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WO2013171560A1 - Battery assembly and module lid for battery assembly - Google Patents

Battery assembly and module lid for battery assembly Download PDF

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Publication number
WO2013171560A1
WO2013171560A1 PCT/IB2013/000899 IB2013000899W WO2013171560A1 WO 2013171560 A1 WO2013171560 A1 WO 2013171560A1 IB 2013000899 W IB2013000899 W IB 2013000899W WO 2013171560 A1 WO2013171560 A1 WO 2013171560A1
Authority
WO
WIPO (PCT)
Prior art keywords
module lid
battery device
busbars
cell
cell monitor
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.)
Ceased
Application number
PCT/IB2013/000899
Other languages
French (fr)
Inventor
Roman STOIBER
Sverre Wiik ∅BERG
Jamie Edward John SAUNDERS
Srivastava Akhilesh KUMAR
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.)
Miljobil Grenland AS
Original Assignee
Miljobil Grenland AS
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 Miljobil Grenland AS filed Critical Miljobil Grenland AS
Publication of WO2013171560A1 publication Critical patent/WO2013171560A1/en
Anticipated expiration legal-status Critical
Ceased 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
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • 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
    • H01M10/04—Construction or manufacture in general
    • H01M10/0413—Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
    • 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
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • 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
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • 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
    • 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
    • H01M50/211—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for 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
    • H01M50/271—Lids or covers for the racks or secondary 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
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/284—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with incorporated circuit boards, e.g. printed circuit boards [PCB]
    • 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
    • H01M50/505—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising a single busbar
    • 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
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/058—Construction or manufacture
    • H01M10/0585—Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
    • 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
    • H01M10/64—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
    • 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
    • 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
    • H01M10/6553—Terminals or leads
    • 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
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4271—Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
    • 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
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4278—Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
    • 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
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • a Lithium-Ion (Li-Ion) battery needs individual cell voltage monitoring in order to achieve safe usage and maximized life time/performance.
  • the cell voltages are measured by an electronic monitoring device by means of voltage pickups, permanently attached to cell terminals and transferred to the monitoring device by a wiring harness wit connectors.
  • the electronic monitoring device typically consists of a printed circuit board (PCB) in an enclosure, located as close as possible to the voltage pickups.
  • PCB printed circuit board
  • pouch cell modules using cells with cell tabs on the same end the space in between the pouch cells is typically used for retention or wiring harness.
  • the top of conventional modules is usually covered by a lid with pure protective function.
  • the present invention aims to improve the safety of handling modules during assembly and makes obsolete.
  • the present invention provides a novel battery assembly to package and retain the cell monitor PCB in an assembly of Li-Ion pouch cells in the most space efficient way.
  • the present invention moreover features fast assembly and protection to the PCB during assembly process.
  • the present invention also provides a novel module lid for a battery assembly.
  • Another object of the present invention is to improve the safety of handling battery devices during assembly and preclude the need of using protective sheets or devices for assembly.
  • Yet another object of the present invention is to improve the crash safety by providing electrical separation between the cell tabs and contribute to better battery performance under warm conditions or during high currents.
  • said battery device comprises a plurality of unit cells having cell tabs and a plurality of busbars for electrically connecting said cell tabs,
  • said cell monitor PCB is electrically linked with said unit cells and has provisions provided thereon at predetermined positions for engaging with said busbars
  • module lid is configured to accommodate therewithin said cell tabs, said busbars and said cell monitor PCB,
  • cassette slots for matchingly engaging with said battery device.
  • said module lid is thermally conductive but electrically non-conductive in nature and being configured to act as heat sink for heat generated by said busbars.
  • said unit cells are Lithium ion pouch cells.
  • the busbar bays and the cassette slots are configured to engage with said busbars and said battery device respectively in a Poka-yoke proof manner.
  • said module lid is provided with integrated supporting bosses for providing mechanical strength to said cell monitor PCB.
  • said cell monitor PCB is provided with temperature sensors.
  • busbar bays for accommodating said busbars
  • the invented module lid is thermally conductive but electrically non- conductive in nature and being configured to act as heat sink for heat generated by said busbars.
  • said cell monitor PCB is connected to the busbars through contact springs provided with said module lid.
  • the module lid may be provided with plastic clips for retaining said cell monitor PCB in position or said cell monitor PCB may be fastened to said module lid.
  • the busbar bays and the cassette slots are configured to engage with said busbars and said battery device respectively in a Poka-yoke proof manner.
  • coding of the busbar bays and cassette slots provides poka-yoke proof design.
  • the module lid may be fixed to the battery device by means of mechanical fasteners.
  • Figure 3 is another bottom perspective view of a portion of the module lid assembly and a portion of PCB area, in accordance to an embodiment of the present invention.
  • FIG. 4 is a flowchart for the module assembly, in accordance to an embodiment of the present invention.
  • the method of assembling the battery device features fast assembly and enables protection to the PCB (1.2) in the protecting module lid (1.1) during assembly process, likewise the coding of the busbar bays (1.4) and cassette slots (1.5) provides poka-yoke proof design by being assembled to components that only match in one specific way, otherwise not allowing the lid to be lowered down and thus assembled completely to the module.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Materials Engineering (AREA)
  • Battery Mounting, Suspending (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Description

BATTERY ASSEMBLY AND MODULE LID FOR BATTERY ASSEMBLY
FIELD OF INVENTION
The present invention relates generally to a novel battery assembly and more particularly, packaging and retention concept to improve cost effectiveness of Li-Ion battery modules and increase volumetric efficiency thereof. The present invention also relates to a novel module lid for battery assembly.
BACKGROUND OF THE INVENTION
A Lithium-Ion (Li-Ion) battery needs individual cell voltage monitoring in order to achieve safe usage and maximized life time/performance. The cell voltages are measured by an electronic monitoring device by means of voltage pickups, permanently attached to cell terminals and transferred to the monitoring device by a wiring harness wit connectors. The electronic monitoring device typically consists of a printed circuit board (PCB) in an enclosure, located as close as possible to the voltage pickups. In pouch cell modules using cells with cell tabs on the same end, the space in between the pouch cells is typically used for retention or wiring harness. The top of conventional modules is usually covered by a lid with pure protective function.
The printed circuit board (PCB) typically needs an enclosure to protect and retain it safely. The packaging of the PCB respectively control unit is usually in contradiction to achieve highest possible energy density on module level since the cell monitor is an inherent part of a Li-Ion battery module and therefore counts to the overall efficiency and thus energy density (both gravimetric and volumetric).
The disadvantage associated with conventional battery assemblies is that handling the battery modules during assembling is not safe and requires protective sheets or special devices for assembly. Moreover, conventional battery assemblies are not crash safe and the electrical separation between the cell tabs is always not proper.
With a view, therefore, to overcome the problem associated with conventional battery assemblies the inventors felt the need to develop a cost effective, safe and low cost/low weight high volume manufacturing battery modules with very high volumetric efficiency. The present invention aims to improve the safety of handling modules during assembly and makes obsolete. The present invention provides a novel battery assembly to package and retain the cell monitor PCB in an assembly of Li-Ion pouch cells in the most space efficient way. The present invention moreover features fast assembly and protection to the PCB during assembly process. The present invention also provides a novel module lid for a battery assembly. OBJECTS OF THE INVENTION
Accordingly, the objective of present invention is to provide an improved, cost effective, safe and low cost/low weight high volume manufacturing of battery assemblies/modules, particularly Li-Ion battery assemblies/modules, with high volumetric efficiency.
Another object of the present invention is to improve the safety of handling battery devices during assembly and preclude the need of using protective sheets or devices for assembly.
Yet another object of the present invention is to improve the crash safety by providing electrical separation between the cell tabs and contribute to better battery performance under warm conditions or during high currents.
Further objects and features of the invention will become apparent from the following detailed description when considered in conjunction with the drawings.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a battery assembly having a battery device, a cell monitor PCB and a module lid for covering said battery device and said cell monitor PCB,
wherein said battery device comprises a plurality of unit cells having cell tabs and a plurality of busbars for electrically connecting said cell tabs,
and wherein said cell monitor PCB is electrically linked with said unit cells and has provisions provided thereon at predetermined positions for engaging with said busbars,
and wherein said module lid is configured to accommodate therewithin said cell tabs, said busbars and said cell monitor PCB,
and wherein said module lid is provided with:
short-circuit protection fins for electrically insulating said cell tabs from one another,
- busbar bays for accommodating said busbars, and
cassette slots for matchingly engaging with said battery device.
The module lid covering the battery device protects the cell tabs and busbars and serves as mechanical retention for the PCB.
Preferably in the invented battery assembly, said module lid is thermally conductive but electrically non-conductive in nature and being configured to act as heat sink for heat generated by said busbars. According to a preferred embodiment of the invented battery assembly, said unit cells are Lithium ion pouch cells.
According to a particular embodiment of the invented battery assembly, said cell monitor PCB is connected to the busbars through contact springs provided with said module lid. The cell monitor PCB may be retained in position by means of plastic clips provided with said module lid; alternatively, said cell monitor PCB may be fastened to said module lid.
According to another embodiment of the invented battery assembly, the busbar bays and the cassette slots are configured to engage with said busbars and said battery device respectively in a Poka-yoke proof manner. Preferably, in the invented battery assembly, said module lid is provided with integrated supporting bosses for providing mechanical strength to said cell monitor PCB.
According to yet another embodiment of the invented battery assembly said cell monitor PCB is provided with temperature sensors.
In the invented battery assembly said module lid may be fixed to the battery device by means of mechanical fasteners.
The present invention also provides a novel module lid for battery assembly, said battery assembly having a battery device and a cell monitor PCB, wherein said module lid is configured to accommodate therewithin said cell monitor PCB , cell tabs and busbars of said battery device,
and wherein said module lid is provided with:
short-circuit protection fins for electrically insulating said cell tabs from one another,
busbar bays for accommodating said busbars, and
cassette slots for matchingly engaging with said battery device.
Preferably the invented module lid is thermally conductive but electrically non- conductive in nature and being configured to act as heat sink for heat generated by said busbars.
According to a preferred embodiment of the invented module lid, said cell monitor PCB is connected to the busbars through contact springs provided with said module lid. The module lid may be provided with plastic clips for retaining said cell monitor PCB in position or said cell monitor PCB may be fastened to said module lid.
According to another embodiment of the invented the module lid the busbar bays and the cassette slots are configured to engage with said busbars and said battery device respectively in a Poka-yoke proof manner. In other words, coding of the busbar bays and cassette slots provides poka-yoke proof design. The module lid may be fixed to the battery device by means of mechanical fasteners.
According to yet another embodiment of the invented module lid is provided with integrated supporting bosses for providing mechanical strength to said cell monitor PCB.
In the present invention the short-circuit protection fins also give mechanical support to the cell monitor PCB during assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
For better understanding, an illustrative embodiment of the invention will be described with reference to the accompanying drawings. It will however be appreciated that the embodiments exemplified in the drawings is merely illustrative and not limitative to the scope of the invention, because it is quite possible, indeed often desirable, to introduce a number of variations in the particular embodiment that has been shown in the drawings. In the accompanying drawings:
Figurel is a perspective view the battery device, in accordance to an embodiment of the present invention,
Figure 2 is a bottom perspective view the module lid assembly, in accordance to an embodiment of the present invention,
Figure 3 is another bottom perspective view of a portion of the module lid assembly and a portion of PCB area, in accordance to an embodiment of the present invention, and
Figure 4 is a flowchart for the module assembly, in accordance to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
Referring now to the drawings where in the showings is for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same.
As shown in figure 1 of the accompanying drawings, according to a preferred embodiment the invented battery assembly (1) comprises of a battery device (4.2), a cell monitor PCB ( 1.2) and a module lid (1.1) .
In one embodiment of the present invention, the battery device (4.2) constitutes an on- vehicle power source system for electric vehicles, particularly electric automobiles. The electric automobiles include hybrid electric vehicles that include an internal combustion engine and an electric machine as a driving source of the vehicle and pure electric vehicles that include an electric machine as the only driving source of the vehicle. However, it may herein be noted that the application of the battery device (4.2) is not limited to on-vehicle power source system, and the same may be used with other applications, such as in maritime and stationary applications. The battery device (4.2) includes a plurality of cells and is constituted as, for instance, a lithium ion battery device that includes a plurality of lithium-ion battery cells.
The battery device (4.2), as best shown in figure 1 , includes stacked Lithium-Ion (Li-ion) pouch cells (also numbered as "Li-ion pouch cells 4.2"). As would be apparent to those skilled in the art that stacked Lithium-Ion (Li-ion) pouch cells includes a plurality of unit cells mounted in a battery cartridge. The unit cells are adapted to be electrically connected to one another.
The battery assembly (1) further includes a cell monitor printed circuit board (PCB) (1.2). The cell monitor PCB (1.2) is retained in the assembly of Li-Ion pouch cells in the most space efficient way. The most efficient way to package the cell monitor PCB (1.2) is to locate it between two rows of the cell tabs arranged in the battery device (4.2). The printed circuit board (PCB) (1.2.) is a plate-shaped member. The printed circuit board (PCB) (1.2) has provisions provided thereon at predetermined positions where the busbars of the Li-ion pouch cells 4.2 may be connected to the printed circuit board (PCB) (1.2). Further, contact springs (2.2) are directly populated to the PCB (1.2).
The battery assembly (1 ) further includes a protective module lid (1.1). The protective module lid (1.1) includes a plurality of busbar bays (1.4) and cassette slots (1.5).
The method of assembling the battery device, features fast assembly and enables protection to the PCB (1.2) in the protecting module lid (1.1) during assembly process, likewise the coding of the busbar bays (1.4) and cassette slots (1.5) provides poka-yoke proof design by being assembled to components that only match in one specific way, otherwise not allowing the lid to be lowered down and thus assembled completely to the module.
The module lid (1.1) is fixed to the battery device (4.2) with screws (1.6) and the PCB (1.2) is held in the module either by plastic clips (1.8). Optionally, the PCB (1.2) may also be held in the module with screws. The PCB (1.2) can directly be populated with temperature sensors (2.1 ) by for example SMD or wire-bond technology, thus specific retention and wiring for these components may be avoided. The module lid (1.1) covering the battery device (4.2) protects the cell tabs and busbars and serves as mechanical retention for the PCB (1.2). Moreover, the module lid (1.1) features short- circuit protection fins (1.3), which in addition to increased safety during a crash or similar also give mechanical support to the PCB during assembly due to integrated supporting bosses (1.7). The lid material furthermore is made of electrically non-conductive but thermally conductive material and acts as a heat sink for heat generated by the busbars. The busbars are contacted by the PCB with contact springs (2.2) by e.g. SMD assembly.
The invention will improve cost effective, safe and low cost/low weight high volume manufacturing of Li-Ion battery modules with very high volumetric efficiency. It will improve the safety of handling modules during assembly and makes protective sheets or devices for assembly obsolete. The monitor PCB (1.2) and module lid (1.1) will be provided to the assembly line as one subassembly as shown in figures and thus support a simple line layout with high efficiency. It also will improve the crash safety by providing electrical separation between the cell tabs and will contribute to better battery performance under warm conditions or during high currents.
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

Claims

1. A battery assembly having a battery device, a cell monitor PCB and a module lid for covering said battery device and said cell monitor PCB,
wherein said battery device comprises a plurality of unit cells having cell tabs and a plurality of busbars for electrically connecting said cell tabs,
and wherein said cell monitor PCB is electrically linked with said unit cells and has provisions provided thereon at predetermined positions for engaging with said busbars,
and wherein said module lid is configured to accommodate therewithin said cell tabs, said busbars and said cell monitor PCB,
and wherein said module lid is provided with:
short-circuit protection fins for electrically insulating said cell tabs from one another,
- busbar bays for accommodating said busbars, and
cassette slots for matchingly engaging with said battery device.
2. The battery device as claimed in claim 1 , wherein said module lid is thermally conductive but electrically non-conductive in nature and being configured to act as heat sink for heat generated by said busbars.
3. The battery device as claimed in ay of the above claims, wherein said unit cells are Lithium ion pouch cells.
4. The battery device as claimed in any of the above claims, wherein said cell monitor PCB is connected to the busbars through contact springs provided with said module lid.
5. The battery device as claimed in any of the above claims, wherein said cell monitor PCB is retained in position by means of plastic clips provided with said module lid.
6. The battery device as claimed in any of the above claims 1 to 5, wherein said cell monitor PCB is fastened to said module lid;
7. The battery device as claimed in any of the above claims, wherein the busbar bays and the cassette slots are configured to engage with said busbars and said battery device respectively in a Poka-yoke proof manner.
8. The battery device as claimed in any of the above claims, wherein said module lid is provided with integrated supporting bosses for providing mechanical strength to said cell monitor PCB.
9. The battery device as claimed in any of the above claims, wherein said cell monitor PCB is provided with temperature sensors.
10. The battery device as claimed in any of the above claims, wherein said module lid is fixed to the battery device by means of mechanical fasteners.
1 1. A module lid for battery assembly, said battery assembly a battery device and a cell monitor PCB, wherein said module lid is configured to accommodate therewithin said cell monitor PCB , cell tabs and busbars of said battery device, and wherein said module lid is provided with:
short-circuit protection fins for electrically insulating said cell tabs from one another,
busbar bays for accommodating said busbars, and
cassette slots for matchingly engaging with said battery device.
12. The module lid as claimed in claim 1 1 , wherein said module lid is thermally conductive but electrically non-conductive in nature and being configured to act as heat sink for heat generated by said busbars.
13. The module lid as claimed in any of the above claims, wherein said cell monitor PCB is connected to the busbars through contact springs provided with said module lid.
14. The module lid any of the above claims, wherein said module lid is provided with plastic clips for retaining said cell monitor PCB in position.
15. The module lid as claimed in any of the above claims 1 1 to 13, wherein cell monitor PCB said is fastened to said module lid.
16. The module lid as claimed in any of the above claims, wherein the busbar bays and the cassette slots are configured to engage with said busbars and said battery device respectively in a Poka-yoke proof manner.
17. The module lid as claimed in any of the above claims, wherein said module lid is fixed to the battery device by means of mechanical fasteners.
18. The module lid as claimed in any of the above claims, wherein said module lid is provided with integrated supporting bosses for providing mechanical strength to said cell monitor PCB.
PCT/IB2013/000899 2012-05-18 2013-05-20 Battery assembly and module lid for battery assembly Ceased WO2013171560A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN1532MU2012 2012-05-18
IN1532/MUM/2012 2012-05-18

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CN104577195A (en) * 2015-02-09 2015-04-29 芯创力源（北京）科技发展有限公司 Power flexible package lithium ion battery module
CN106207245A (en) * 2015-05-29 2016-12-07 丰田自动车株式会社 The manufacture method of set of cells
CN109286046A (en) * 2018-08-31 2019-01-29 深圳市科陆电子科技股份有限公司 A battery energy storage system
CN111971848A (en) * 2018-12-26 2020-11-20 株式会社Lg化学 Battery module configured to allow accurate temperature sensing, and battery pack and vehicle including the same
RU237074U1 (en) * 2025-07-10 2025-09-08 Публичное акционерное общество "Энергия" AUTONOMOUS BATTERY MODULE BASED ON LITHIUM-ION BATTERIES

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Cited By (7)

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Publication number Priority date Publication date Assignee Title
CN104577195A (en) * 2015-02-09 2015-04-29 芯创力源（北京）科技发展有限公司 Power flexible package lithium ion battery module
CN106207245A (en) * 2015-05-29 2016-12-07 丰田自动车株式会社 The manufacture method of set of cells
CN109286046A (en) * 2018-08-31 2019-01-29 深圳市科陆电子科技股份有限公司 A battery energy storage system
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CN111971848A (en) * 2018-12-26 2020-11-20 株式会社Lg化学 Battery module configured to allow accurate temperature sensing, and battery pack and vehicle including the same
US12074342B2 (en) 2018-12-26 2024-08-27 Lg Energy Solution, Ltd. Battery module structured so as to allow accurate temperature sensing, and battery pack and motor vehicle comprising same
RU237074U1 (en) * 2025-07-10 2025-09-08 Публичное акционерное общество "Энергия" AUTONOMOUS BATTERY MODULE BASED ON LITHIUM-ION BATTERIES

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