comprising an electrical harness 600, with a gap providing a harness passage 610 in the end portion 500 to allow the electrical harness 600 to pass through. The electrical harness 600 runs through the subassembly and is encased within the elongate casing 120.
Figure 7 illustrates part of a vehicle traction battery pack subassembly 100 according to the present invention with the elongate housing 120 removed. Figure 7 shows the electrical harness 600 running through the subassembly, with a harness passage 700 provided in the bulkhead to allow the electrical harness 600 to pass through.
Each subassembly 100 can be connected at each end portion 500 to a busbar connection, which enables different combinations of the subassemblies to be connected in series and in parallel, depending on the demands required by one or more vehicle controllers operatively connected to the subassemblies 100.
The electrical harness 600 is arranged to facilitate monitoring of the electrical cells 110. The harness 600 is arranged to provide a connection to a cells supervision circuit (CSC) and provide electrical signals indicative of measurements taken by sensing elements of the electrical harness 600 to the CSC. The CSC may perform some computation in dependence on the received signals, for example to determine whether a module parameter indicated by the measurements taken by the sensing elements is within a safe operating range.
The sensing elements can comprise a voltmeter for measuring the voltage of one or more of the cell clusters. The sensing elements can comprise a thermistor for measuring the temperature of one or more of the electrical cells.
Figure 8 illustrates a cross section of part of a vehicle traction battery pack subassembly 100 according to the present invention with the section 360 removed. Figure 8 shows adhesive material 410, 800 arranged to secure the plurality of electrical cells within the elongate casing 120. Adhesive material 800 adheres the electrical cell 110 on the left of Figure 8 to side face 352. Adhesive material can also be provided to adhere the electrical cell 110 on the right of Figure 8 to side face 362, not shown in Figure 8. Adhesive material 410 is located between the electrical cells 110, which are provided in the same chamber 200. The adhesive material 410, 800 can be a thermal interface material, which allows the transfer of heat from the electrical cells 110 to the elongate casing 120, which can then transfer the heat to a cooling plate of a battery pack, not shown. Figure 8 shows an insulating sheet 810, provided on the elongate section 350.
Figure 9 illustrates a vehicle traction battery pack 900 according to the present invention. The vehicle battery pack 900 comprises a plurality of vehicle traction battery pack subassemblies according to the present invention. The subassemblies 100 are arranged in a stack 910 in a direction 920 extending perpendicular to the lengthways direction 130.
The elongate casing 120 of each vehicle traction battery pack subassembly 100 is fastened to an elongate casing 120 of an adjacent vehicle traction battery pack subassembly 100. For a subassembly 100 with an adjacent subassembly 100 on each side, the first lip 310 of the subassembly 100 is mounted to a first adjacent one of the plurality of vehicle traction battery pack subassemblies 100, and the second lip 320 is mounted to a second adjacent subassembly 100 on the other adjacent side.
Figure 10 shows two subassemblies 100 mounted together. Figure 10 shows a first indent 330 of a first subassembly 1010 which has received the first lip 310 of a second subassembly 1020. Similarly, the second indent 340 of the first subassembly 1010 has received the second lip 320 of a third subassembly, not shown. Figure 10 also shows that the side face 362 of the first subassembly 1010 is in contact with the side face 352 of the second subassembly 1020.
The first lip 310, second lip 320, first indent 330 and second indent 340 of the subassemblies 100 enable tessellation of the subassemblies 100, which allows for easy assembly of the stack 910 of subassemblies 100, and provides additional structural rigidity to the battery pack 900.
Each subassembly 100 can be placed adjacent to another subassembly 100 in the stack 910 whilst it is being assembled and the lips received by corresponding indents can be welded or otherwise fixed together. This provides a battery pack 900 which contributes to the structural rigidity of the vehicle.
Figure 11 shows a lid 1100, which can be part of the battery pack 900. Figure 12A shows a baseplate 1200 which can be part of the battery pack 900. The baseplate 1200 can also be referred to as a bashplate. The lid 1100 and the baseplate 1200 can enclose the plurality of vehicle traction battery pack subassemblies 100, with the plurality of vehicle traction battery pack subassemblies 100 mounted on the baseplate 1200.
According to the present invention, there is provided a vehicle traction battery pack 900, comprising a plurality of vehicle traction battery pack subassemblies 100, each vehicle traction battery pack subassembly 100 comprising: a plurality of electrical cells 110, an elongate casing 120 containing the plurality of electrical cells 110. The elongate casing 120 is elongate in a lengthways direction 130. The elongate casing 120 comprises a casing base 1300 comprising a plurality of casing openings 1310 as illustrated in Figure 13. The casing base can be provided by, for example, the bottom face 353 of section 350.
The baseplate 1200 of the vehicle traction battery pack comprises a plurality of elongate galleries 1210 as shown in Figure 12A. Figure 123 shows some of the plurality of elongate galleries 1210. Each one of the plurality of elongate galleries 1210 comprises two gallery sidewalls 1211, 1212, a gallery base 1213, and a gallery opening 1214 opposite the gallery base 1213.
The plurality of vehicle traction battery pack subassemblies 100 are mounted on the baseplate 1200 in alignment with the plurality of elongate galleries 1210 such that the plurality of casing openings 1310 of each vehicle traction battery pack subassembly 100 face an aligned said gallery opening 1214.
In Figures 12A, 123, the plurality of elongate galleries 1210 are arranged so that there are multiple lines 1220 of elongate galleries 1210, where in each line 1220 there are multiple elongate galleries 1210 arranged end-to-end. Each line 1220 extends in a lengthways direction 1230. Figures 12A and 12B shows each gallery in a line 1220 ending at a portion of a ridge 1240. The ridges 1240 in Figures 12A and 123 extend in a direction 1231, which is perpendicular to the lengthways direction 1230.
For the example shown in Figure 12A, 12B, each elongate casing 120 of the plurality of vehicle traction battery pack subassemblies 100 straddles and extends along the gallery openings 1214 of multiple elongate galleries 1210 arranged in one of the lines 1220.
In other examples, each line 1220 comprises a single elongate gallery 1210, and so each elongate casing 120 of the plurality of vehicle traction battery pack subassemblies 100 straddles the gallery opening 1214 of one elongate gallery 1210.
Figure 14 shows a cross-sectional view of a plurality of subassemblies 100 mounted to a baseplate 1200 according to the present invention. The baseplate 1200 in Figures 12A, 123, 14 comprises a corrugated sheet 1400. The corrugated sheet 1400 comprises peaks 1410 and troughs 1420. The troughs 1420 of the corrugation provide the plurality of elongate galleries 1210.
As illustrated in Figures 12A, 12B, the corrugated sheet comprises one or more ridges 1240 extending in a direction perpendicular to a lengthways direction 1230. Each ridge 1240 spans across multiple peaks 1410 and troughs 1420. Each ridge 1240 has a maximum height below a height of the peaks 1410 and above the gallery bases 1213 provided by the troughs 1420.
For each pair of adjacent galleries 1210 arranged in one of the lines 1220 which each have multiple galleries, a portion 1250 of one of the one or more ridges 1240 provides an end of one gallery 1210 and an end of the adjacent gallery 1210. The ridge portions 1250 do not seal adjacent galleries 1210 from another, thereby allowing hot gases emitted from the casing openings 1310 in a venting event to disperse across the galleries 1210 and the baseplate 1200.
As described above, each elongate casing 120 of the plurality of vehicle traction battery pack subassemblies 100 can contain at least two chambers 200 arranged in a line 210 end-to-end extending in the lengthways direction 130, and at least one bulkhead 150. Each one of the at least two chambers 200 is separated from an adjacent chamber 200 by one of the at least one bulkhead 150. Each one of the at least two chambers 200 contains at least one of the plurality of electrical cells 110.
In an embodiment where the plurality of galleries 1210 are arranged in lines 1220 where each line 1220 comprises multiple galleries 1210, each one of the at least two chambers 200 is aligned with a corresponding one gallery 1210 of said multiple galleries 1210 in the line 1220.
Each one of the at least two chambers 200 corresponds to one or more of the plurality of casing openings 1310 in the casing base 1300.
Figure 15 shows a vehicle traction battery pack 900 in accordance with the present invention, viewed from underneath the elongate casings 120 with the casing bases 1300 in view. The baseplate is not shown in Figure 15. As shown in Figures 13 and 15, each casing base 1300 comprises one or more interval portions 1320. The interval portions 1320 do not have any of the plurality of casing openings 1310. Each interval portion 1320 spans across two chambers 200 of a subassembly 100.
Each interval portion 1320 in a vehicle traction battery pack subassembly 100 substantially aligns in a direction perpendicular to the lengthways direction 1230 with a corresponding interval portion 1320 in an adjacent vehicle traction battery pack subassembly to form at least one line 1500 of aligned interval portions 1320, each one of the at least one line 1500 of aligned interval portions extending in a direction extending perpendicular to the lengthways direction 1230. Each one of the at least one line 1500 of aligned interval portions 1320 overlies one of the one or more ridges 1240.
Each bulkhead 150 overlies a corresponding interval portion 1320 and a corresponding ridge portion 1250.
Figure 16 show a battery pack 900 in accordance with the present invention. Figure 16 shows the plurality of vehicle traction battery pack subassemblies 100 mounted to the baseplate 1200. The plurality of elongate galleries 1210 extend in the lengthways direction 1230, and the plurality of vehicle traction battery pack subassemblies are arranged in a stack 910 in a direction extending perpendicular to the lengthways direction 1230.
Figure 16 shows that some of the galleries 1210 extend beyond the ends of the battery pack subassemblies 100. The galleries 1210 and the remaining space within the battery pack enclosure when the lid 1100 and the baseplate 1200 enclose the plurality of subassemblies 100 provide a venting volume. This enables any hot gases escaping a chamber 200 of an elongate casing 120, via the casing openings 1310, to expand and cool in the gallery 1210 aligned with that chamber 200 and also to the surrounding galleries 200 and space within the enclosure. By enabling a volume for hot gases to expand this can help to cool the hot gases from a venting event.
Figure 17 illustrates part of a subassembly 100 according to the present invention. Figure 17 shows part of a subassembly 100 with section 360 removed and the electrical cell 110 or cells 110 removed from one of the chambers 200. One or more insulating sheets 810 are arranged to cover the plurality of casing openings 1310. The one or more insulating sheets 810 comprise an Anti Thermal Propagation (ATP) material. In Figure 17, one insulating sheet 810 covers a plurality of casing openings in one chamber 210.
In Figure 17, the one or more insulating sheets 810 can be mica sheets or other insulator. The insulating sheet or sheets prevent hot gases from entering the elongate casing 120. The insulating sheets 810 are arranged to be ruptured over the casing openings 1310 associated 35 with a chamber when hot gases are produced within a chamber, due to a venting event. The insulating sheets 810 can therefore allow for hot gases to escape the chamber in a venting event to allow the hot gases to expand and cool in the galleries 1210 and the rest of the venting volume. When the insulating sheet or sheets are intact in other chambers 200, i.e. without any ruptures, this may also prevent hot gases from a venting event in one chamber 200 entering the other chambers 200.
According to the present invention, there is provided a vehicle traction battery pack 900. The battery pack 900 comprises: a plurality of vehicle traction battery pack subassemblies 100, each vehicle traction battery pack subassembly 100 comprising: a plurality of electrical cells 110 and an elongate casing 120 containing the plurality of electrical cells 110. The elongate casing 120 is elongate in a lengthways direction 130 and comprises at least two chambers 200 arranged in a line 210 end-to-end in the lengthways direction 130, and at least one bulkhead 150. Each chamber 200 is separated from an adjacent chamber 200 by one of the at least one bulkhead 150. Each chamber 200 contains at least one of the plurality of electrical cells 110.
The plurality of vehicle traction battery pack subassemblies 100 are stacked adjacent to one another in a direction perpendicular to the lengthways direction 1230. The bulkheads 150 in adjacent vehicle traction battery pack subassemblies 100 substantially align with one another to provide at least one line 1800 of bulkheads. The at least one line 1800 of bulkheads extend in a direction perpendicular to the lengthways direction 1230. Figure 18A and Figure 18B illustrates part of a vehicle traction battery pack according to the present invention. Figure 18B is a schematic of part of a vehicle traction battery pack viewed from above. Figure 188 shows lines 1800 of bulkheads.
As previously described, each bulkhead 150 comprises a cell connector 400. Each electrical cell 110 comprises a first terminal 115 at a first end 113, a second terminal 116 at a second end 114. At least one of the first terminal 115 and second terminal 116 of each electrical cell 110 is connected to the cell connector 400 of one of the at least one bulkhead 150. The first terminal 115 and second terminal 116, for example those shown in Figure 4, comprise a flexible connector.
Figure 19 shows a bulkhead according to the present invention. Each bulkhead comprises four flanges 1900. Each of the four flanges 1900 is provided at one of four corners of the 35 bulkhead.
As shown in Figures 16 and 18, the vehicle traction battery pack comprises one or more load transfer structures 1600. Each of the one or more load transfer structures 1600 is arranged at a first end or a second end of one of the at least one line 1800 of bulkheads 150 and extends therefrom along the at least one line.
As shown in Figure 16, one of the one or more load transfer structures 1600 is provided at the first end of one of the at least one line 1800 of bulkheads 150 and another of the one or more load transfer structures 1600 is provided at the second end of the one of the at least one line 1800 of bulkheads.
The battery pack 900 shown in Figure 18A also comprises one or more beams 1810 extending in the lengthways direction (shown as 1260 in Figure 14). Each of the one or more beams 1810 is mounted adjacent to the elongate casing 120 of at least one of the plurality of vehicle traction battery pack subassemblies 100. The one or more beams 1810 can provide structural support for the battery pack 900.
The line 1800 of bulkheads 150 can provide a virtual structural beam due to their alignment, which can act as a load transfer structure in a side-pole impact of the vehicle. By having the line 1800 of bulkheads 150 act as a load transfer structure, this can help to reduce damage to other parts of the vehicle traction battery pack 900 during a side-pole impact, for example the electrical cells 110. The alignment of the lines 1800 with the load transfer structures 1600 can also help in this regard. The shape of the bulkheads 150, including the four flanges 1900, advantageously provides a bulkhead 150 with high structural strength. The flexible connectors for the electrical cells allow for some flexing of the terminals 115, 116 without breaking the connection to the cell connector, which can help prevent damage to the electrical cells 110 in a side-pole impact.
Each bulkhead 150 comprises a bulkhead insulating material surrounding the cell connector.
The bulkhead insulating material can comprise a plastics material. For example, the plastics material can be a high temperature thermoset plastic. The bulkhead insulating material can comprise a ceramics material. The bulkhead insulating material can comprise a mastic material.
The bulkhead insulating material can comprise an intumescent material. For example, the intumescent material can be applied to a base component, for instance a plastic base component. In other examples, the insulating material may consist of an intumescent material. By having a bulkhead 150 comprising an intumescent material, this can help to prevent hot gases in a venting event in one chamber 200 entering an adjacent chamber 200, due to the bulkhead 150 expanding in the heat.
Figure 20 shows a cross-section of part of an example battery pack 900. Figure 20 illustrates an embodiment of an elongate gallery 2210 which does not use the corrugated sheet 1400 of Figure 14 but instead the elongate gallery 2210 is formed from discrete gallery sidewalls 2211, 2212 bridging from the baseplate 2200 to the cell stack 910. In this embodiment the gallery base 2213 is formed of the portion of baseplate 2200 between the gallery sidewalls 2211, 2212, and a gallery opening 2214 is opposite the gallery base 2213. Thus, in Figure 20, there are two side walls between an elongate gallery 2210 and a neighbouring elongate gallery 2210a, 2210b. The skilled person will appreciate that alternatively a single sidewall may be used to form the sidewall of both an elongate gallery 2210 and its neighbouring gallery 2210a, 2210b. The gallery opening 2214 is configured to align with a plurality of casing openings 1310, as previously illustrated in Figure 13, and this alignment provides for any hot gases escaping via the casing openings 1310 to expand and cool in the gallery 2210 in like manner to that described above.
It will be noted that the gallery sidewalls 2211, 2212 of Figure 20 are not straight, but have at least one curve or bend which facilitates a buckling of the sidewalls 2211, 2212 under vertical loading such as may occur when an upwards force is applied to the underside of the baseplate 2200. Such loading may occur if the vehicle in which the battery pack 900 is fitted hits or rests on an object such that the baseplate is indented upwards. In this way the gallery sidewalls 2211, 2212 and baseplate 2200 form a collapsible battery support structure which provides for under body protection of the cell stacks 910 by absorbing deformation loads which may arise in off-road use cases or in abuse cases.
Figure 21 shows a vehicle 2100 according to the present invention. The vehicle 2100 comprises a vehicle traction battery pack 900 according to the invention.
In the examples illustrated, the electrical cells 110 can be pouch cells or prismatic cells.
It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims (15)

  1. CLAIMS1. A vehicle traction battery pack subassembly, comprising: a plurality of electrical cells; an elongate casing containing the plurality of electrical cells, wherein the elongate casing is elongate in a lengthways direction; wherein each electrical cell comprises a front face, a back face, a first end and a second end, wherein the front face and the back face extend between the first end and the second end, wherein a first terminal of the electrical cell is provided at the first end and a second terminal of the electrical cell is provided at the second end; wherein the plurality of electrical cells are arranged within the elongate casing to form at least one line of electrical cells arranged end-to-end, wherein the at least one line of electrical cells extends in the lengthways direction.
  2. 2. A vehicle traction battery pack subassembly as claimed in claim 1, wherein the elongate casing comprises a hollow profile.
  3. 3. A vehicle traction battery pack subas14sembly as claimed in claim 2, wherein the elongate casing comprises: a first lip extending at least partially along the lengthways direction, said first lip protruding in a first direction away from the hollow profile; a second lip extending at least partially along the lengthways direction, said second lip protruding in a second direction opposite the first direction.
  4. 4. A vehicle traction battery pack subassembly as claimed in claim 3, wherein the elongate casing comprises: a first indent suitable for receiving, in use, the first lip of an elongate casing of a first adjacent vehicle traction battery pack subassembly on one side of the vehicle traction battery pack subassembly, the first indent extending at least partially along the lengthways direction; and a second indent for receiving, in use, the second lip of an elongate casing of a second adjacent vehicle traction battery pack subassembly on the other side of the vehicle traction battery pack subassembly, the second indent extending at least partially along the lengthways direction.
  5. 5. A vehicle traction battery pack subassembly as claimed in any preceding claim, wherein the elongate casing comprises two elongate open-profile sections joined together, and wherein the cross section of each of the two sections comprises a top face, a bottom face and a side face configured as a C-section.
  6. 6. A vehicle traction battery pack subassembly as claimed in claim 5, wherein for a first one of the two elongate sections the top face protrudes further from the side face than the bottom face, and for a second one of the two elongate sections the bottom face protrudes further from the side face than the top face and wherein the two sections are arranged so that the top faces of each of the two sections contact and substantially overlap one another, and the bottom faces of each of the two sections contact and substantially overlap one another.
  7. 7. A vehicle traction battery pack subassembly as claimed in claim 6, when dependent upon claim 3, wherein the first lip is provided by one of the top face and bottom face of one of the two sections and the second lip is provided by an opposite one of the top face and bottom face of the other of the two sections.
  8. 8. A vehicle traction battery pack subassembly as claimed in any of claims 5 to 7, when dependent upon claim 4, wherein the first indent is provided by one of the top face and bottom face of the two sections and the second indent is provided by an opposite one of the top face and bottom face of the other of the two sections.
  9. 9. A vehicle traction battery pack subassembly as claimed in any preceding claim, wherein the elongate casing comprises at least two chambers arranged in a line end-to-end, the line extending in the lengthways direction, and at least one bulkhead disposed between and separating adjacent chambers, wherein each of the at least two chambers contains at least one of the plurality of electrical cells.
  10. 10. A vehicle traction battery pack subassembly as claimed in claim 9, wherein each bulkhead comprises a cell connector.
  11. 11. A vehicle traction battery pack subassembly as claimed in any preceding claim comprising an electrical harness, wherein the electrical harness is contained within the elongate casing and runs the length of the elongate casing.
  12. 12. A vehicle traction battery pack comprising a plurality of vehicle traction battery pack subassemblies as claimed in any preceding claim.
  13. 13. A vehicle battery pack as claimed in claim 12, wherein the vehicle traction battery pack subassemblies are arranged in a stack in a direction extending perpendicular to the lengthways direction.
  14. 14. A vehicle traction battery pack as claimed in claim 13, when dependent upon claim 8, wherein the first lip of the subassembly is mounted to a first adjacent one of the plurality of vehicle traction battery pack subassemblies, and the second lip is mounted to a second adjacent one and wherein for at least one of the plurality of vehicle traction battery pack subassemblies, the first indent of the elongate casing has received the first lip of a first adjacent one of the plurality of vehicle traction battery pack subassemblies, and the second indent of the elongate casing has received the second lip of a second adjacent one of the plurality of vehicle traction battery pack subassemblies.
  15. 15. A vehicle comprising a vehicle traction battery pack as claimed in any of claims 12 to 14.
GB2218498.0A 2022-12-08 2022-12-08 A vehicle traction battery pack subassembly, a vehicle traction battery pack and a vehicle Pending GB2625266A (en)

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US6063520A (en) * 1996-04-12 2000-05-16 Mitsubishi Chemical Corporation Lightweight battery container and method for fabrication of same
US20150283965A1 (en) * 2014-04-08 2015-10-08 Maxwell Technologies, Inc. Methods and apparatuses for temperature control in energy storage devices
WO2021164559A1 (en) * 2020-02-18 2021-08-26 比亚迪股份有限公司 Battery, battery module, battery pack, and electric vehicle
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