DE102009016573B4 - METHOD FOR ASSEMBLING A BATTERY - Google Patents

Abstract

A method of assembling a battery comprising
- that a plurality of battery cooling plates (202) are provided, which are connected to one another in a frame shape, a space between the battery cooling plates (202) being provided which is sufficient to accommodate two battery cells (210, 212),
- That a spring element (214) between two battery cells (210, 212) is arranged in layers to provide a battery pack assembly (208)
- that the battery pack assembly (208) is pressed together, so that the thickness of the battery pack assembly (208) in the compressed state is smaller than the distance between two adjacent battery cooling plates (202) in the frame,
- That the battery pack assembly (208) between two adjacent battery cooling plates (202) is pushed, and
- That as soon as the battery pack assembly (208) is positioned between two adjacent battery cooling plates (202) in the frame, the spring element (214) is expanded to the first battery cell (210) against the first cooling plate (202) and the second Press the battery cell (212) against the second battery cooling plate (202).

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from the preliminary U.S. Application No. 61 / 043,614 which was filed on April 9, 2008.

TECHNICAL AREA

The present invention relates to methods of assembling a battery. The field generally related to the disclosure particularly includes batteries and their components as well as methods for their manufacture and assembly, and in particular battery cooling plates or fins.

BACKGROUND

For the efficient operation of some batteries, for example lithium ion batteries, it may be desirable to cool the battery. This can be achieved by passing a liquid coolant through a cooling plate or fin which can be positioned adjacent to a battery cell or arranged between battery cells. As the commercial use of such batteries increases, effective methods of manufacturing their components and assembly operations in manufacturing are becoming increasingly important.

The EP 1 387 424 A2 teaches a fuel cell stack in which power generation cells, end plates and first and second cooling cells are provided. The first and second cold rooms are formed between the end plates. A cooling liquid is supplied to the first cooling cells in order to cool the energy generation cells. A predetermined number of energy generation cells are arranged between a respective first cooling cell and a respective second cooling cell.

The EP 1 577 966 A2 discloses an accumulator device which is formed by a plurality of frame elements. Each frame element contains a cooling structure and is designed to accommodate a respective battery cell. The accumulator structure is formed by a stack of successive frames and consequently by a sequence of accumulator cells and cooling structures. The cooling structures of directly adjacent frames can be fluidly connected to one another via a passage structure.

The WO 1999/05746 A1 relates to an energy storage device and describes a battery cell stack in which a spring element is formed between directly adjacent cell elements in order to compensate for displacements which can occur due to different volumes of the individual cells in the charged and in the uncharged state.

The US 4,060,670 A. describes an arrangement of flat battery cells in which contact elements are designed to improve the contact between adjacent battery cells in a cell stack and between terminal battery cells and an external electrical tap.

The DE 602 13 474 T2 shows devices and methods for temperature control in electrochemical cells. In an arrangement described there, a so-called cooling bellows is provided, which is of serpentine design and in which individual ones of a plurality of electrochemical cells are arranged in intermediate spaces.

The invention is based on the object of specifying methods for assembling batteries which are particularly effective.

SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The object on which the invention is based is achieved in a method for assembling a battery according to the invention with the features of independent patent claim 1 and alternatively according to the invention with the features of independent patent claim 2.

An exemplary embodiment comprises a method for assembling battery cooling plates which are connected to one another in a frame shape, a space being provided between cooling plates which is sufficient to accommodate two battery cells. A spring element is arranged in layers between two battery cells in order to provide a battery pack assembly which is pressed together, so that the thickness of the battery pack assembly in the compressed state is smaller than the distance between two adjacent cooling plates in the frame. The battery pack assembly is then slid between two adjacent cooling plates, and once the battery pack assembly is positioned between two adjacent cooling plates in the rack, the spring element expands to the first battery cell against the first cooling plate and the second battery cell against the second cooling plate to press.

Another exemplary embodiment includes a method that includes providing a single substrate having a plurality of spaced-apart battery cooling plates defined therein. A battery cell can be attached to one or both sides of each cooling plate. The substrate includes a connecting portion that couples adjacent cooling plates to one another, and the connecting section comprises at least one cooling channel that communicates with each of the adjacent cooling plates. The arrangement provides a plurality of cooling plates which are designed as a component in series. The substrate can be bent at the connection section in such a way that adjacent cooling plates and the batteries attached thereto can be provided in a position one above the other in relation to one another.

Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It is to be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

Figure list

• 1 ein Verfahren zum Zusammenbau einer Batterie unter Verwendung eines Kühlplattengestells und einer Batteriepaket-Baugruppe gemäß einer beispielhaften Ausführungsform zeigt;
• 2 eine Explosionsdarstellung einer Batteriepaket-Baugruppe und zugeordneter Halter gemäß einer beispielhaften Ausführungsform ist;
• 3 eine Darstellung einer Halter-Batteriepaket-Baugruppe in einem zusammengepressten Zustand gemäß einer beispielhaften Ausführungsform ist;
• 4 ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 5A ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 5B ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 5C ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 5D ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 6 ein Verfahren zum Zusammenbauen eines Abschnitts einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 7 ein Verfahren zum Zusammenbauen eines Abschnitts einer Batterie gemäß einer beispielhaften Ausführungsform zeigt;
• 8 ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt; und
• 9 ein Verfahren zum Zusammenbauen einer Batterie gemäß einer beispielhaften Ausführungsform zeigt.

Exemplary embodiments of the invention will be better understood from the following detailed description and accompanying drawings, in which:

• 1 10 shows a method of assembling a battery using a cooling plate rack and a battery pack assembly in accordance with an exemplary embodiment;
• 2nd FIG. 3 is an exploded view of a battery pack assembly and associated holder according to an example embodiment;
• 3rd FIG. 4 is an illustration of a holder-battery pack assembly in a compressed state according to an example embodiment;
• 4th 10 shows a method of assembling a battery in accordance with an exemplary embodiment;
• 5A 10 shows a method of assembling a battery in accordance with an exemplary embodiment;
• 5B 10 shows a method of assembling a battery in accordance with an exemplary embodiment;
• 5C 10 shows a method of assembling a battery in accordance with an exemplary embodiment;
• 5D 10 shows a method of assembling a battery in accordance with an exemplary embodiment;
• 6 10 shows a method of assembling a portion of a battery according to an example embodiment;
• 7 10 shows a method of assembling a portion of a battery according to an example embodiment;
• 8th 10 shows a method of assembling a battery in accordance with an exemplary embodiment; and
• 9 10 shows a method of assembling a battery according to an example embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following description of the embodiment (s) is merely exemplary (illustrative) in nature and is not intended to limit the invention, its application, or uses.

Now referring to the 1 to 5 An exemplary embodiment includes a method of manufacturing a battery assembly that includes a plurality of battery cells and cooling plates. As in 1 A cooler assembly may be shown in one illustrative embodiment 200 be provided with a variety of cooling plates 202 that have cooling fluid flow paths defined therein and a first series of components 204 to provide a first manifold section and a second series of components 206 to provide a second manifold for routing cooling fluid in series from one cooling plate to the next cooling plate. Between the adjacent main body sections of cooling plates 202 can be a room 224 be provided in which a battery pack assembly 208 can be used.

Now referring to 2nd In an exemplary embodiment, the battery pack assembly 208 a first battery cell 210 and a second battery cell 212 exhibit. Between the first battery cell 210 and the second battery cell 212 can be a spring element 214 be arranged. In one embodiment, the spring element 214 one or more undulating substrates for applying a biasing force against both the first battery cell 210 as well as the second battery cell 212 include. In other embodiments, the spring 214 a resilient foam, a rubber or rubber or an elastomeric material. Both the first battery cell 210 as well as the second battery cell 212 can make a first connection 218 and a second connector 220 exhibit. The first battery cell 210 , the spring element 214 and the second battery cell 212 can by one or more holders 216 in one pressed together to be held together. In one embodiment, multiple holders 216 be used. In one embodiment, the battery pack assembly 208 and the holder 216 through a hydraulic clamp 500 held together. 3rd shows an exemplary embodiment of a holder battery pack assembly 222 where the first battery cell 210 , the spring element 214 and the second battery cell 212 held together in a compressed state.

Now referring to 4th may, in an exemplary embodiment, the holder battery pack assembly 222 to be used the battery pack assembly 208 in between the main body portions of adjacent cooling plates 202 provided space 224 use. In an exemplary embodiment, the holder battery pack assembly 222 over neighboring cooling plates 202 arranged so that the holder 216 at least partially on a portion of the adjacent cooling plates 202 lie on. The holder battery pack assembly 222 can be positioned such that the battery pack assembly 208 with the room 224 is aligned, and the battery pack assembly 208 can go down into the room 224 be pushed so that the battery pack assembly 208 completely in the room 224 is included and the spring element 214 drives the first battery cell against a first cooling plate and so that the spring element 214 the second battery cell 212 against a second adjacent cooling plate 202 drives to heat transfer between the battery cells 210 , 212 in the cooling plates 204 to promote.

Now referring to 5A can be an electrical, pneumatic or hydraulic assembly clamping device 500 the holder 216 around the battery pack 208 around that is the first and second battery cell 210 , 212 with the spring in between, close. The assembly clamping device 500 presses the battery pack 208 ( 5B) together and is then used to make the battery pack 208 between two cooling plates 202 of the frame ( 5C ). Once the battery pack 208 has been inserted into the frame, the assembly clamping device 500 opened so the holder 216 their grip on the battery pack 208 release.

Now referring to the 6 to 9 Another exemplary embodiment includes a method of manufacturing a battery assembly that is a continuous component 300 having a plurality of cooling plates formed in series. The continuous component 300 can be a first substrate 302 have, which at least partially defines a plurality of cooling plates and connecting sections extending therebetween. A second substrate (not shown) can be die cut or otherwise formed to define a pattern of lands and channels. The first substrate 302 can cover the bridges and channels. For example, the first substrate 302 at least a portion of a first cooling plate 304 , a first connecting section 306 that leads away from it and with a second cooling plate 308 is connected, a second connecting portion 310 that leads away from it and with a third cooling plate 312 is connected, and a third connecting portion 314 that leads away from it and with a fourth cooling plate 316 is connected, and a fourth connecting section leading away therefrom 318 define. The pattern of a first cooling plate and a connecting section leading away from it and connected to a second cooling plate can be repeated several times depending on the size of the battery arrangement to be produced. The connecting sections 306 , 310 , 314 , 318 can have varying sizes and can be positioned in different locations. In an exemplary embodiment, the first connection section 306 , the second connecting section 310 , the third connecting section 314 and the fourth connection section 318 by forming a first window 320 , a second window 322 , a third window 324 and a fourth window 326 in the substrate 302 are provided so that the connecting sections 306 , 310 , 314 and 318 have a height which is substantially less than that of the cooling plates 304 , 308 , 312 , 316 and so that the connecting portions can be easily bent by 180 °. There will be at least one cooling path 328 through the cooling plates 304 , 308 , 312 , 316 and the connecting sections 306 , 310 , 314 and 318 intended. A first battery cell 330 can over a first page 332 a cooling plate 304 be positioned. In one embodiment, the first battery cell 330 for example by using a thermally conductive adhesive on the first side 332 appropriate. In another embodiment, the battery cell 330 be layered in position when the substrate 302 is bent. If necessary, a second battery 334 over a second page 336 a cooling plate 304 be positioned. The battery cells can be on the first side 332 and / or the second page 336 from each of the cooling plates attached or adjacent to the first side 332 and / or the second page 336 be positioned by each of the cooling plates.

In one embodiment, the battery cells on both the first side 332 as well as the second page 336 Each cooling plate are attached, the connecting sections can be bent by 180 °, so that the battery cells on the first side 332 are attached by adjacent cooling plates, are positioned immediately adjacent to each other. For example, a battery cell 330 on each of the first pages 332 the first cooling plate 304 be attached, and another battery cell 330 can on a second cooling plate 308 be attached, the first connecting portion 306 can be bent such that a blocking of the cooling passage 328 through the first connection section 306 runs, is avoided, so the first battery cells 330 are immediately adjacent to each other. Then the second connection section 310 be bent in the opposite direction so that the second battery cells 330 on each of the second sides 336 the second cooling plate 308 and the third cooling plate 312 are immediately adjacent to each other.

This process of bending the connecting portions can be repeated until a battery of sufficient size has been formed.

8th Another exemplary embodiment illustrates a method of manufacturing a battery using a continuous component 300 having a cooling fluid flow path defined therein 328 comprises, wherein the continuous component 300 at locations A and B can be bent and used to make a battery in a manner similar to that shown in Figs 6 to 7 is described.

9 10 shows another exemplary embodiment that includes a method of manufacturing a battery using a continuous component 300 includes the cooling fluid flow paths 328 therein to define a plurality of cooling plate parts (individually defined by lines C, D and E). Each can have an inlet manifold flow path 900 and an outlet manifold flow path 902 be provided for cooling fluid communicating with each of the cooling plate parts C, D and E. The continuous component 300 can be generally curved at the intersection of lines CD and DE and used to make a battery in a manner similar to that in Figs 6 to 7 is described.

The above description of embodiments of the invention is merely exemplary in nature, and thus modifications thereof are not to be regarded as a departure from the spirit and scope of the invention.

Claims (2)

A method of assembling a battery comprising - that a plurality of battery cooling plates (202) are provided, which are connected to one another in a frame shape, a space between the battery cooling plates (202) being provided which is sufficient to accommodate two battery cells (210, 212), - that a spring element (214) is arranged in layers between two battery cells (210, 212) in order to provide a battery pack assembly (208), - that the battery pack assembly (208) is pressed together so that the thickness of the battery pack assembly (208) in the compressed state is smaller than the distance between two adjacent battery cooling plates (202) in the frame, - That the battery pack assembly (208) is pushed between two adjacent battery cooling plates (202), and - That as soon as the battery pack assembly (208) is positioned between two adjacent battery cooling plates (202) in the frame, the spring element (214) is expanded to the first battery cell (210) against the first cooling plate (202) and the second Press the battery cell (212) against the second battery cooling plate (202). A method of assembling a battery comprising - That a single substrate (302) is provided which has a plurality of spaced-apart battery cooling plates (304, 308, 321, 316) defined therein, the single substrate (302) comprising a connecting section (306, 310, 314), which is adjacent Coupling battery cooling plates (304, 308, 321, 316) with one another, and the connecting section (306, 310, 314) has at least one cooling channel (328) which communicates with each of the adjacent battery cooling plates (304, 308, 321, 316), - that a battery cell (330, 334) is attached to at least one or both sides (332, 336) of each battery cooling plate (304, 308, 321, 316), and that a bend is carried out on the connecting section (306, 310, 314) in such a way that - That adjacent battery cooling plates (304, 308, 321, 316) are positioned in a superimposed position with respect to each other.

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