CN105789507A - 用于牵引电池单元阵列的保持组件 - Google Patents

用于牵引电池单元阵列的保持组件 Download PDF

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Publication number
CN105789507A
CN105789507A CN201610009077.4A CN201610009077A CN105789507A CN 105789507 A CN105789507 A CN 105789507A CN 201610009077 A CN201610009077 A CN 201610009077A CN 105789507 A CN105789507 A CN 105789507A
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band
end plate
traction battery
array
connector
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CN105789507B (zh
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白炫珉
帕特里克·丹尼尔·玛古尔
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Ford Global Technologies LLC
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Ford Global Technologies LLC
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    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
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    • B60L50/00—Electric propulsion with power supplied within the vehicle
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    • Y04S30/00—Systems supporting specific end-user applications in the sector of transportation
    • Y04S30/10—Systems supporting the interoperability of electric or hybrid vehicles
    • Y04S30/14—Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

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

本发明提供一种用于牵引电池单元阵列的保持组件。提供一种牵引电池组件。所述牵引电池组件可包括电池单元的阵列、一对端板、带以及连接件。所述一对端板中的每个可设置在所述阵列的相对的端部上并限定边缘和在所述边缘之间的接纳凹槽。所述带可具有使带能够安放在所述接纳凹槽中的尺寸并环绕所述阵列和所述端板。所述连接件可连接所述带的端部使得所述端板压紧所述电池单元。所述端板中的每个均可在所述端板的中间区域进一步限定所述接纳凹槽，使得所述带在由所述阵列限定的外表面的大致中部处环绕所述阵列。

Description

用于牵引电池单元阵列的保持组件
技术领域
本公开涉及用于在车辆中使用的高电压电池的支撑结构。
背景技术
诸如电池电动车辆(BEV)、插电式混合动力电动车辆(PHEV)、轻度混合动力电动车辆(MHEV)或者全混合动力电动车辆(FHEV)的车辆包含能量储存装置(诸如高电压(HV)电池)，以作为车辆的推进源。HV电池可包括用于协助管理车辆的性能和操作的组件和系统。HV电池还可包括电池单元端子之间电互连的一个或更多个电池单元阵列和互连汇流条。结构支撑组件可协助将HV电池的部件保持在各种构造中。HV电池和周围环境可包括用于协助管理HV电池部件、系统以及各个电池单元的温度的热管理系统。
发明内容
一种牵引电池组件包括电池单元的阵列、一对端板、带以及连接件。所述一对端板种的每个设置在所述阵列的相对的端部上，并限定边缘和在所述边缘之间延伸的接纳凹槽。所述带具有使带能够安放在所述接纳凹槽中的尺寸并环绕所述阵列和所述端板。所述连接件连接所述带的端部使得所述端板压紧所述电池单元。所述带的两个端部的每个可限定套环，并且，所述连接件可包括钩环。所述钩环还可包括具有两末端的主体和闸，所述主体被构造穿过两个套环而延伸至两末端，所述闸枢转地固定到所述两末端中的一个。所述闸可被构造为接合所述两末端中的另一个。所述连接件可以是由铝合金或者是包覆有热塑性材料的铝芯制成的。所述带可以是非导电材料的以电隔离所述电池单元。所述接纳凹槽可具有容纳提升工具的至少一部分的尺寸。所述带可以是由聚酯长丝纱线织成的单个部件。所述端板中的每个均可在所述端板的中间区域进一步限定所述接纳凹槽，使得所述带在由所述阵列限定的外表面的大致中部处环绕所述阵列。所述带可以是由具有超过所述电池单元的预定膨胀载荷的拉伸载荷能力的材料制成的。所述连接件和所述带的端部可被彼此布置为使得当相对的压紧载荷施加到所述端板时所述连接件和所述带的端部自接合并向所述带施加张力。
一种电气化车辆，包括：电机、电池单元的阵列和电池保持组件，所述电池保持组件包括带、一对端板和连接件。所述电池单元的阵列被构造为向所述电机提供电力。所述带具有第一端部和第二端部。所述一对端板中的每个设置在所述阵列的相对的端部上。每个端板限定接纳凹槽以接纳所述带的一部分并定向所述部分使得所述带在所述电池单元的中部处环绕所述阵列和所述端板。所述连接件使所述第一端部和所述第二端部固定到彼此使得所述电池保持组件向所述电池单元和所述端板施加压紧力。所述连接件、第一端部以及第二端部可被彼此布置为使得当相对的压紧载荷施加到所述端板时所述连接件、第一端部和第二端部自接合并向所述带施加张力。第一端部和第二端部中的至少一个可包括通过注射成型、结构反应注射成型或嵌入成型而包覆有塑性树脂的连接部。所述接纳凹槽可具有能够容纳提升工具的至少一部分的尺寸。所述带的端部中的每个可限定套环。所述连接件可包括钩环，所述钩环包括具有两末端的主体和闸，所述主体被构造为穿过两个套环而延伸至两末端，所述闸枢转地固定到所述两末端中的一个并被构造为接合所述两末端中的另一个。
一种用于车辆牵引电池的保持组件，所述保持组件包括第一端板、第二端板、第一对相对的带和第二对相对的带。所述第一端板和第二端板是分隔开的，并且每个端板在端板表面的两侧上限定边缘。第一对相对的带中的每个限定末端并且从所述第一端板和第二端板朝向彼此延伸。第二对相对的带中的每个限定末端并且从所述第一端板和第二端板朝向彼此延伸。所述末端包括公连接部或母连接部，所述公连接部或母连接部被构造为当压紧力施加到所述端板时与所述一对连接部中的另一连接部自接合。所述端板还包括与端板形成一体的母连接部，其中，所述两对相对的带被构造为在所述带的与所述末端相对的部分处与所述母连接部配合。所述两对相对的带可与所述端板形成一体。所述端板中的每个还可包括设置在其中的陶瓷的或热固性嵌入件，以增强所述端板的被构造为承受来自第一对相对的带和第二对相对的带的载荷的部分。所述两对相对的带是由非导电材料制成的，以电隔离所述电池单元。所述第一对相对的带和第二对相对的带可以是棒球帽带。所述公连接部可以是钩部，所述母连接部可包括孔，所述孔具有接纳所述钩部的尺寸。
附图说明
图1示出电池电动车辆的示意图。
图2是牵引电池的一部分的示例的透视图。
图3A是图2的牵引电池的电池单元阵列的示例的透视图。
图3B是图2的牵引电池的一部分的端板的示例的透视图。
图3C是图2的牵引电池的一部分的俯视图。
图4是用于保持组件的连接件(attachmentfitting)的透视图。
图5A是端板和保持组件的示例的透视图。
图5B是图5A的端板和保持组件的透视图，示出了保持带彼此接合并将电池单元阵列保持在它们之间。
图6是图5A的端板中的一个的俯视截面图，示出了增强嵌入件。
图7A是用于牵引电池的保持组件的连接件的示例的透视图。
图7B是图7A的连接件的侧视截面图。
图8是用于牵引电池的保持组件的连接件的另一示例的透视图。
图9是用于牵引电池的压紧操作的一部分的示例的透视图。
图10A和10B是用于牵引电池的提升操作的部分的示例的透视图。
具体实施方式
在此描述本公开的实施例。然而，应理解的是，公开的实施例仅为示例并且其它实施例可以采用多种和替代的形式。附图不一定按比例绘制；可夸大或最小化一些特征以示出特定部件的细节。因此，在此所公开的具体结构和功能细节不应被解释为限制，而仅作为用于教导本领域技术人员以多种形式使用本公开的实施例的代表性基础。如本领域普通技术人员将理解的，参照任一附图示出和描述的各种特征可与在一个或更多个其它附图中示出的特征相组合，以产生未明显示出或描述的实施例。示出的特征的组合为典型应用提供代表性实施例。然而，对于特定应用或实施方式，可期望与本公开的教导一致的特征的各种组合和变型。
图1示出了插电式混合动力电动车辆(PHEV)的示例的示意图。插电式混合动力电动车辆12可包括机械地连接到混合动力传动装置16的一个或更多个电机14。电机14能够作为马达或发电机运转。此外，混合动力传动装置16机械地连接到发动机18。混合动力传动装置16还机械地连接到驱动轴20，驱动轴20机械地连接到车轮22。当发动机18开启或关闭时，电机14可提供推进和减速能力。电机14还用作发电机，并且能够通过回收在摩擦制动系统中通常以热量形式损失的能量来提供燃料经济效益。由于混合动力电动车辆12可在特定条件下以电动模式或混合动力模式运转以降低车辆12的综合油耗，因此电机14还可提供降低的污染排放。
牵引电池或电池包24储存并提供能够被电机14使用的能量。通常，牵引电池24从牵引电池24中的一个或更多个电池单元阵列(有时称为电池单元堆)提供高电压DC输出。电池单元阵列可包括一个或更多个电池单元。牵引电池24通过一个或更多个接触器(未示出)电连接到一个或更多个电力电子模块26。所述一个或更多个接触器在断开时将牵引电池24与其它部件隔离，并在闭合时将牵引电池24连接到其它部件。电力电子模块26还电连接到电机14，并在牵引电池24和电机14之间提供双向传输电能的能力。例如，典型的牵引电池24可提供DC电压，而电机14可能需要三相AC电压来运转。电力电子模块26可将DC电压转换成电机14所需的三相AC电压。在再生模式下，电力电子模块26可将来自用作发电机的电机14的三相AC电压转换成牵引电池24所需的DC电压。在此的描述同样适用于纯电动车辆。对于纯电动车辆，混合动力传动装置16可以是连接到电机14的齿轮箱并且可不存在发动机18。
牵引电池24除了提供用于推进的能量之外，还可为其他车辆电气系统提供能量。典型的系统可包括DC/DC转换器模块28，DC/DC转换器模块28将牵引电池24的高电压DC输出转换成与其他车辆负载兼容的低电压DC供应。其他高电压负载(诸如，压缩机和电加热器)可直接地连接到高电压而不使用DC/DC转换器模块28。在典型的车辆中，低电压系统电连接到辅助电池30(例如，12V电池)。
电池能量控制模块(BECM)33可与牵引电池24通信。BECM33可用作牵引电池24的控制器，并且还可包括管理各个电池单元的温度和荷电状态的电子监控系统。牵引电池24可具有温度传感器31，诸如热敏电阻或其它温度计量器。温度传感器31可与BECM33通信，以提供关于牵引电池24的温度数据。温度传感器31还可位于牵引电池24中的电池单元上或者在牵引电池24中的电池单元附近。还预期不止一个温度传感器31可用于监控电池单元的温度。
车辆12可以是(例如)电动车辆(诸如，PHEV、FHEV、MHEV或BEV)，在车辆中牵引电池24可通过外部电源36进行再充电。外部电源36可连接至电源插座。外部电源36可以电连接到电动车辆供电设备(EVSE)38。EVSE38可提供用于调节和管理电源36和车辆12之间的电能传输的电路和控制。外部电源36可向EVSE38提供DC电力或AC电力。EVSE38可具有用于插入到车辆12的充电端口34的充电连接器40。充电端口34可以是被配置为将电力从EVSE38传输到车辆12的任何类型的端口。充电端口34可以电连接到充电器或车载电力转换模块32。电力转换模块32可以调节从EVSE38供应的电力，以向牵引电池24提供合适的电压水平和电流水平。电力转换模块32可与EVSE38配合，以协调向车辆12的电力传送。EVSE连接器40可具有与充电端口34对应的凹入匹配的插脚。
所讨论的多个不件可具有一个或更多个关联的控制器，以控制并监控部件的运转。控制器可经由串行总线(例如，控制器局域网(CAN))或经由离散导体进行通信。
电池单元(诸如，棱柱型电池单元)可包括将储存的化学能转换为电能的电化学电池单元。棱柱型电池单元可包括壳体、正极(阴极)和负极(阳极)。电解质可允许离子在放电期间在阳极和阴极之间运动，然后在再充电期间返回。端子可允许电流从电池单元流出以被车辆使用。当多个电池单元按照阵列定向时，每个电池单元的端子可与彼此相邻的相反的端子(正和负)对准，且汇流条可协助促进多个电池单元之间的串联连接。电池单元还可被并联布置，使得相似的端子(正和正或者负和负)彼此相邻。例如，两个电池单元可被布置为正极端子彼此相邻，接下来两个电池单元可被布置为负极端子彼此相邻。在这个示例中，汇流条可接触全部四个电池单元的端子。可利用液体热管理系统、空气热管理系统或现有技术中已知的其它方法对牵引电池24加热和/或冷却。
图2示出牵引电池(在此主要指牵引电池100)的示例的一部分。预期牵引电池100可以包括图2中未示出的其它部件。牵引电池100可包括电池单元阵列104和保持组件。电池单元阵列104可包括多个电池单元106并且可限定如图3A中所示的外表面108。在一个示例中，保持组件可包括一对端板110、保持带112和连接件114。如图3B中进一步所示的，每个端板110可限定竖边缘120和在竖边缘120之间横向延伸的接纳凹槽124。预期接纳凹槽124的构造的其它示例是可用的。例如，端板110可限定竖边缘120的局部切口(未示出)。作为另一个示例，端板110可限定横跨在竖边缘120之间的横向凸起(未示出)以限定用于容纳保持带112的凹槽。保持带112可具有能够安放在接纳凹槽124中的尺寸并且可限定第一端部130和第二端部132。保持带112和接纳凹槽124可彼此布置为使得保持带112在电池单元阵列104的一部分(电池单元106的高度的大致中点)处环绕电池单元阵列104和端板110。
连接件114可使第一端部130和第二端部132彼此连接，使得将压紧力施加到电池单元阵列104，如由图3C中示出的力箭头140所示。所述力可以是均匀分布的力、非均匀分布的力或是局部集中力，如由力箭头140所示的。例如，在电池单元阵列(诸如，电池单元阵列104)的组装过程中，首先电池单元106可在电池单元106之间堆叠有非导电的间隔件。压紧和捆扎电池单元106可有助于管理由于电池单元106的变化荷电状态、温度和寿命而可能产生的电池单元106的鼓胀。另外，压紧电池单元106可提供电池单元106的紧凑型个体以简化安装、运输和装卸。
预期保持带112可具有各种结构组成。例如，保持带112可以是通过将聚酯长丝纱线织成单个带而制成的网状带，类似于安全带的组成。连接件114可具有用于促进第一端部130和第二端部132的连接的各种设计。例如，连接件114可包括固定到第一端部130和第二端部132的可连接的公接合部和母接合部，类似于安全带扣的那种连接。在如图4中所示的另一示例中，连接件114可以是钩环，所述钩环包括可延伸通过第一端部130和第二端部132的套环的主体136。闸(gate)138可枢转地固定到主体136并被构造为旋转并接合主体136的鼻部139以防止保持带112失去张力。如果(例如)可通过与连接件114相邻的其它部件的方式获得电池单元阵列104的电绝缘，则连接件114可以是由铝合金制成的。连接件114可被构造为开闭多次。还预期连接件114的其它示例可以是永久闭合的。或者，如果(例如)连接件114要求是非导电的，则连接件114可以是由包覆有热塑性塑料的铝芯制成的。可与铝芯一起使用的的热塑性塑料的示例包括聚醚酮、聚醚砜、聚酰胺或聚亚苯基(polyphenylene)。
图5A和图5B示出了用于协助保持电池单元阵列(诸如电池单元阵列104)的保持组件的另一示例。这个示例中的保持组件可包括一对端板200。端板200可彼此分隔开以适于在端板200之间定位电池单元阵列104。端板200可限定竖边缘204。一个或更多个保持带210可从竖边缘204延伸。一个或更多个保持带210可包括用于连接相对的保持带210的连接件的另一示例(诸如公连接部214和母连接部216的组合)。如图5A和图5B中所示，公连接部214和母连接部216可包括用于促进相对的保持带210的机械连接的一系列互锁齿，类似于拉链带。在特定情况下，增加互锁齿的数量可增加保持组件的互锁强度，并通过将总拉伸载荷分配在全部的齿上来减小每个单独的齿上的剪切载荷，从而允许保持组件能够承受较大的电池单元106鼓胀力。保持带210可以是对称的，使得有两个端板200压紧阵列；然而，这两个端板200是使用两次的相同部件。根据封装约束和相邻的车辆部件，公连接部214和母连接部216可沿着电池单元阵列104的长度而布置在不同位置。
虽然在图5A和图5B中保持带210示出为与端板200形成一体，但预期保持带210可以是通过各种类型的连接部(未示出)固定到端板200的独立个体。例如，端板200可包括成型在端板200的拐角内的公连接部。具有两个母端部的保持带可在端板200之间延伸并与每个端板200的公连接部配合。这个示例可为在具有不同长度的多个电池单元阵列的系统中使用共同的端板提供条件。由于独立的端板和保持带可支持更大的运输密度，因此从运输角度来看也可以获得益处。在另一个示例中，端板200中的一个可包括成型在端板200的拐角内的母连接部，端板200中的另一个可包括从其延伸的保持带。
多种制造选择和材料选择可适用于保持带210。例如，可使用结构反应注射成型(SRIM)来制备干燥、连续的纤维网或纤维毡(或预制件)，其可被放置在一个闭式模具中，然后可在模具中注射两种反应液体。然后，可将预制件浸渍到树脂基体中。用于SRIM的常见树脂包括聚氨酯、丙烯酰胺和二环戊二烯。在另一示例中，各种热塑性基体可以与碎玻璃纤维或碳纤维注射成型。适合的热塑性基体的示例包括聚丙烯、聚乙烯、聚对苯二甲酸丁酯、聚酰胺6、聚酰胺6-6、聚醚酰亚胺和聚亚苯基。与SRIM关联的连续的、预定的纤维取向相比，在注射成型工艺期间，这个示例中的纤维可沿着塑料流动的方向取向。
图6示出了强刚性、陶瓷或热固性材料嵌入件230的示例，所述嵌入件230可被成型到具有热塑性基体的端板200中以协助抵制高负载的玻璃纤维毡或带234拉穿较软的热塑性基体，并将总载荷传递到由端板200保持的电池单元。
虽然图5A和图5B示出了从每个端板200延伸的保持带210，但预期其它适合的带结构是可用的。例如，图7A和图7B示出了包括公带250a和母带250b的一对保持带250。这对保持带250在此还可以是指棒球帽带。保持带250可以是在连续纤维毡或单向带255中由第一悬置连接部254制成的预制件，在一个示例中，所述第一悬置连接部254可以是金属柱。然后，如图7B中的保持带250的截面图所示，塑性树脂258可通过注射成型、SRIM或嵌入成型来浸渍所述预制件。作为连接件的另一示例，母带250b可限定孔252以接纳从公带250a伸出的连接部254，从而促进保持带250的彼此接合。夹子256可在孔252和连接部254的任一侧上固定到保持带250以协助防止脱离。包覆成型可用于这个示例中的制造。利用包覆成型，预制件(连接部254和连续的纤维垫或单向带255)可被放置在模具中，随后由塑性树脂258包覆成型。
图8示出了包括公带280a和母带280b的一对保持带280。在连接件的又一示例中，公带280a可包括用于插入到由母带280b限定的槽284中的钩282。所述钩282可悬置在成型在整个公带280a中的纤维增强部中。为了制造，首先可制备纤维预制件，诸如由橡胶软管(未示出)中的纤维增强部或多股纤维线(未示出)组成的斜纹层。混合并挤压的预裁切橡胶带可通过压延工艺添加到预制件上，然后在闭式模具中固化。
图9至图10B示出了使用端板110、保持带112、连接件114和电池单元阵列104的压紧操作和提升操作的示例。预期还可以以图9至图10B中示出的方式压紧和提升上述的保持带、连接件和端板的其它示例。可因通过一对压紧工具300或通过在电池单元阵列104受到压紧时执行的二次连接操作(根据保持连接部的种类)所施加的压紧载荷而发生保持带112的第一端部130和第二端部132的接合或连接。一旦保持带112接合，一个或更多个提升工具306可通过接纳凹槽124而抓住端板110，并随后将牵引电池100移动到期望的位置。通过使用在此描述的连接件和带的示例中的一个，当力施加到端板时(诸如，当压紧工具300对端板110施加压紧载荷时)，其公连接部和母连接部可自接合。
虽然上面描述了多个实施例，但是并不意味着这些实施例描述了权利要求所囊括的所有可能的形式。说明书中使用的词语为描述性词语而非限制词语，并且应理解的是，在不脱离本公开的精神和范围的情况下，可作出各种改变。如之前所述的，可组合各个实施例的特征以形成本公开的可能未被明确描述或示出的进一步的实施例。虽然各种实施例可描述为在一个或更多个期望的特性方面提供优点或比其他实施例或现有技术更优，但是本领域的普通技术人员应该认识到，一个或更多个特征或特性可被折中，以实现期望的整体系统属性，这取决于具体的应用或实施方式。这些属性可包括但不限于：可销售性、外观、稳定性、鲁棒性、顾客可接受性、可靠性、准确性等。因此，被描述为在一个或更多个特性方面不如其他实施例或现有技术的实施方式的实施例并不在本公开的范围之外，并且可以期望用于特定应用。

Claims (8)

1.一种牵引电池组件，包括：
电池单元的阵列；
一对端板，每个端板设置在所述阵列的相对的端部上并限定边缘和在所述边缘之间延伸的接纳凹槽；
带，具有使带能够安放在所述接纳凹槽中的尺寸，并环绕所述阵列和所述端板；
连接件，连接所述带的端部使得所述端板压紧所述电池单元。
2.根据权利要求1所述的牵引电池组件，其中，所述带的端部中的每个限定套环，其中，所述连接件包括钩环，所述钩环包括具有两末端的主体和闸，所述主体被构造为穿过两个套环而延伸至两末端，所述闸枢转地固定到所述两末端中的一个并被构造为接合所述两末端中的另一个。
3.根据权利要求2所述的牵引电池组件，其中，所述连接件是由铝合金或者包覆有热塑性材料的铝芯制成的。
4.根据权利要求1所述的牵引电池组件，其中，所述带是非导电材料的，以电隔离所述电池单元。
5.根据权利要求1所述的牵引电池组件，其中，所述接纳凹槽具有容纳提升工具的至少一部分的尺寸。
6.根据权利要求1所述的牵引电池组件，其中，所述带是由聚酯长丝纱线织成的单个部件。
7.根据权利要求1所述的牵引电池组件，其中，所述端板中的每个均在所述端板的中间区域进一步限定所述接纳凹槽，使得所述带在由所述阵列限定的外表面的大致中部处环绕所述阵列，其中，所述带是由具有超过所述电池单元的预定膨胀载荷的拉伸载荷能力的材料制成的。
8.根据权利要求1所述的牵引电池组件，其中，所述连接件和所述带的端部被彼此布置为使得当相对的压紧载荷施加到所述端板时所述连接件和所述带的端部自接合并向所述带施加张力。
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