Patent Description:
Different kind of battery packs are widely used in electric vehicles, for example. There is a plurality of modular battery modules available in the market that can be used to form a desired battery pack. A structure of the battery modules may be complicated that may cause drawbacks in a manufacturing, for example. In addition, an efficient heat transfer in the battery modules of the battery pack may be challenging. The known solutions have many drawbacks especially in the above mentioned areas.

Hence, there is a need for a more sophisticated battery module that can be used to form the battery packs with a desired capacity and further alleviates the issues of the known solution.

<CIT> discloses a battery pack includes a first core pack and a second core pack each holding a plurality of unit cells. The unit cells of a first cell group or second cell group that is closest to a connector are electrically connected to the connector through a third busbar. The unit cells of the first cell group or second cell group that is most distant from the connector are electrically connected to the connector through a fourth busbar.

<CIT> discloses a battery module including a module terminal, an electrochemical cell, and a busbar electrically connecting at least a subset of the cell to the module terminal. The busbar includes an electrically conductive substrate and an insulating layer disposed between the substrate and an end of the cell. The substrate includes primary connection through holes, each primary connection through hole having a second diameter and aligned with a first end of a unique cell of the cell. The insulating layer includes a secondary connection through hole. Each secondary connection through-hole has a third diameter and is concentric with a corresponding one of the primary through-holes. The third diameter is smaller than the second diameter, and an electrical connector extends between the board and the cell terminal and provides an electrical connection between the board and the cell terminal.

<CIT> discloses a battery tray comprising a plurality of battery receptacles and arranged into receptacle rows for holding a plurality of batteries and a conductor passageway which passes through a receptacle row is disclosed. The battery receptacle comprises a first portion which is a top portion having a top end, a second portion which is a base portion having a bottom end and a peripheral portion extending between the first portion and the second portion and surrounding the receptacle axis to define a battery compartment. The conductor passageway is formed on the peripheral portion and extends in a direction parallel to the row axis and offset therefrom.

The present invention is defined by the subject matter of the independent claims.

The embodiments and features, if any, described in this specification that do not fall under the scope of the independent claim are to be interpreted as examples useful for understanding various embodiments of the invention.

All combinations of the embodiments are considered possible if their combination does not lead to structural or logical contradiction.

A plurality of battery cells may be used to form a battery module, and a plurality of the battery modules may be used to form a battery pack with a desired capacity. A structure of battery modules having a plurality of battery cells is often complex. The complexity may cause challenges in a manufacturing of the battery modules. In addition, the cells need an efficient heat transfer system that may cause more issues to the structure. The solution according to the invention provides the battery module and the battery pack having a simple structure with the efficient heat transfer.

According to an aspect, there is provided a battery module comprising a plurality of battery cells having two opposite ends, a first busbar assembly comprising at least a first busbar coupled with a first busbar frame, and a second busbar assembly comprising at least a second busbar coupled with a second busbar frame configured to couple the battery cells electrically to form desired battery configuration, and a main frame having side walls forming a housing and a middle wall inside the housing dividing an inner space of the housing in a vertical direction to a first and a second sections, wherein the middle wall comprises a plurality of holes for receiving the battery cells such that one end of battery cell is in the first section and another end in the second section, and wherein the middle wall further comprises a plurality fastening members for fastening the first busbar assembly to the middle wall in the first section and the second busbar assembly to the middle wall in the second section such that the battery cells are arranged between the first and the second busbar assemblies which couple the battery cells to the battery module.

The term "vertical direction" refers to a height H of the module, the term "width direction" refers to a width W of the module and the term "longitudinal direction" refers to a length L of the module. These directions are illustrated by arrows in <FIG>.

Referring to <FIG>, which illustrates the whole battery module, and <FIG>, which illustrates one end of the battery module in detail. In an embodiment, the battery module <NUM>, comprises a plurality of the battery cells <NUM> having two opposite ends. A shape of the battery cell may be cylindrical, for example. Two opposite ends may refer to terminals of the battery. One end may comprise a positive terminal and another one a negative terminal, wherein the terminals are on the opposite ends of the cylindrical battery cell. The cells may be arranged into the module such that their longitudinal axis is substantially parallel to the vertical direction H of the module.

Still referring to <FIG> and <FIG>, in an embodiment, the battery module <NUM> further comprises the first busbar assembly 104A comprising at least the first busbar 106A coupled with the first busbar frame 108A, and the second busbar assembly 104B comprising at least the second busbar 106B coupled with the second busbar frame 108B. The first and the second busbar assemblies 104A - B are configured to electrically couple the battery cells <NUM> together to form the desired battery configuration having the desired capacity. The busbars may be plate-like parts made of conductive material which, in an installed state, are in contact with the terminals of the battery cells. The first busbar assembly may be used to electrically couple the desired terminals of the battery cells together in the first end of the cells, and the second busbar may be used to electrically couple the desired terminals in the second end of the cells to form the desired battery capacity. The busbar frames may not be conductive and may be made of a plastic, for example.

Referring now to <FIG> and <FIG>, in an embodiment, the module further comprises the main frame <NUM> having the side walls 112A - D forming the housing. The side walls cover the main frame from sides such that the side walls form uniform entity around the frame. The frame (housing) may be open from a top side TS and from a bottom side BS.

In an embodiment, the main frame <NUM> further comprises the middle wall <NUM> inside the housing dividing an inner space of the housing in the vertical direction H to the first and the second sections 116A - B. The first section 116A may be an upper portion of the inner space which is above the middle wall <NUM>, and the second section 116B may be a lower portion of the inner space which is below the middle wall as illustrated in <FIG> is a cross section of the frame in the longitudinal direction. The first and the second sections of the frame may be substantially similar having the same features. The middle wall <NUM> comprises a plurality of holes <NUM> for receiving the battery cells <NUM>. The middle wall may be a thin plate-like structure which supports the cells, arranged into the holes, substantially from the middle of the cells in the vertical direction. In other words, the middle wall may be substantially in the middle of the cell in the vertical direction, then the distance between the middle wall and both end of the cell is substantially the same. The middle wall may be thin such that it covers the battery cells as less as possible when the cells are placed into the holes. In other words, it covers the battery cells from the middle such that a major part of the battery cells is not covered.

Referring now to <FIG> which is a cross section of the battery module <NUM> in the longitudinal direction L. Features that have cross hatching are sectioned. For example, every other battery cell <NUM>, which is visible in <FIG>, is sectioned and every other battery cell <NUM> is not. In an embodiment, the cells <NUM> may be arranged such that one end of battery cell is in the first section of the frame 116A and another end of the battery cell is in the second section 116B. As described above, the sections 116A, 116B are separated by the middle wall <NUM> having a plurality of holes <NUM> for the battery cells <NUM>. It is good to understand that all the cells may not be arranged the same way. Different kind of serial and/or parallel wirings may be implemented with the battery cells to get the desired battery configuration and capacity. For example, two thirds of the cells may be arranged such that the end of the cell having the positive terminal is in the first section of the frame, and one third of the cells may be arranged such that the end of the cell having the positive terminal is in the second section of the frame. Then one third of the cells may be arranged the other way around than two thirds of the cells from the terminals point of view in the one frame section. This was just one example, and as described the cells may be arranged a plurality of ways to get the desired configuration. In addition, structures and/or amount of the busbars in the first and the second busbar assembly may vary according to the desired battery configuration. To form the different battery configuration with the different capacity from the battery cells is well known and can be seen as obvious to the skilled person and hence, it is not described with greater details in this application.

Referring now to <FIG>, <FIG> and <FIG>, in an embodiment, the middle wall further comprises, on both sides, a plurality fastening members <NUM> for fastening the first busbar assembly 104A to the main frame110 in the first section 116A, and the second busbar assembly 104B to the main frame <NUM> in the second section 116B such that the battery cells <NUM> are arranged between the first and the second busbar assemblies 104A - B, wherein the busbar assemblies 104A - B couple the battery cells <NUM> to the battery module <NUM>. In other words, the cells are arranged between the first and the second busbar assembly, wherein the first busbar assembly is coupled with the middle wall in the first section of the frame, and respectively the second busbar assembly is coupled with the middle wall in the second section of the frame.

In an embodiment, the busbar assemblies may be coupled only with the middle wall via fastening members, not with the other parts of the frame like side walls, for example. Then all the fastening members may be placed in the middle wall. In another embodiment, a part of the fastening members of the middle wall may be in connection with the side walls. In other words, some of the fastening members may be in the middle wall and further in connection with the side walls.

Conventionally the battery modules comprise one or more separate support parts for holding the cells in the desired arrangement, and to couple the cells into the frame. This may make the known battery module structures complex. In the invention, the middle wall that acts as a support part, is integrated with the frame. Hence, the battery module assembly comprises only the main frame that forms the side walls around the battery cells, and further provides the middle wall having the holes for supporting and holding the battery cells in the module with the busbar assemblies. This is very beneficial especially from a manufacturing point of view since the main frame having the middle wall can be made of the one part by an injection moulding, for example. In addition, when the middle wall is integrated in the frame, the assembling of the battery module is simpler and easier since there is less parts in the assembly.

In an embodiment, the fastening members in the middle wall comprise a protrusion like a screw boss (screw tower). The protrusion may comprise a hole configured to receive a screw used for fastening the busbar assemblies in the middle wall (main frame).

Referring now to <FIG>, the battery module <NUM> comprises a first conduit 122A in vicinity of a first end of the frame <NUM> for leading a heat transfer substance into the module, and a second conduit 122B in vicinity of a second end of the frame <NUM> for leading the heat transfer substance out of the battery module. The battery pack made of the battery modules may comprise a heat transferring system used for cooling and/or heating the battery cells. For example, the system may be used for transferring heat produced by the battery cells, in other words cooling the cells. It is also possible to use the system for transferring heat to the cells in cold conditions, for example. The heat transfer substance used for transferring heat. It may be liquid and/or gas, for example.

In an embodiment, the first conduit 122A comprises one or more inlets 124A for leading the heat transfer substance into the first and/or the second section of the frame 116A - B, and the second conduit 122B comprises one or more outlets 124B for leading the heat transfer substance out of the first and/or second section of the frame 116A - B.

In an embodiment, the battery cells in the module may be divided in three groups in the longitudinal direction, and hence the holes in the middle wall may have the same grouping. Referring now to <FIG>, in an embodiment the holes <NUM> in the middle wall <NUM> are in the three groups G1 - G3. The fastening members <NUM>, like the screw bosses, may be on the edge of each group and/or between them. In an embodiment, the screw bosses of the group G1 and/or the group G3 that are closest to the side wall may be integrated with the side wall.

In an embodiment, the first conduit 122A comprises three inlets 124A in the first and the second section configured to lead the heat transfer substance to each of the groups G1 - G3. In other words, the inlets are placed in the conduit such that there is the inlet for each group of the cells on both sections of the main frame. Respectively the second conduit 122A comprises three outlets 124B in the first and the second section for leading the heat transfer substance out of each group G1 - G3. Hence, the outlets are also placed in the conduit such that there is the outlet for each group of the cells on both sections of the frame. It is still good to understand that the heat transfer substance may also move between the groups.

In an embodiment, the holes (and the cells) may also be divided differently than presented above (three groups). There may be more or less than three groups, depending on the capacity of the module. Then also the amount of the inlets and outlets in the conduits may be adjusted to be accordant with the amount the of the groups in both sections of the frame.

Referring now to <FIG> which illustrates the busbar frame according to an embodiment. The first and/or the second busbar frame 108A - B comprises at least one groove <NUM> placed in the frame such that it is in vicinity of one or more the ends of the battery cells <NUM> when the busbar assembly 104A - B is installed into the module <NUM> having the battery cells <NUM>. The groove is configured to enable access of the heat transfer substance to the ends of the battery cells. The busbar frame may a plate-like part having a large top and bottom surface. The bottom surface may refer to a surface which is against the end of battery cells in the installed state. The at least one groove may extend in the bottom surface though the busbar frame in a longitudinal direction from a first end FE and to a second end SE of the frame.

The busbar frame 108A - B may comprise cavities <NUM> configured to receive the end of the battery cells. The cavity may block, at least partly, the flow of the heat transfer substance to the end of the cell. Still, it is important from the cooling point of view that the heat transfer substance is in contact with the ends of the cells since the ends generate the most heat. The groove opens the structure of the busbar frame such that the heat transfer substance can be in connection with the end of the battery cell placed in the cavity. The groove(s) <NUM> may create a channel network <NUM> extending thought the busbar frame 108A - B such that the heat transfer substance can flow through the cavities <NUM> and be in contact with the ends of the cells <NUM>. The channel network may connect all the cavities.

As described above, the holes (and the battery cells) may be divided into the three groups G1 - G3 in the middle wall <NUM>, for example. The busbar frame 108A - B may comprise the above mentioned channel network 142A - C, created by the groove(s) <NUM>, for each of these groups G1 - G3 as illustrated in <FIG>. The first channel network 142A may be for the first group G1, the second channel network 142B may be for the second group G2, and the third channel network 142C may be for the third group G3, for example. The different channel networks 142A - C may not be coupled together by the groove(s) <NUM>. As described above, there may be less or more than three groups and the amount of the channel networks may be adjusted with the mount of the groups.

The channel network of each group may comprise a plurality of openings in the first end of the first and second busbar frame enabling progress of the heat transfer substance into the channel network (grooves) and a plurality of the opening in the second end enabling progress of the heat transfer substance out of the channel network. In <FIG>, there is illustrated four openings on both ends of the busbar frame per group.

In an embodiment, illustrated for example in <FIG> and <FIG>, the first busbar frame 108A is arranged between the first busbar 106A and the battery cells <NUM>, and the second busbar frame 108B is arranged between the second busbar 106B and the battery cells <NUM>. As discussed above, the one of the busbar assemblies, having the busbar and the busbar frame, is in the first section of the frame, and another one busbar assembly, having the busbar and the busbar frame, is in the second section of the frame.

Referring to <FIG>, in an embodiment there is a gap between the first busbar assembly 104A and the middle wall <NUM> in the first section 116A, and between the second busbar assembly 104B and the middle wall <NUM> in the second section of the frame 116B. As described above, the middle wall is plate-like structure in the middle of the cells that holds the cells and substantially prevents a lateral movement of the cells in the module. The busbar and the busbar frame are also plate-like parts and there is the gap (space) between the busbar assemblies and the middle wall. As described, the middle wall may cover the battery cells only from the middle when arranged into the holes, and then a major part of the cells is not covered. Then the heat transfer substance can easily be in contact with the cells in the first and the second sections. The heat transfer substance is flowed in the gap in the first and the second sections such that the substance is efficiently in contact with the cells. The gap enables access of the heat transfer substance to battery cells.

In an embodiment, there is a gap between the adjacent battery cells <NUM> arranged between the first and the second busbar assemblies 104A - B. The gap between the adjacent cells enables access of the heat transfer substance to all battery cells and also enables better flow of the substance.

In an embodiment, at least part of the fastening members of the middle wall comprises at least one guiding wall configured to guide a flow of the heat transfer substance inside the battery module. This is not illustrated in Figures. As described, the fastening member may be the screw boss, and one or more adjacent screw bosses may be coupled together with the guiding wall. Referring now to <FIG>, there may be three groups of the holes G1 - G3 for the cells dividing the cells into the three groups, for example. The screw bosses that are between the groups may comprise the guiding wall separating, at least partly, the groups from each other from the heat transfer substance flowing point of view. For example, the screw bosses between the group G1 and G2 may comprise the guiding wall, and also the screw bosses between the group G2 and G3.

Referring to <FIG>, in an embodiment, a first edge of the side walls of the frame comprises a first locking element 130A and a second edge of the side walls of the frame comprises a second locking element 130B, wherein the second locking element 130B is configured to receive the first locking element 130A. The first locking element may be a protrusion and the second locking element may be a groove configured to receive the protrusion. The locking elements lock the modules together when two or more modules are stacked one on the other.

In an embodiment, the first and/or second locking element comprises a sealing element, like a gasket, for sealing the interface between the two or more modules stacked one on the other. The sealing may be configured to keep the heat transfer substance inside the module(s), for example.

In an embodiment, the middle wall is substantially in the middle of the housing (side walls) in the vertical direction. Referring to <FIG>, which is the cross section of the main frame, the middle wall <NUM> is substantially in the middle of the main frame in the vertical direction. Then a size (volume) of the first and second section of the frame are substantially the same.

In an embodiment, the side walls 112A - D comprise one or more fastening members <NUM> for coupling a plurality of the battery modules <NUM> together. The fastening members are illustrated in <FIG>, for example. The fastening member may a hole on the side walls enabling a use of separate fastening means for fastening the modules together. The fastening means may comprise a bolt and/or a threaded bar and/or a nut, for example. In another embodiment, the side walls may comprise a flange in vicinity of the first and the second edge of the side walls. The flange of the first edge of the first module is configured to be placed against the flange of the second edge of the second module. The flange may comprise one or more holes used for coupling the modules together from the flanges by a screw, for example. The holes may be aligned when the flanges are set against to each other. The flange may extend perpendicularly away from the side wall outside of the frame.

Referring to <FIG>, according to another aspect, there is provided a battery pack <NUM> comprising a plurality of the battery modules <NUM>. The battery modules may have all the features described in this application. The <FIG> illustrates the battery pack <NUM> comprising four battery modules 100A - D. This is just one example, and the number of the modules in the battery pack may vary according to the needs.

Still referring to <FIG>, in an embodiment, a plurality of the battery modules 100A - D is stacked one on the other wherein a top 100A and a bottom module 100D comprises a cover 136A - B. In an embodiment, the same cover is used in the top and the bottom modules. In another embodiment, there is a separate top cover 136A and a separate bottom cover 136B. The covers may further comprise the same locking features as the frame with or without the sealing member. The covers may further comprise one or more holes <NUM> for the fastening means configured to fasten a plurality of the battery modules and the covers together to form the desired battery pack. As wrote, the fastening members may comprise the screw and/or threaded bar with nut, for example. The holes may comprise threads.

In an embodiment, the cover 136A - B comprises an inlet connector 138A and an outlet connector 138B for leading the heat transfer substance into and/or out of the first and the second conduit 122A - B of the frame <NUM> of the battery module <NUM>. In <FIG>, the inlet and the outlet connectors are in the top cover 136A, but the connectors may also be in the bottom cover 136B. The heat transfer system may be coupled with the inlet and outlet connectors.

The battery module according to the invention provides the structure that alleviates many issues of the known solutions. The main frame of the module comprises the integrated middle wall that removes needs for separate support elements for the battery cells, hence the battery module assembly has less parts and its structure is simpler. In addition, the structure enables the efficient way to transfer heat from/to the battery cells.

Claim 1:
A battery module (<NUM>) comprising:
a plurality of battery cells (<NUM>) having two opposite ends;
a first busbar assembly (104A) comprising at least a first busbar (106A) coupled with a first busbar frame (108A), and a second busbar assembly (104B) comprising at least a second busbar (106B) coupled with a second busbar frame (108B) configured to electrically couple the battery cells (<NUM>); and
a main frame (<NUM>) having side walls (112A - D) forming a housing and a middle wall (<NUM>) inside the housing dividing an inner space of the housing in a vertical direction to a first and a second section (116A - B), wherein the middle wall (<NUM>) comprises a plurality of holes (<NUM>) for receiving the battery cells (<NUM>) such that one end of each battery cell (<NUM>) is in the first section (116A) and another end is in the second section (116B), and wherein the middle wall (<NUM>) is substantially in the middle of the battery cells (<NUM>) in the vertical direction supporting the battery cells (<NUM>) substantially from the middle, and
wherein the middle wall (<NUM>) further comprises a plurality fastening members (<NUM>) for fastening the first busbar assembly (104A) to the main frame (<NUM>) in the first section (116A) and the second busbar assembly (104B) to the main frame (<NUM>) in the second section (116B) such that the battery cells (<NUM>) are arranged between the first and the second busbar assemblies (104A - B) which couple the battery cells (<NUM>) to the battery module (<NUM>).