CN116845320A - Battery cell grouping solution for traction battery packs - Google Patents

Battery cell grouping solution for traction battery packs Download PDF

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Publication number
CN116845320A
CN116845320A CN202310243503.0A CN202310243503A CN116845320A CN 116845320 A CN116845320 A CN 116845320A CN 202310243503 A CN202310243503 A CN 202310243503A CN 116845320 A CN116845320 A CN 116845320A
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CN
China
Prior art keywords
cell
battery
battery cells
assembly
battery pack
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.)
Pending
Application number
CN202310243503.0A
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Chinese (zh)
Inventor
帕特里克·丹尼尔·马圭尔
张哲春
M·杜加斯
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.)
Ford Global Technologies LLC
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Ford Global Technologies LLC
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
Priority claimed from US17/894,514 external-priority patent/US20230327249A1/en
Application filed by Ford Global Technologies LLC filed Critical Ford Global Technologies LLC
Publication of CN116845320A publication Critical patent/CN116845320A/en
Pending legal-status Critical Current

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Classifications

    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—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
    • H01M50/264—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks for cells or batteries, e.g. straps, tie rods or peripheral frames
    • 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
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

The present disclosure provides a "battery cell grouping solution for traction battery packs". Battery cell grouping solutions for assembling traction battery packs including a cell-pack battery system are disclosed. The cell grouping assembly may be used to establish a common datum reference plane with respect to a plurality of battery cell groups. An exemplary assembly method may include positioning the battery cell stack relative to the cell grouping assembly and then applying a compressive force to the battery cell stack to provide the cell-battery pack system. The grouped stacks may then be positioned to a housing tray of the traction battery pack.

Description

Battery cell grouping solution for traction battery packs
Cross Reference to Related Applications
This disclosure claims priority from U.S. provisional application No. 63/322,766, filed on day 23 of 3.2022, which is incorporated herein by reference.
Technical Field
The present disclosure relates generally to traction battery packs, and more particularly to systems and methods for assembling traction battery packs including cell-pack battery systems.
Background
Motorized vehicles differ from conventional motor vehicles in that motorized vehicles include a drive train having one or more electric machines. Alternatively or in addition to the internal combustion engine, the electric machine may drive an electrically powered vehicle. The traction battery pack may power the motor and other electrical loads of the vehicle.
Conventional traction battery packs include a battery cell stack called a battery array. The battery array includes various array support structures (e.g., array frames, spacers, rails, walls, end plates, ties, etc.) arranged to group and support battery cells in a plurality of individual cells within a traction battery pack housing.
Disclosure of Invention
A traction battery pack according to an exemplary aspect of the present disclosure includes, among other things: a housing assembly; and a cell-to-cell battery system housed within the housing assembly and including a first cell stack, a second cell stack, and a cell grouping assembly. The cell grouping assembly establishes a common datum reference plane for aligning a first set of battery cells of the first cell stack and a second set of battery cells of the second cell stack relative to the cell grouping assembly.
In another non-limiting embodiment of the aforementioned traction battery pack, the first cell stack establishes a first cell row of a cell matrix of the cell-battery pack battery system, and the second cell stack establishes a second cell row of the cell matrix.
In another non-limiting embodiment of any of the foregoing traction battery packs, the housing tray of the housing assembly provides a cell compression opening for compressing the cell matrix.
In another non-limiting embodiment of any of the foregoing traction battery packs, the cell grouping assembly comprises: a first end wall; a second end wall; and a cross member extending between the first end wall and the second end wall.
In another non-limiting embodiment of any of the foregoing traction battery packs, the first set of battery cells is aligned with respect to a first side of the beam and the second set of battery cells is aligned with respect to a second side of the beam.
In another non-limiting embodiment of any of the foregoing traction battery packs, the first end wall and the second end wall are metallic structures and the cross-beam is a polymeric structure.
In another non-limiting embodiment of any of the foregoing traction battery packs, an opening is formed through the first end wall or the second end wall. The opening is configured to receive a compression device or fastener.
In another non-limiting embodiment of any of the foregoing traction battery packs, a structural adhesive is applied between the first cell stack and the cell grouping assembly.
In another non-limiting embodiment of any of the foregoing traction battery packs, the cell-battery pack battery system includes a third cell stack, a fourth cell stack, and a second cell grouping assembly. The second cell grouping assembly establishes an additional common datum reference plane for aligning a third group of battery cells of the third cell stack and a fourth group of battery cells of the fourth cell stack relative to the second cell grouping assembly.
In another non-limiting embodiment of any of the foregoing traction battery packs, the second cell grouping assembly is positioned adjacent to the cell grouping assembly.
A method for assembling a traction battery pack according to another exemplary aspect of the present disclosure includes, among other things: disposing a first set of battery cells relative to a first side of the cell grouping assembly; and disposing a second set of battery cells relative to a second side of the cell grouping assembly. The first set of battery cells, the second set of battery cells, and the cell grouping assembly establish a portion of a cell-battery pack battery system of the traction battery pack.
In another non-limiting embodiment of the foregoing method, the method includes applying a compressive force to the first and second sets of battery cells via the cell grouping assembly after the disposing.
In another non-limiting embodiment of any of the foregoing methods, the method includes positioning the cell-pack battery system within a cell compression opening of a housing tray of the traction battery pack after the applying.
In another non-limiting embodiment of any of the foregoing methods, the method includes, after the applying, securing a cross member of the cell grouping assembly from movement relative to at least one end wall of the cell grouping assembly.
In another non-limiting embodiment of any of the foregoing methods, a first side of the cell grouping assembly establishes a first common datum reference plane for alignment of the first set of battery cells and a second side of the cell grouping assembly establishes a second common datum reference plane for alignment of the second set of battery cells.
In another non-limiting embodiment of any of the foregoing methods, the method comprises: the first set of battery cells is positioned on a planar surface prior to the disposing.
In another non-limiting embodiment of any of the foregoing methods, the planar surface establishes a third common datum reference plane for aligning the first set of battery cells.
In another non-limiting embodiment of any of the foregoing methods, the method comprises: disposing a third set of battery cells relative to the first side of the second cell grouping assembly; and disposing a fourth set of battery cells relative to a second side of the second cell grouping assembly.
In another non-limiting embodiment of any of the foregoing methods, the method includes positioning the second cell grouping assembly adjacent to the cell grouping assembly.
In another non-limiting embodiment of any of the foregoing methods, the method includes bonding the first set of battery cells to the first side and bonding the second set of battery cells to the second side.
The embodiments, examples and alternatives of the foregoing paragraphs, claims or the following description and drawings (including any of their various aspects or corresponding individual features) may be employed independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.
Various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
Drawings
Fig. 1 schematically shows an electrically powered vehicle.
Fig. 2 shows a traction battery pack of the motorized vehicle of fig. 1.
Fig. 3 illustrates a cell-pack battery system of the traction battery pack of fig. 2.
Fig. 4, 5, 6, 7 and 8 schematically illustrate a method for grouping battery cells together as part of a manufacturing process for assembling a battery cell-battery pack battery system for a traction battery pack.
Detailed Description
The present disclosure details a cell grouping solution for assembling a traction battery pack including a cell-battery pack battery system. The cell grouping assembly may be used to establish a common datum reference plane with respect to a plurality of battery cell groups. An exemplary assembly method may include positioning the battery cell stack relative to the cell grouping assembly and then applying a compressive force to the battery cell stack to provide the cell-battery pack system. The grouped stacks may then be positioned to a housing tray of the traction battery pack. These and other features are discussed in more detail in the following paragraphs of this detailed description.
Fig. 1 schematically illustrates an electrically powered vehicle 10. The motorized vehicle 10 may include any type of motorized driveline. In an embodiment, the motorized vehicle 10 is a Battery Electric Vehicle (BEV). However, the concepts described herein are not limited to BEVs and are extendable to other motorized vehicles, including, but not limited to, hybrid Electric Vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, and the like. Thus, although not specifically shown in the exemplary embodiment, the motorized vehicle 10 may be equipped with an internal combustion engine that may be employed alone or in combination with other power sources to propel the motorized vehicle 10.
In an embodiment, the motorized vehicle 10 is an automobile. However, motorized vehicle 10 may alternatively be a pick-up truck, van, sport Utility Vehicle (SUV), or any other vehicle configuration. Although specific component relationships are shown in the drawings of the present disclosure, the illustrations are not intended to limit the disclosure. The placement and orientation of the various components of the motorized vehicle 10 are schematically illustrated and may vary within the scope of the present disclosure. Furthermore, the various figures attached to this disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to emphasize certain details of particular components or systems.
In the illustrated embodiment, the motorized vehicle 10 is a pure electric vehicle propelled solely by electric power (such as by one or more electric machines 12) without the assistance of an internal combustion engine. The electric machine 12 may act as an electric motor, a generator, or both. The electric machine 12 receives electrical power and may convert the electrical power into torque for driving one or more drive wheels 14 of the motorized vehicle 10.
The voltage bus 16 may electrically couple the motor 12 to a traction battery pack 18. Traction battery pack 18 is capable of outputting electrical power to power motor 12 and/or other electrical loads of electric vehicle 10.
The traction battery pack 18 may be secured to an underbody 22 of the motorized vehicle 10. However, it is within the scope of the present disclosure that traction battery pack 18 may be located elsewhere on electric vehicle 10.
Traction battery pack 18 is an exemplary motorized vehicle battery. Traction battery pack 18 may be a high voltage traction battery pack including a cell-to-pack battery system 20. Unlike conventional traction battery pack battery systems, the cell-battery pack battery system 20 incorporates battery cells or other energy storage devices, without the cells being arranged in separate arrays or modules inside the battery housing. Thus, the cell-to-cell battery system 20 eliminates most, if not all, of the array support structures (e.g., array frames, spacers, rails, walls, end plates, binders, etc.) necessary to group battery cells into arrays/modules. Further, the cell-to-battery pack battery system 20 may provide the overall voltage bus potential of the traction battery pack 18 with a single battery cell rather than a conventional battery system that requires multiple individual battery arrays/modules that must be connected together after being positioned within the battery housing to achieve the overall voltage potential.
Referring now to fig. 2 and 3, the traction battery pack 18 may include a housing assembly 24 arranged to house the battery cell-pack battery system 20. In an embodiment, the battery cell-pack battery system 20 includes a plurality of battery cells 26 held within an interior region 28 established by the housing assembly 24.
The battery cells 26 may supply electrical power to various components of the motorized vehicle 10. The battery cells 26 may be stacked side-by-side with respect to one another to construct a cell stack 30, and the cell stacks 30 may be positioned side-by-side in rows to provide a cell matrix 32.
In an embodiment, each cell stack 30 includes eight individual battery cells 26, and the cell matrix 32 includes four cell stacks 30 having a total of thirty-two battery cells 26. Providing a uniform number of battery cells 26 and a uniform number of cell stacks 30 may help support an efficient electrical bus arrangement. Although a particular number of battery cells 26 and cell stacks 30 are shown in the various figures of the present disclosure, the cell-to-cell pack battery system 20 of the traction battery pack 18 may include any number of battery cells 26 and any number of cell stacks 30. In other words, the present disclosure is not limited to the exemplary configurations shown in fig. 2 and 3.
In an embodiment, battery cell 26 is a prismatic lithium ion cell. However, battery cells having other geometries (cylindrical, soft pack, etc.) and/or chemistries (nickel-metal hydride, lead acid, etc.) may alternatively be utilized within the scope of the present disclosure.
The housing assembly 24 of the traction battery pack 18 may include a housing cover 34 and a housing tray 36. The housing cover 34 may be secured to the housing tray 36 to provide an interior region 28 for housing the battery cell-pack battery system 20.
The housing tray 36 may include a bottom plate 38 and a plurality of side walls 40 arranged relative to one another to provide a cell compression opening 42. The bottom panel 38 and the side walls 40 may be mechanically coupled to each other, such as by welding, for example.
During assembly of traction battery pack 18, housing cover 34 may be secured to housing tray 36 at interface 44 that substantially encloses interior region 28. In some embodiments, mechanical fasteners 46 may be used to secure the housing cover 34 to the housing tray 36, but other fastening methods (adhesion, etc.) may also be suitable.
The cell matrix 32 of the cell-pack battery system 20 may be positioned within the cell compression openings 42 provided by the housing tray 36. The exemplary housing tray 36 is depicted as including a single cell compression opening 42, however, it should be understood that the present disclosure extends to structural assemblies that provide one or more cell compression openings. The housing cover 34 may cover the cell matrix 32 within the cell compression openings 42 to enclose the battery cells 26 on substantially all sides. Once fully assembled and positioned relative to the housing tray 36, the cell matrix 32 can establish a single cell that can provide the overall voltage bus potential of the traction battery pack 18.
The housing tray 36 may compress and retain the cell matrix 32 when the cell matrix 32 is received within the cell compression opening 42. In an embodiment, the side walls 40 of the housing tray 36 apply a force to the cell matrix 32 when the cell matrix 32 is positioned within the cell compression openings 42.
In an embodiment, to insert the cell matrix 32 into the cell compression opening 42, the cell matrix 32 may be compressed first and then moved into place in the cell compression opening 42 when compressed. A compressive force F may be applied to an opposite end of one of the cell stacks 30 C . Compression force F C Essentially compressing the battery cells 26 within the cell stack 30, thereby compressing the cell stack 30 and each battery cell 26 to a reduced thickness. When the compression force F C When applied to the cell stack 30, the cell stack 30 may be moved by a downward force F D Inserted into the corresponding cell compression openings 42. Downward force F D May be applied directly to one or more of the battery cells 26.
Although the term "downward" is used herein to describe a downward force F D It should be understood that the term "downward" is also used herein to refer to all forces tending to press the cell stack 30 into the cell compression opening 42. In particular, the term "downward" refers to being substantially perpendicular to the compressive force F C Whether or not the force is truly in a "downward" direction. For example, the present disclosure extends to cell stacks compressed in a lateral direction and inserted into cell compression openings.
The cell stack 30 may be individually compressed and inserted into the cell compression opening 42. In another embodiment, the entire cell matrix 32 is compressed and inserted into the cell compression openings 42. As schematically shown in fig. 3, in such an embodiment, an additional compressive force F X The cell stacks 30 may be compressed together to insert the cell matrix 32 into the cell compression openings 42. Compression force F X Generally perpendicular to the compressive force F C . Compression force F X Can be matched with the compression force F C Applied together. Force F can then be applied D To move the entire cell matrix 32 into the cell compression openings 42.
In an embodiment, the entire perimeter of the cell compression opening 42 is defined by the side walls 40 of the housing tray 36. The sidewalls 40 may apply compressive force to the battery cells 26 around the entire perimeter of the cell matrix 32. Thus, the sidewalls 40 may serve as a rigid ring-like structure that compresses and tightly holds the cell matrix 32.
The above-described configuration is considered a cell-to-cell pack type of battery pack that is different from conventional battery pack types that include a housing holding an array of battery cells that are enclosed by an array support structure that is spaced apart from the walls of the battery housing, and wherein the battery housing does not apply a compressive force to any of the battery cells. The cell-pack type of battery packs described herein also eliminates rigid cross members that are typically secured to the housing tray of a conventional traction battery pack to provide mounting points for securing the battery array and housing cover.
With continued reference to fig. 1-3, fig. 4-8 schematically illustrate a method for assembling the traction battery pack 18 and, in particular, for grouping the battery cells 26 together to form a cell stack 30 of the cell-to-cell pack battery system 20. The method may include a greater or lesser number of steps than recited below, and the exact order of the steps is not intended to limit the disclosure.
Referring first to fig. 4, the battery cells 26 of the first group G1 may be positioned on a planar surface 50. The battery cells 26 may be arranged side-by-side along a cell stack axis a to establish one of the cell stacks 30 of the cell-battery pack system 20. Each battery cell 26 may include a major side 52, a minor side 54, a top side 56, and a bottom side 58. In an embodiment, the bottom side 58 of each battery cell 26 is positioned in contact with the planar surface 50. However, any surface of the battery cell 26 may be disposed relative to the planar surface 50.
The planar surface 50 may be part of an assembly pallet or some other structure associated with a workstation of a manufacturing assembly line. The planar surface 50 may establish a first common base reference plane 60 for aligning and grouping the battery cells 26 relative to one another. Thus, in this embodiment, the bottom side 58 of each battery cell 26 is aligned with respect to a first common base reference plane 60.
Next, as shown in fig. 5, the battery cells 26 of the first group G1 may be moved into position relative to the cell grouping assembly 62. The cell sub-assembly 62 may be positioned against the planar surface 50 before or after positioning the battery cells 26 of the first group G1 on the planar surface 50. The cell subassembly 62 may include a first end wall 64, a second end wall 66, and a cross-member 68 extending between the first end wall 64 and the second end wall 66. The cross-beam 68 may be configured to move axially relative to the first end wall 64, the second end wall 66, or both. In an embodiment, the first end wall 64 and the second end wall 66 are metallic structures and the cross-beam 68 is a polymeric structure. However, the exact material composition of each sub-component of the cell grouping assembly 62 is not intended to limit the present disclosure.
The battery cells 26 or the cell grouping assembly 62 may be moved such that one of the minor sides 54 of each battery cell 26 is disposed in contact with the first side 70 of the beam 68. The first side 70 of the beam 68 may establish a second common base reference plane 72 for aligning and grouping the battery cells 26 relative to one another in order to establish one of the cell stacks 30. The first and second common base reference planes 60, 72 may be beneficial when the battery cells 26 have slightly different sizes due to tolerance stack-up and other manufacturing complexities. As schematically depicted, any tolerance variations of the battery cells 26 are thus away from the first side 70 of the beam 68.
During this stage of the method, the battery cells 26 may be bonded together by applying a structural adhesive 74. Structural adhesive 74 may be applied between the minor side 54 and the first side 70 of the beam 68, between the battery cells 26 located at the ends of the first group G1 and each end wall 64, 66 of the cell subassembly 62, and/or between the major sides 52 of adjacent battery cells 26. Once cured, the structural adhesive 74 may stiffen the cell stack 30, thereby preventing sagging and/or buckling or otherwise twisting. The structural adhesive 74 may be an epoxy or any other suitable adhesive.
Referring now to fig. 6, the battery cells 26 of the second group G2 may be moved into position relative to both the planar surface 50 and the cell grouping assembly 62. The battery cells 26 of the second group G2 may establish additional cell stacks 30 of the cell-battery pack battery system 20. The battery cells 26 of the second group G2 may be moved such that the bottom sides 58 of the battery cells 26 are arranged to contact the planar surface 50 and one of the minor sides 54 of each battery cell 26 is arranged to contact the second side 76 of the beam 68. The second side 76 is the side opposite the first side 70 of the beam 68. The second side 76 may establish a third common base reference plane 78 for aligning and grouping the battery cells 26 of the second group G2 relative to one another in order to establish another one of the cell stacks 30. The third common base reference plane 78 is parallel to the second common base reference plane 78. Thus, the cell grouping assembly 62 can provide a fiducial reference point referenced to at least two sides (e.g., bottom and minor sides) of each cell stack 30 positioned thereon.
Referring to fig. 7, the method steps schematically shown in fig. 4, 5 and 6 may be repeated in order to provide a desired number of cell stacks 30. The cell sub-assemblies 62 for grading a desired number of cell stacks 30 to be used within the cell-battery pack system 20 may be arranged side-by-side with each other such that the first end wall 64 and the second end wall 66 of adjacent cell sub-assemblies 62 abut each other. The width W1 of the first end wall 64 and the second end wall 66 of each cell sub-assembly 62 may be slightly greater than the width W2 spanning from one side of the battery cells 26 of the first group G1 to the opposite side of the battery cells 26 of the second group G2, which are arranged relative to the cell sub-assemblies 62. Thus, when the cell sub-assemblies 62 abut each other, the battery cells 26 held within the adjacent cell sub-assemblies 62 do not interfere with each other.
Referring now to fig. 8, the method may next be performed by applying a compressive force Fc to each cell stack 30. The compression device 80 may be positioned within an opening 82 formed in each of the end walls 64, 66 of the cell grouping assembly 62. The openings 82 may additionally be configured to receive fasteners for mounting the cell grouping assembly 62 to the housing tray 36. The compression devices 80 can be moved toward each other to maintain each of the cell subassemblies 62 along each cell stack axis aThe opposite ends of the battery cells 26 exert a compressive force F C . Compression force F C Essentially compressing the battery cells 26 within each cell stack 30, thereby compressing the cell stack 30 and the individual battery cells 26 to a desired cell stack length L.
In an embodiment, the compressive force F exerted by the compression device 80 on the battery cells 26 C Is about 3 kilonewtons. However, the actual compressive force applied may vary depending on the type of battery cell and other factors. In this disclosure, the term "about" means that the expressed amount or range need not be exact, but may be approximate and/or larger or smaller, reflecting acceptable tolerances, conversion factors, measurement errors and the like.
The compression device 80 may be driven to apply a compressive force Fc via a pneumatic actuator. However, other types of actuators may alternatively be employed to achieve the desired compressive load. Further, the compression device 80 may be configured to simultaneously engage one or more of the cell grouping assemblies 62.
The beam 68 may move relative to one or both of the end walls 64, 66 of each cell subassembly 62 when a compressive force Fc is applied. Once the desired compressive load is placed on each set of battery cells 26, the positioning of beam 68 may be fixed against further movement. In an embodiment, a nut 84 may be inserted onto the threaded portion 86 of the cross-beam 68 to prevent further movement of the cross-beam 68 relative to one or both of the end walls 64, 66.
After the desired compressive force Fc is applied, the cell grouping assembly 62 (and the cell stack 30 held therein) can be moved together as a unit into the cell compression opening 42 of the housing tray 36 in a manner similar to that shown in fig. 3. Thus, upon completion of the above-described method, the cell grouping assembly 62 establishes a portion of the cell matrix 32 of the cell-battery pack battery system 20.
The example manufacturing processes described herein provide a method for grouping battery cells together to form a cell matrix of a cell-battery pack battery system using one or more cell grouping assemblies. The cell grouping assembly provides a solution to various assembly complexities that may occur due to eliminating many array support structures associated with conventional traction battery packs.
Although various non-limiting embodiments are shown with specific components or steps, embodiments of the present disclosure are not limited to these specific combinations. Some features or components from any of the non-limiting embodiments may be used in combination with features or components from any of the other non-limiting embodiments.
It should be understood that the same reference numerals indicate corresponding or analogous elements throughout the several views. It should be understood that while particular component arrangements are disclosed and illustrated in the exemplary embodiments, other arrangements may benefit from the teachings of this disclosure.
The above description should be construed as illustrative and not in any limiting sense. Those of ordinary skill in the art will appreciate that some modifications may occur within the scope of the present disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.

Claims (15)

1. A traction battery pack, comprising:
a housing assembly; and
a cell-to-cell battery system housed within the housing assembly and including a first cell stack, a second cell stack, and a cell grouping assembly,
wherein the cell grouping assembly establishes a common datum reference plane for aligning a first set of battery cells of the first cell stack and a second set of battery cells of the second cell stack relative to the cell grouping assembly.
2. The traction battery pack of claim 1, wherein the first cell stack establishes a first cell row of a cell matrix of the cell-battery pack battery system and the second cell stack establishes a second cell row of the cell matrix, and optionally wherein a housing tray of the housing assembly provides a cell compression opening for compressing the cell matrix.
3. The traction battery pack of claim 1 or 2, wherein the cell grouping assembly comprises: a first end wall; a second end wall; and a cross member extending between the first end wall and the second end wall.
4. The traction battery pack of claim 3, wherein the first set of battery cells are aligned with respect to a first side of the beam and the second set of battery cells are aligned with respect to a second side of the beam.
5. The traction battery pack of claim 3, wherein the first end wall and the second end wall are metallic structures and the cross-beam is a polymeric structure.
6. The traction battery pack of claim 3, comprising an opening formed through the first end wall or the second end wall, wherein the opening is configured to receive a compression device or fastener.
7. The traction battery pack of any one of the preceding claims, comprising a structural adhesive applied between the first cell stack and the cell grouping assembly.
8. The traction battery pack of any one of the preceding claims, wherein the cell-battery pack battery system comprises a third cell stack, a fourth cell stack, and a second cell grouping assembly, wherein the second cell grouping assembly establishes an additional common reference plane for aligning a third group of battery cells of the third cell stack and a fourth group of battery cells of the fourth cell stack relative to the second cell grouping assembly, and optionally wherein the second cell grouping assembly is positioned adjacent to the cell grouping assembly.
9. A method for assembling a traction battery pack, comprising:
disposing a first set of battery cells relative to a first side of the cell grouping assembly; and
a second set of battery cells is disposed relative to a second side of the cell grouping assembly,
wherein the first set of battery cells, the second set of battery cells, and the cell grouping assembly establish a portion of a cell-battery pack battery system of the traction battery pack.
10. The method of claim 9, comprising applying a compressive force to the first and second sets of battery cells via the cell grouping assembly after the disposing.
11. The method of claim 10, comprising positioning the cell-pack battery system within a cell compression opening of a housing tray of the traction battery pack after the applying.
12. The method of claim 10, comprising securing a cross member of the cell sub-assembly from movement relative to at least one end wall of the cell sub-assembly after the applying.
13. The method of any of claims 9 to 12, wherein the first side of the cell grouping assembly establishes a first common datum reference plane for aligning the first group of battery cells and the second side of the cell grouping assembly establishes a second common datum reference plane for aligning the second group of battery cells, and optionally the method comprises positioning the first group of battery cells on a planar surface prior to the arranging, and optionally wherein the planar surface establishes a third common datum reference plane for aligning the first group of battery cells.
14. The method of any one of claims 9 to 13, comprising:
disposing a third set of battery cells relative to the first side of the second cell grouping assembly; and
disposing a fourth set of battery cells relative to a second side of the second cell grouping assembly; and
optionally including positioning the second cell grouping assembly adjacent to the cell grouping assembly.
15. The method of any of claims 9 to 14, comprising bonding the first set of battery cells to the first side and bonding the second set of battery cells to the second side.
CN202310243503.0A 2022-03-23 2023-03-14 Battery cell grouping solution for traction battery packs Pending CN116845320A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US63/322,766 2022-03-23
US17/894,514 2022-08-24
US17/894,514 US20230327249A1 (en) 2022-03-23 2022-08-24 Battery cell grouping solutions for traction battery packs that include cell-to-pack battery systems

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CN116845320A true CN116845320A (en) 2023-10-03

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