BATTERY MODULE, A BATTERY PACK, AN ELECTRIC VEHICLE, A BMM CARRIER, A BMM ARRANGEMENT AND A METHOD FOR ASSEMBLING A BATTERY MODULE

A battery module includes: a plurality of battery cells; a cell carrier including a plurality of cell retainers, each of the cell retainers being configured to hold one of the battery cells in a form locking manner; and a battery management module (BMM) arranged within a group of the cell retainers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of European Patent Application No. 21203346.8, filed in the European Patent Office on Oct. 19, 2021, and Korean Patent Application No. 10-2022-0133889, filed in the Korean Intellectual Property Office on Oct. 18, 2022, the entire content of both of which are incorporated herein by reference.

BACKGROUND

Aspects of embodiments of the present disclosure relate to a battery module, a battery pack including the battery module, an electric vehicle including the battery pack, a battery management module (BMM) carrier, a BMM arrangement, and a method for assembling a battery module.

2. Description of the Related Art

Recently, vehicles for transportation of goods and peoples have been developed that use electric power as a source for motion. Such an electric vehicle is an automobile that is propelled by an electric motor using energy stored in rechargeable batteries. An electric vehicle may be solely powered by batteries or may be a hybrid vehicle powered by, for example, a gasoline generator or a hydrogen fuel power cell. A hybrid vehicle may include a combination of electric motor and conventional combustion engine. Generally, an electric-vehicle battery (EVB or traction battery) is a battery used to power the propulsion of battery electric vehicles (BEVs). Electric-vehicle batteries differ from starting, lighting, and ignition batteries in that they are designed to provide power for sustained periods of time. A rechargeable (or secondary) battery differs from a primary battery in that it is designed to be repeatedly charged and discharged, while the latter is designed to provide an irreversible conversion of chemical to electrical energy. Low-capacity rechargeable batteries are used as power supplies for small electronic devices, such as cellular phones, notebook computers, and camcorders, while high-capacity rechargeable batteries are used as power supplies for electric and hybrid vehicles and the like.

Rechargeable batteries may be used as a battery module formed of a plurality of unit battery cells coupled together in series and/or in parallel to provide a high energy content, such as for motor driving of a hybrid vehicle. The battery module may be formed by interconnecting the electrode terminals of the plurality of unit battery cells in a manner depending on a desired amount of power and to realize a high-power rechargeable battery.

Battery modules can be constructed either in a block design or in a modular design. In the block design, each battery is coupled to a common current collector structure and a common battery management system, and the unit thereof is arranged in a housing. In the modular design, pluralities of battery cells are connected together to form submodules, and several submodules are connected together to form the battery module. In automotive applications, battery systems generally include a plurality of battery modules connected together in series to provide a desired voltage. The battery modules may include submodules with a plurality of stacked battery cells, and each stack includes cells connected in parallel that are, in turn, connected in series (XpYs) or cells connected in series that are, in turn, connected in parallel (XsYp).

A battery pack is a set of any number of (usually identical) battery modules. The battery modules may be configured in series, parallel, or a mixture of both to deliver the desired voltage, capacity, and/or power density. Components of a battery pack include the individual battery modules and the interconnects, which provide electrical conductivity between the battery modules.

A battery system may further include a battery management system (BMS), which is an electronic system that manages the rechargeable battery, battery module, and battery pack, such as by protecting the batteries from operating outside their safe operating area (or safe operating parameters), monitoring their states, calculating secondary data, reporting that data, controlling its environment, authenticating it, and/or balancing it. For example, the BMS may monitor the state of the battery as represented by voltage (such as total voltage of the battery pack or battery modules, voltages of individual cells, etc.), temperature (such as average temperature of the battery pack or battery modules, coolant intake temperature, coolant output temperature, or temperatures of individual cells, etc.), coolant flow (such as flow rate, cooling liquid pressure, etc.), and current. Additionally, a BMS may calculate values based on the above items, such as minimum and maximum cell voltage, state of charge (SoC) or depth of discharge (DoD) to indicate the charge level of the battery, state of health (SoH; a variously-defined measurement of the remaining capacity of the battery as % of the original capacity), state of power (SoP; the amount of power available for a defined time interval given the current power usage, temperature, and other conditions), state of safety (SoS), maximum charge current as a charge current limit (CCL), maximum discharge current as a discharge current limit (DCL), and internal impedance of a cell (to determine open circuit voltage).

The BMS may be centralized such that a single controller is connected to the battery cells through a multitude of wires. The BMS may be also distributed, in which a BMS board is installed at each cell with just a single communication cable between the battery and a controller. Or the BMS may have a modular construction including a few controllers, each handling a certain number (e.g., a group or subset) of cells with communication between the controllers. Centralized BMSs are most economical but are least expandable and are plagued by a multitude of wires. Distributed BMSs are the most expensive but are simplest to install and offer the cleanest assembly. Modular BMSs offer a compromise of the features and problems of the other two topologies.

A BMS may protect the battery pack from operating outside its safe operating area. Operation outside the safe operating area may be indicated by overcurrent, over-voltage (e.g., during charging), over-temperature, under-temperature, over-pressure, and ground fault or leakage current detection. The BMS may prevent (or mitigate) operation outside the battery’s safe operating area by including an internal switch, such as a relay or solid-state device, which opens if the battery is operated outside its safe operating area, by requesting the devices to which the battery is connected to reduce or even terminate using the battery, and by actively controlling the environment, such as through heaters, fans, air conditioning, or liquid cooling.

The mechanical integration of such a battery system requires appropriate mechanical connections between the individual components, for example, between battery cells, the BMS, and the housing. These connections must remain functional and safe throughout the average service life of the battery system. Further, installation space and interchangeability requirements must be met, especially in mobile applications.

Conventional battery systems, despite any modular structure, generally include a battery housing that acts as enclosure to seal the battery system against the environment and provides structural protection of the battery system’s components. Housed battery systems are generally mounted as a whole into their application environment, for example, into an electric vehicle. Thus, the replacement of defective system parts, such as a defective battery submodule, requires dismounting (or removing) the whole (or entire) battery system from its application environment and removal of its housing. Even defects of small and/or cheap system parts may lead to dismounting and replacement of the entire battery system and its separate repair. Because high-capacity battery systems are expensive, large, and heavy, such a service procedure is burdensome and the storage, such as in the mechanic’s workshop, of the bulky battery systems is difficult.

Static control of battery power output and charging may not be sufficient to meet the dynamic power demands of various electrical consumers connected to the battery system. Thus, steady exchange of information between the battery system and the controllers of the electrical consumers may be employed. This information may include the battery system’s actual state of charge (SoC), potential electrical performance, charging ability, and internal resistance as well as actual or predicted power demands or surpluses of the consumers.

Therefore, battery systems may include a battery management system (BMS) for obtaining and processing such information on a system level and may include a plurality of battery module managers, also called battery management modules (BMMs), which are part of the system’s battery modules and obtain and process relevant information on a module level. The BMS usually measures the system voltage, the system current, the local temperature at different places inside the system housing, and the insulation resistance between live components and the system housing. The BMMs usually measure the individual cell voltages and temperatures of the battery cells in a battery module.

Thus, the BMS/BMM is provided to manage the battery pack, such as by protecting the battery from operating outside its safe operating area (or safe operating parameters), monitoring its state, calculating secondary data, reporting that data, controlling its environment, authenticating it, and/or balancing it.

In conventional battery packs including cylindrical cells having an axis in a Z direction, battery management systems are generally placed within a battery module on a top or, when packaging space in the Z direction is not available, =on a side of the battery module.

SUMMARY

The present disclosure is defined by the appended claims and their equivalents. Any disclosure lying outside the scope of the claims and their equivalents is intended for illustrative as well as comparative purposes.

According to one embodiment of the present disclosure, a battery module includes: a plurality of battery cells; a (e.g., at least one) cell carrier; and a battery management module (BMM). The cell carrier includes a plurality of cell retainers, and each of the cell retainers is configured to hold one of the battery cells in a form locking manner. The BMM is arranged within a plurality of of the cell retainers.

According to another embodiment of the present disclosure, a battery pack includes a plurality of battery modules as described above.

Another embodiment of the present disclosure provides an electric vehicle including a battery module as described above and/or a battery pack as described above.

Another embodiment of the present disclosure provides a BMM carrier configured to retain a BMM within a plurality of adjacent cell retainers of a cell carrier for a battery module.

Another embodiment of the present disclosure provides a BMM arrangement including: a plurality of BMMs; a collector circuit board configured to electrically connect the BMMs with one or more battery cells; and an adapter mounted to the collector circuit board. The adapter is configured to be arranged within a cell retainer of a cell carrier in a form locking manner.

Another embodiment of the present disclosure provides a method for assembling a battery module as described above. The method includes: a) providing a plurality of battery cells, a cell carrier, and a battery management module (BMM), the cell carrier including a plurality of cell retainers, and each of the cell retainers being configured to hold one of the battery cells in a form locking manner; and b) arranging the BMM within a plurality of the cell retainers.

Further aspects and features of the present disclosure can be learned from the dependent claims and/or the following description.

DETAILED DESCRIPTION

Reference will now be made, in detail, to embodiments, examples of which are illustrated in the accompanying drawings. Aspects and features of the present disclosure, and implementation methods thereof, will be described with reference to the embodiments as shown in the accompanying drawings.

According to one embodiment of the present disclosure, a battery module includes: a plurality of battery cells, a (e.g., at least one) cell carrier, and a battery management module (BMM). The cell carrier includes (or defines) a plurality of cell retainers. Each of the cell retainers is configured (e.g., shaped) to hold one of the battery cells in a form locking manner, for example, by providing a cavity in which a battery cell can be retained (or held). Thus, the cell carrier is configured to retain the plurality of battery cells.

The BMM is arranged within a plurality of (e.g., at least two) of the cell retainers. For example, the BMM is held by the same cell carrier as the battery cells but is held by two of the cell retainers that could be used to hold the battery cells. Because the retainers for holding the battery cells are used to accommodate the BMM, a separate holder or retainer to fix the BMM inside the battery module can be omitted. Thus, the BMM is accommodated in a space-saving manner between the battery cells and within the battery module. The package-optimized BMM is placed in an existing cell carrier and, therefore, saves space and additional monetary savings are achievable as the manufacture of such a battery module can be efficiently performed. Arranging the BMM within at least two of the cell retainers means that the BMM is arranged near to the battery cells, which can facilitate the electrical connection between the BMM and the battery cells.

In some embodiments, the BMM is arranged within at least two of the cell retainers in a form locking manner to efficiently and reliably mount the BMM within the cell retainer.

In some embodiments, the battery module includes a BMM carrier configured to retain the BMM within the at least two cell retainers. The BMM carrier is configured to be arranged within at least two of the cell retainers and to hold the BMM therein. Therefore, the BMM can have any shape that is suitable for being held by the BMM carrier. For example, the BMM may include a printed circuit board and an electrical connector that are retained in the BMM carrier. While the printed circuit board and the electrical connector would otherwise be difficult to mount to the at least one cell retainer, the BMM carrier has a shape that matches the at least two cell retainers to be arranged therein in a form locking manner. Thus, the BMM carrier matches the shape of the at least two cell retainers to facilitate an arrangement of the BMM in a form locking manner within the cell retainer.

In some embodiments, the BMM carrier is arranged in two or more adjacent cell retainers. In such an embodiment, the BMM extends in one direction to a greater extent than an extension of battery cells, for example, a diameter of one of the battery cells. For example, the BMM may include a printed circuit board having an extension (e.g., a dimension or a greatest dimension) that is larger than the diameter of each of the cylindrical battery cells. Adjacent cell retainers are connected to each other so that the BMM carrier can be arranged within the adjacent cell retainers. Therein, the BMM carrier may accommodate the printed circuit board, which is thereby arranged within the adjacent cell retainers. For example, the BMM carrier is arranged in two adjacent cell retainers in a form locking manner as described above.

In some embodiments, each of the battery cells is cylindrically shaped, and each of the cell retainers is at least partly cylindrically shaped and/or has a cylindrical through-hole (e.g., an opening). The cylindrical shape allows for an effective and simple arrangement of cylindrically shaped battery cells within the cell retainers, which include a cylindrical cavity for accommodating a battery cell. A cylindrical through-hole enables an efficient mounting of the battery cells by insertion of the battery cells into the cell retainer at one end thereof opposite to the through-hole, while the battery cells are accessible at both ends thereof to provide electrical connection. Alternatively or additionally, the cell retainers may have the shape of a cylindrical segment and/or adjacent cell retainers may be connected with each other. For example, adjacent cell retainers within one row may be connected with each other. In some embodiments, each of the retainers includes a ring-shaped projection to prevent the battery cells and/or the BMM held therein from moving (or from falling out of the cell retainer(s)).

In some embodiments, the battery module includes a removable bottom cover, and the BMM is removably arranged within the at least two cell retainers to enable simple and efficient service and/or changing of the BMM. After the bottom cover is removed, the BMM can be removed by, for example, pulling the BMM out of the at least two retainers in which the BMM is arranged.

In some embodiments, the battery module includes an adapter and a collector circuit board configured to electrically connect the BMM with one or more of the battery cells. The adapter may be mounted to the collector circuit board and arranged within one of the cell retainers in a form locking manner. The adapter is mounted to the collector circuit board to fix the position of the collector circuit board relative to the adapter. The adapter is arranged within one of the cell retainers to be retained therein. Thus, the collector circuit board is held in a fixed position relative to the cell carrier within the battery module. This embodiment enables holding the collector circuit board in a space-saving manner because the adapter is retained within one of the cell retainers. The collector circuit board can be formed by a printed circuit board (e.g., in a flat arrangement of electronics components), which consumes a minimal amount of mounting space in a z-direction (e.g., a height direction). In some embodiments, the adapter is cylindrically shaped to be retained in one of the cell retainers in a form locking manner.

In some embodiments, the battery module includes a plurality of BMMs, and the collector circuit board is configured to electrically connect each of the battery cells to one of the BMMs. In such an embodiment, the BMMs can be efficiently and space-savingly held by the cell carrier, which is particularly useful when cylindrical cells are used in the battery module because, depending on the number of battery cells, two or more BMMs may be necessary to electrically interconnect each of the battery cells with one of the BMMs. To electrically connect each of the battery cells with one of BMMs, the collector circuit board may include an electrical connector to which an interconnection arrangement can be connected, and the interconnection arrangement may electrically interconnect the collector circuit board with each of the battery cells, by, for example, current collector structures, such as busbars.

In some embodiments, the plurality of cell retainers is arranged in a hexagonal pattern and/or the plurality of cell retainers is arranged in a meandering row so that a plurality of adjacently arranged rows form a hexagonal arrangement of cell retainers. The hexagonal pattern may be called a honeycomb pattern. The hexagonal pattern means that cell retainers are surrounded (e.g., surrounded in a plan view) in a regular pattern by six neighboring cell retainers of the cell carriers and/or of the battery module. The arrangement of the battery cell retainers in a hexagonal pattern allows for a particularly space-saving construction of the battery module.

In some embodiments, the battery module includes a plurality of the cell carriers, and each of the cell carriers is stackable. The battery module may be built from stacked cell carriers. For example, the cell carriers may be shaped and/or configured to be arranged next to each other while efficiently using the available space. For example, an effective arrangement of cell retainers means that neighboring cell carriers can be arranged next to each in other in a stacked manner without leaving a gap between battery cells that are retained within the cell retainers. In some embodiments, the cell carriers include mechanical connection members that are configured to guide neighboring cell carriers during manufacturing so that the neighboring cell carriers are effectively arranged next to each other and configured to mechanically hold the neighboring cell carriers next to each other in the mounted state. This enables the adjacently arranged cell carriers to be arranged adjacent to each other in a stacked manner to provide a modularly constructed battery module and facilitates efficient mountability of the battery module. Therein, the BMM is arranged within at least two of the cell retainers of one of the plurality of cell carriers and/or within cell retainers of two adjacently arranged cell carriers. For example, a BMM may be retained by the cell retainers of a single cell carrier while an adjacent cell carrier retains only battery cells, or a BMM may be retained by cell retainers of adjacently arranged cell carriers. This efficiently enables highly variable possibilities of mounting the battery module by allowing different possibilities of arranging cell carriers, battery cells, and the BMM for mounting the battery module.

According to another embodiment of the present disclosure, a battery pack is includes a plurality of battery modules as described above. For example, the battery pack includes a plurality of battery modules, each of which includes a cell carrier with a plurality of cell retainers. The BMM is retained within at least two of the cell retainers. This provides space-saving construction of the battery pack. The battery pack and/or the battery modules of the battery pack may include any of the above-mentioned features.

Yet another embodiment of the present disclosure provides an electric vehicle including at least one battery module as described above and/or at least one battery pack as described above. For example, the electric vehicle includes a plurality of battery modules, each of which includes at least one cell carrier with a plurality of cell retainers. The BMM is retained within at least two of the cell retainers. This provides a space-saving design. The electrical vehicle and/or the battery modules mounted therein may include any of the above-mentioned features.

Yet another embodiment of the present disclosure provides a BMM carrier configured to retain a BMM within at least two adjacent cell retainers of at least one cell carrier for a battery module. In some embodiments, the BMM carrier includes a housing made of plastic. In some embodiments, the housing includes two cylindrical carrier sections that are configured to be retained in one cell retainer, respectively. The BMM carrier enables the retainers for holding the battery cells to be used to accommodate the BMM, as described above. Thus, a separate holder or retainer to fix the BMM inside the battery module may be omitted. Thus, the BMM can be accommodated in a space-saving manner between the battery cells and within the battery module. The BMM carrier may include any of the features as described above with reference to the BMM carrier.

Yet another embodient of the present disclosure provides a BMM arrangement including: at least two BMMs; a collector circuit board configured to electrically connect the at least two BMMs with one or more battery cells; and an adapter mounted to the collector circuit board. The adapter is configured to be arranged within a cell retainer of a cell carrier in a form locking manner. The BMM arrangement is configured to be mounted in a battery module. The adapter retains the adapter within a battery cell retainer, and therefore, the BMM arrangement is held fixed in the battery module. In some embodiments, the BMM arrangement includes one BMM carrier for each of the at least two BMMs, and each of the BMM carriers is configured to retain a BMM within at least two adjacent cell retainers of the cell carrier. The BMM arrangement and its components may include the features as described above

Yet another embodiment of the present disclosure provides a method for assembling a battery module as described above. The method includes: a) providing a plurality of battery cells, at least one cell carrier, and at least one battery management module (BMM), the at least one cell carrier including a plurality of cell retainers, and each of the cell retainers being configured to hold one of the battery cells in a form locking manner; and b) arranging the at least one BMM within at least two of the cell retainers. This method provides a battery module as described before. The method can be modified so that the assembled battery module includes any of the above-mentioned features.

FIG.1illustrates a schematic view of an electric vehicle300according to an embodiment of the present disclosure. The electric vehicle300is propelled by an electric motor310using energy stored in rechargeable batteries arranged in a battery pack10. The battery pack10is a set of any number of battery modules12. The battery modules12each include a plurality of secondary battery cells20. Components of the battery pack10include the individual battery modules12and interconnects301, which provide electrical conductivity between battery modules12. Each of the battery modules12includes the battery cells20.

FIG.2illustrates a sectional view of a battery module12according to an embodiment of the present disclosure.

The battery module12includes a cell carrier30including (or forming) a plurality of cell retainers31. The plurality of cell retainers31is arranged in a hexagonal pattern (see, e.g.,FIGS.10A and10B). A plurality of the cell retainers31is arranged in meandering row so that a plurality of adjacently arranged rows form a hexagonal arrangement of cell retainers31. In some embodiments, the cell carrier30is made of a polymer to provide a lightweight cell carrier30that is efficient to manufacture.

Each of the cell retainers31is configured to hold (or accommodate) one of the battery cells20in a form locking manner. Each of the battery cells20is cylindrically shaped, and each of the cell retainers31is cylindrically shaped. The shape of the battery cells20and the cell retainers31match (or correspond) such that the battery cells20can be held by the cell retainers31in a form locking manner. Each of the cell retainers31has a cylindrical through-hole (e.g., an opening) through (or into) which one of the battery cells20can be inserted to be retained in the cell retainer31. Each of the retainers31includes a projection34to prevent the battery cells20held therein from moving (e.g., from falling out of the bottom thereof). The projection34is ring-shaped to effectively reduce the diameter of the through-hole and/or the cell retainer31.

The battery module12includes two battery management modules21, abbreviated as BMMs21. Each of the BMMs21is arranged in two of the cell retainers31. In the illustrated embodiment, the BMMs21are arranged within the same meandering row of the cell carrier30and in two pairs32a,32bof adjacent cell retainers31of the same meandering row. The cell retainer31between the two pairs32a,32bof adjacent cell retainers31retains an adapter23, which is further described with reference toFIG.6. The two pairs32a,32bof adjacent cell retainers31are pairs of connected cell retainers31. For example, the cell carrier30is shaped so that each of the cell retainers31of the two pairs32a,32bis a cylinder segment, and a circumferential section of the cell retainer31of one of the two pairs32a,32bis open to connect to the other cell retainer31of said pair32a,32b.

The battery module12includes two BMM carriers24configured to retain the BMMs21within the cell retainers31. For example, the battery module12includes one BMM carrier24for each of the BMMs21. By using the BMM carriers24, the BMMs21are arranged within the cell retainers31in a form locking manner. Each of the BMM carriers24is configured to hold a printed circuit board26of one of the BMMs21. The BMM carrier24is, in one embodiment, made of a polymer. The printed circuit board26of each of the BMMs21is arranged in one of the two pairs32a,32bof cell retainers31. In some embodiments, the BMM carrier24is held with a plastic clip system into the cell carrier30. The BMM carriers24are further described with respect toFIG.5.

The BMMs21, together with the BMM carriers24, have the same shape as the battery cells20and can be placed between a cell stack formed by the battery cells20(see, e.g.,FIGS.8and9). Accordingly, no separate part has to be produced to retain the BMMs21in the battery module12

FIG.3is a perspective view of a battery module12according to an embodiment of the present disclosure.

The battery module12includes the cell carrier30as shown inFIG.2and as explained with reference thereto. The two BMMs21are shown below the cell carrier30. The BMMs21may be mounted to the cell carrier30by inserting the BMMs21and the BMM carriers24into the cell retainers31as indicated by the dashed line.

The battery module12includes a collector circuit board22, which is configured to electrically connect each of the battery cells20with one of the BMMs21. The battery module12includes an interconnection arrangement25and a plurality of busbars41. The interconnection arrangement25includes a flat flex cable (FFC), and the collector circuit board22includes a flexible printed circuit (FPC). The interconnection arrangement25is electrically connected with the collector circuit board22, which is electrically connected to the BMMs21, as explained in more detail with reference toFIG.6. The interconnection arrangement25extends throughout the battery module12to electrically interconnect the collector circuit board22with each of the busbars41. The busbars41are configured and arranged to electrically interconnect a plurality of battery cells20with each other and with the collector circuit board22via the interconnection arrangement25. For example, each of the busbars41electrically interconnects a meandering row of battery cells20with each other. Thus, each of the plurality of battery cells20is electrically interconnected with one of the BMMs21. The BMMs21are mounted by inserting the BMMs21and the BMM carriers into the pairs32a,32bof adjacent cell retainers31that are arranged below the collector circuit board22.

In some embodiments, the battery cells20are cylindrical cells with a diameter of at least 30 mm, and in some embodiments, at least 32 mm. In some embodiments, the diameter of the cell retainer31is at least 30 mm or at least 32 mm. This allows for the battery cells20having a similar diameter to be held in the cell retainers31and provides sufficient space for the BMMs21to be arranged within the battery retainers31.

FIG.4illustrates a top view of the battery module12and the collector circuit board22according to an embodiment of the present disclosure.

The representation of the battery module12and the collector circuit board22with the interconnection arrangement25is provided to show the arrangement of the pairs32a,32bof adjacent cell retainers31in which the BMMs21are arranged. Between the two pairs32a,32bof adjacent cell retainers31, another cell retainer31is arranged. In this cell retainer31, that is, the cell retainer31which is arranged between the two pairs32a,32bof adjacent cell retainers31, an adapter23, which is shown inFIG.6and described in more detail with reference thereto, is to be retained for mounting the collector circuit board22to the battery module12.

In the illustrated embodiment, the battery module12includes two adjacently arranged cell carriers 30.1, 30.2. The cell carriers 30.1, 30.2 are stackable to be stacked to form a modular battery module12, as described with reference toFIGS.8and9. The pairs32a,32bof adjacent cell retainers31in which the BMMs21are to be arranged are in the cell carrier 30.1 as indicated schematically. The cell carrier 30.2 adjacently arranged to the cell carrier 30.1 includes only the battery cells20.

FIG.5is a perspective and semi-transparent view of a BMM carrier24for carrying a battery management module (BMM)21according to an embodiment of the present disclosure.

The BMM carrier24is configured to retain the BMM21within two adjacent cell retainers31of a cell carrier30for a battery module12. In some embodiments, the BMM carrier24includes a housing made of plastic. The housing has two cylindrical carrier sections28a,28bthat are configured to be retained in one of the cell retainers31, respectively. The carrier sections28a,28bhave a diameter that matches the diameter of the cell retainers31such that carrier sections28a,28bcan be held in a form locking manner within the cell retainers31.

The BMM21includes a printed circuit board26(indicated with a dotted line) with an electrical connector27. The printed circuit board26is retained within the BMM carrier24so that the electrical connector27remains accessible. The printed circuit board26extends through the BMM carrier24from one of the carrier sections28ato the other carrier section28b.

FIG.6is a perspective view of a BMM arrangement33according to an embodiment of the present disclosure. The BMMs arrangement33includes two BMMs21, a collector circuit board22configured to electrically connect the two BMMs21to a plurality of battery cells20, and an adapter23mounted to the collector circuit board22. The BMM arrangement33as shown inFIG.6is at least partly shown in and/or explained with reference toFIGS.1to5.

The adapter23is configured to be arranged within a cell retainer31of a cell carrier30in a form locking manner. In the illustrated embodiment, the adapter23is schematically illustrated as a cylinder. The adapter23has a diameter that matches the diameter of the cell retainers31such that the adapter23can be held in a form locking manner within the cell retainer31. The adapter23is mounted to the collector circuit board22to ensure that the collector circuit board22is held fixed in the battery module12when the adapter23is mounted to the cell retainer31. The adapter23may be hollow to retain electrical components.

The collector circuit board22has a symmetric shape, and the adapter23is mounted centrally with respect to the collector circuit board22. The collector circuit board22has two outwardly extending sections at which the electrical connectors27of the BMMs21are connectable to the collector circuit board22. The outwardly extending sections of the collector circuit board22are arranged so that the printed circuit boards26and, therefore, the BMMs21, are arrangeable in two pairs32a,32bof adjacent cell retainers31.

The collector circuit board22includes an interconnection connector29to electrically interconnect the collector circuit board22and the interconnection arrangement25as shown in, for example,FIGS.3and4and described with reference thereto. The collector circuit board22is configured to be connected to the two printed circuit boards26via the electrical connectors27.

In some embodiments, the BMM arrangement33includes two BMM carriers24to retain each of the printed circuit boards26, as explained with reference toFIG.5.

FIG.7is a perspective view of a battery pack10according to an embodiment of the present disclosure.

The battery pack10includes a plurality of battery modules12, as described with reference toFIGS.1to6. The battery pack10further includes a removable cover, which provides a removable bottom cover42for the battery modules12. Each of the BMMs21is removably arranged within two of the cell retainers31of the cell carriers30of the battery modules12.

A method for assembly of a battery module12including the battery pack10includes: providing a plurality of battery cells20, the cell carrier30, and two BMMs21; and arranging the two BMMs21within the cell retainers31of the cell carrier30. The electrical interconnection of the components is achieved by attaching (e.g., welding) the interconnection arrangement25to the busbars41of the cell stack, and connecting the interconnection arrangement25with the collector circuit board22. Subsequently, the BMMs21within the BMM carriers24are inserted from the bottom into empty battery slots, that is, empty or unoccupied cell retainers31. The electrical connectors27of the BMMs21are thereby attached to corresponding connector of collector circuit board22.

FIG.8is a perspective view of a cell carrier30and a plurality of battery cells20. The cell carrier30as shown inFIG.8can be used to assemble a battery module12according to embodiments of the present disclosure.

The cell carrier30includes two meandering ribs133a,133bthat are spaced apart from each other. In some embodiments, the cell carriers30and, thus, the meandering ribs133a,133b, are made of a polymer.

The cell carrier30includes a first plurality of cell retainers31aand a second plurality of cell retainers31b. Each of the cell retainers31a,31bis configured to hold a battery cell20in a form locking manner. In one embodiment, each of the plurality of cell retainers31a,31bincludes five cell retainers31a,31b.

The meandering ribs133a,133bdelimit (e.g., form) the cell retainers31a,31b. For example, the surface (e.g., the inner surface) of the cell retainers31a,31bis formed by the meandering ribs133a,133b. The meandering ribs133a,133bprovide (or form) the retainers31a,31bin the form cavities for accommodating battery cells20.

The first plurality of cell retainers31aof the cell carrier30is arranged between the two meandering ribs133a,133b. The two meandering ribs133a,133bare arranged and shaped so that the first plurality of cell retainers31ais meanderingly arranged between the two ribs133a,133b. The first plurality of cell retainers31ais arranged in a first meandering row.

The two meandering ribs133a,133bbasically extend (e.g., generally or primarily extend) in a principal extension plane of the respective rib133a,133b. The meandering (e.g., undulating) ribs133a,133balternatingly extend to either of the two opposite sides with respect the principal extension plane. Therein, each of the two meandering ribs133a,133bhas a width that periodically changes along the respective length of the meandering rib133a,133bto form the cell retainers31a,31bin a meandering, undulating manner.

The second plurality of cell retainers31bis arranged opposite to the first plurality of cell retainers31aand is separated therefrom by one of the at least two meandering ribs133a. For example, the second plurality of cell retainers31bis separated from the first plurality of cell retainers31aby the first meandering rib133a. Thus, the second plurality of cell retainers31bis arranged in a second meandering row that is separated from the first meandering row by the first meandering rib133a.

Each of the first and second plurality of cell retainers31a,31bis arranged in a meandering row so that a plurality of adjacently arranged rows form a hexagonal arrangement of cell retainers31a,31b, which is described in more detail with reference toFIG.10. Thus, the cell retainers31a,31bare arranged in a hexagonal pattern.

In some embodiments, each of the cell retainers31a,31bis cylindrically shaped and includes a cylindrical through-hole or a section thereof. For example, each of the first plurality of cell retainers31ahas a through-hole, and each of the second plurality of cell retainers31bis formed by a cylinder segment and has a corresponding opening in form of a section of a through-hole. Each of the cell retainers31a,31bincludes a projection34to prevent the battery cells20and/or the BMM21held therein from moving, for example, from moving along their cylindrical axes. Each of the projections34is ring-shaped to effectively reduce the diameter of the respective through-hole and/or of the cell retainers31a,31b. For example, each of the projections34of the first plurality of cell retainers31ais O-ring-shaped, and each of the projections34of the second plurality of cell retainers31bis shaped as a segment of an O-ring.

The first plurality of cell retainers31aincludes a plurality of connected cell retainers31a. For example, the cell carrier30is shaped so that each of the first plurality of cell retainers31ais shaped as a cylinder segment, and a circumferential section of each of the cell retainer31ais open connect adjacent cell retainers31aof the first plurality of cell retainers31ato each other. Thus, the first plurality of cell retainers31aforms a meandering row of interconnected cell retainers31a.

Similarly, the second plurality of cell retainers31bincludes a plurality of connected cell retainers31b. For example, the cell carrier30is shaped so that each of the second plurality of cell retainers31bis shaped as a cylinder segment, and a circumferential section of each of the cell retainers31bis open connect to adjacent cell retainers31bof the second plurality of cell retainers31bto each other. Thus, the second plurality of cell retainers31bforms a meandering row of interconnected cell retainers31b.

The cell carrier30is stackable so that a battery module12can be built from stacked cell carriers30.

In some embodiments, the cell carrier30includes an even number of cell retainers31a,31bwhile including an odd number of first cell retainers31aand an odd number of second cell retainers31b. In total, the cell carrier30inFIG.8includes ten cell retainers31a,31b(e.g., five first cell retainers31aand five second cell retainers31b).

Each of the battery cells20has a cylindrical shape. The shape of the battery cells20match the shape of the cell retainers31a,31bsuch that the battery cells20can be held (or fixed) by and within the cell retainers31a,31b. The battery cells20may be mounted to the cell carrier30by inserting them along their respective cylinder axis into the cell retainers31a,31b. Each of the cell retainers31a,31bincludes a projection34that is dimensioned so that the battery cells20are prevented from moving through the cell retainers31a,31b. To improve fastening of the battery cells20within the cell retainers31a,31b, the battery module12may include an adhesive. The adhesive can be applied to the surfaces that delimit the cell retainers31a,31band/or to the projections34.

FIG.9is a perspective view of a cell assembly36. The cell assembly36as shown inFIG.9can be used to assemble a battery module12.

The cell assembly36includes the cell carrier30, as shown inFIG.8and described with reference thereto, the plurality of battery cells20, and a busbar41.

The plurality of battery cells20is arranged in the cell retainers31a,31bof the cell carrier30as described with reference toFIG.8.

The plurality of battery cells20is electrically interconnected by the busbar41, which is welded to the battery cells20to electrically interconnect the battery cells20with each other.

The busbar41includes a plurality of connection members43, each of which is configured and arranged to electrically connect to a terminal of one of the battery cells20retained by the first plurality of cell retainers31a. The connection members43are arranged in a meandering row corresponding to the meandering row in which the first plurality of cell retainers31ais arranged.

The busbar41also includes a covering section44configured and arranged to connect to a plurality of battery cell casings, also called housings, of the battery cells20. The covering section44is arranged in a meandering manner to correspond to the meandering row in which the second plurality of cell retainers31bis arranged.

In the illustrated embodiment, a 5p connection is formed in which ten battery cells20are placed into the plastic cell carrier30and the busbar41is welded with its covering section44on a negative potential on the shoulder of one row (e.g., on the battery cells20retained by the second plurality of cell retainers31b) and the connection members43on the positive terminal on another row (e.g., on the battery cells20retained by the first plurality of cell retainers31a).

A plurality of cell assemblies as shown inFIG.9can be stacked together to form the battery module12as shown inFIG.3and described with reference thereto.

FIGS.10A and10Bare schematic top views of a plurality of adjacently arranged cell carriers30,30.1,30.2,30.3,30.4according to the embodiment shown inFIG.8.FIG.10illustrates the hexagonal arrangement of the first cell retainers31a,31a.1,31a.2,31a.3,31a.4and the second cell retainers31b,31b.1,31b.2,31b.3,31b.4in which battery cells20are to be retained.

For reference, the cell carrier30as illustrated inFIG.8is illustrated inFIG.10Ain a schematic top view. In this figure, the projections34of the cell carrier30are not shown for the sake of simplicity.

FIG.10Billustrates four cell carriers30.1,30.2,30.3,30.4arranged adjacent to each other. In this figure, the projections34of the cell carriers30are not shown for the sake of simplicity. For each of the cell carriers30.1,30.2,30.3,30.4, only one of the first cell retainers31a.1,31a.2,31a.3,31a.4and one of the second cell retainers31b.1,31b.2,31b.3,31b.4is indicated. To distinguish adjacently arranged cell carriers30.1,30.2,30.3,30.4from each other, the cell carriers30.1,30.2,30.3,30.4are alternatingly indicated with a solid line or with a dashed line.

For example, regarding cell carrier30.2, each of the first cell retainers31a.2is arranged in a meandering row and is indicated by a circle with a solid line and each of the second cell retainers31b.2is arranged in a meandering row and is indicated by a circle with a line which is half solid. The first cell retainers31a.2and the second cell retainers31b.2are separated from each other by a meandering rib133a.2. The first cell retainers31a.3and the second cell retainers31b.3of the adjacent cell carrier30.3, indicated by dashed lines, are separated from each other by a meandering rib133a.3. The second cell retainers31b.1and the first cell retainers31a.1of the adjacent cell carrier30.1, indicated by dashed lines, are separated from each other by a meandering rib133a.1. The above configuration can be repeated analogously for any of the cell carriers30.1,30.2,30.3,30.4.

For an illustrative purpose, a boundary B is indicated that represents a section of the exterior contour of the four cell carriers30.1,30.2,30.3,30.4. The cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4, which are not adjacent to the boundary B of the adjacently arranged cell carriers30.1,30.2,30.3,30.4, are arranged in a hexagonal pattern. In other words, each of the cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4that are not adjacent to the boundary B of the adjacently arranged cell carriers30.1,30.2,30.3,30.4has six adjacently arranged cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4

A hexagon H is indicated with a dash-dotted line to illustrate the hexagonal pattern in which the cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4are arranged. The hexagon H is not physically present but is indicated to illustrate the arrangement of the cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4. The hexagon H at the particularly illustrated position illustrates that the second cell retainer31b.3of the cell carrier30.3arranged in the center of the hexagon H has six neighboring cell retainers31a.2,31a.3,31b.3, including three first cell retainers31a.2of the adjacently arranged cell carrier30.2, one first cell retainer31a.3of the cell retainer30.3, and two second cell retainers31b.3of the cell retainer30.3. The above configuration and explanation can be repeated analogously for any of the cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4that are not adjacent to the boundary B of the adjacently arranged cell carriers30.1,30.2,30.3,30.4.

Thus, each of the first and second plurality of cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4, except for the cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4at the boundary B of the cell carriers30.1,30.2,30.3,30.4, is arranged in a meandering row so that a plurality of adjacently arranged rows form a hexagonal arrangement of cell retainers31a.1,31a.2,31a.3,31a.4,31b.1,31b.2,31b.3,31b.4.

Some Reference Signs