EP4690348A1

EP4690348A1 - A method of arranging battery cells

Info

Publication number: EP4690348A1
Application number: EP23813375.5A
Authority: EP
Inventors: Rodyn GILHARRY; Florian Hartmann
Original assignee: Lyten Sweden AB
Current assignee: Lyten Sweden AB
Priority date: 2022-12-07
Filing date: 2023-11-27
Publication date: 2026-02-11
Also published as: WO2024120870A1; SE547906C2; SE2251434A1

Abstract

A method of arranging battery cells for forming a battery assembly, the method comprising: forming a first row of the battery cells by stacking a first plurality of the battery cells and a first plurality of individual, spacers in a mount such that directly adjacent battery cells of the first plurality of the battery cells in the row have one of said first plurality of spacers therebetween and wherein adhesive applied to one or both of said first plurality of spacers and said first plurality of battery cells is configured to adhere the battery cells of the first plurality of battery cells and the spacers of the first plurality of spacers together to form the first row of battery cells; providing the first row of battery cells, once the adhesive has cured, for assembly to form part of the battery assembly

Description

A METHOD OF ARRANGING BATTERY CELLS

Field

The present disclosure relates to a method of arranging a plurality of battery cells for forming a battery assembly. The disclosure also relates to a battery assembly formed by such a method. The disclosure also relates to a kit of parts for use in the method.

Background

A plurality of battery cells, such as cylindrical battery cells, are typically arranged together and then electrically connected to form a battery module assembly. The efficient handling of the plurality of battery cells during assembly is important.

Summary

According to a first aspect of the present disclosure there is provided method of arranging battery cells, comprising cylindrical battery cells, for forming a battery assembly, the method comprising: forming a first row of the battery cells by stacking a first plurality of the battery cells and a first plurality of individual, spacers in a mount such that directly adjacent battery cells of the first plurality of the battery cells have one of said first plurality of spacers therebetween and wherein adhesive applied to one or both of said first plurality of spacers and said first plurality of battery cells is configured to adhere the battery cells of the first plurality of battery cells and the spacers of the first plurality of spacers together to form the first row of battery cells; providing the first row of battery cells, once the adhesive has cured, for assembly to form at least part of the battery assembly.

The formation of a row of battery cells may be advantageous because the row with battery cells interspersed with spacers can be structural and may therefore be handled easily in subsequent assembly steps. Such an approach may also allow for the flexible manufacture of different module sizes, simply by changing the number of battery cells and spacers in the row of battery cells.

In one or more embodiments, the method further comprises forming a second row of the battery cells by stacking a second plurality of the battery cells and a second plurality of the spacers in a mount such that directly adjacent battery cells of the second plurality of battery cells have one of said second plurality of spacers therebetween and wherein adhesive applied to one or both of said second plurality of spacers and said second plurality of battery cells is configured to adhere the battery cells of the second plurality of battery cells and the spacers of the second plurality of spacers together to form the second row of battery cells; and arranging the first row of battery cells together with the second row of battery cells.

In one or more embodiments, the method further comprises forming a first double-row-assembly by: receiving a first elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface, opposed to the first surface, configured to abut a side of the second row of battery cells; affixing the first row of battery cells to the first surface of the first elongate barrier and affixing the second row of battery cells to the second surface of the first elongate barrier.

The formation of one or more double-row-assemblies may be advantageous because a convenient unit is obtained having the cooling and/or thermal barrier functionality required to assemble the battery assembly along with two rows of battery cells.

In one or more embodiments, the first elongate barrier comprises one of: a cooling barrier that includes at least one channel therein for receiving a flow of coolant for cooling the first and second rows of battery cells when in use; and a thermal barrier, which may comprise a material having a thermal conductivity below a predetermined threshold. In one or more embodiments, the affixing of the first row of battery cells to the first surface of the first elongate barrier and the affixing of the second row of battery cells to the second surface of the first elongate barrier comprises affixing by applying adhesive to one or more of the first surface, the second surface, the first row of battery cells and the second row of battery cells and allowing said adhesive to cure.

In one or more embodiments, the battery cells are cylindrical battery cells and each of the first plurality of spacers and/or each of the second plurality of spacers comprises a body having a first concave surface to receive one of the battery cells; a second concave surface to receive a further one of the battery cells, wherein the second concave surface is arranged opposite the first concave surface.

In one or more embodiments, each of at least the first plurality of spacers include a first part of a snap-fit coupling and wherein the method comprises: receiving a second elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface opposed the first surface, wherein the second elongate barrier includes a plurality of complementary second parts of the snap-fit coupling to engage with at least some of the respective first parts of the snap-fit coupling present on the first plurality of spacers of the first row of battery cells; and affixing the second elongate barrier to the first row of battery cells at least by snap-fitting the first parts and the second parts together.

The snap-fit coupling may provide for one or both of ease of assembly and compression of any adhesive and/or potting between the battery cells and the spacers and/or between the battery cells and the second elongate barrier.

More generally, in one or more embodiments, each of at least the first plurality of spacers include a first part of a coupling and wherein the method comprises: receiving a second elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface opposed the first surface, wherein the second elongate barrier includes a plurality of complementary second parts of the coupling to engage with at least some of the respective first parts of the coupling present on the first plurality of spacers of the first row of battery cells or wherein a third part of the coupling engages both the first and second parts; and affixing the second elongate barrier to the first row of battery cells at least by engaging the first parts and the second parts together or engaging the third part with the first and the second parts.

In one or more embodiments, the method further comprises forming a second double-row-assembly by: forming a third row of the battery cells by stacking a third plurality of the battery cells and a third plurality of spacers in a mount such that directly adjacent battery cells of the third plurality of the battery cells have one of said third plurality of spacers therebetween and wherein adhesive applied to one or both of said third plurality of spacers and said third plurality of battery cells is configured to adhere the battery cells of the third plurality of battery cells and the spacers of the third plurality of spacers together to form the third row of battery cells; forming a fourth row of the battery cells by stacking a fourth plurality of the battery cells and a fourth plurality of the spacers in a mount such that directly adjacent battery cells of the fourth plurality of battery cells have one of said fourth plurality of spacers therebetween and wherein adhesive applied to one or both of said fourth plurality of spacers and said fourth plurality of battery cells is configured to adhere the battery cells of the fourth plurality of battery cells and the spacers of the fourth plurality of spacers together to form the fourth row of battery cells; forming the second double-row-assembly by: receiving a third elongate barrier having a first surface configured to abut a side of the third row of battery cells and a second surface, opposed to the first surface, configured to abut the fourth row of battery cells; affixing the third row of battery cells to the first surface of the third elongate barrier and affixing the fourth row of battery cells to the second surface of the third elongate barrier; and wherein each of at least the fourth plurality of spacers include a first part of the snap-fit coupling and wherein the method further comprises: forming a first quad-row-assembly by: affixing the first double-row-assembly and the second doublerow-assembly together at least by snap-fitting the first parts of at least some of the fourth plurality of spacers of the second double-row-assembly with the second parts of the second elongate barrier of the first double-row-assembly.

In one or more examples, the affixing of the first double-row-assembly and the second double-row-assembly together may be provided by a more general coupling, such as other than a snap-fit coupling, as described below.

In one or more embodiments, the method further comprises forming a cell block by affixing the first quad-row-assembly to further assemblies comprising one or more of: four rows of the battery cells; two rows of the battery cells; and single rows of the battery cells.

In one or more embodiments, the method further comprises forming the battery assembly by: providing the cell block on a base plate; electrically connecting the plurality of battery cells of the cell block; assembling side walls at sides of the cell block and a top plate over the cell block to thereby enclose the cell block.

According to a second aspect of the disclosure there is provided a battery assembly formed by the method of the first aspect.

In one or more examples, the battery assembly comprises a battery module sub-assembly, a battery module or a battery pack. According to a third aspect of the disclosure there is provided a kit of parts for arranging a plurality of battery cells, comprising cylindrical battery cells, for forming a battery assembly, comprising a mount configured to hold a row of battery cells in place during an adhesive curing process and a plurality of individual spacers, each spacer configured to be located and adhered between directly adjacent battery cells in the row.

In one or more embodiments, each of the spacers comprises a body having a first concave surface to receive one of the battery cells; a second concave surface to receive a further one of the battery cells, and wherein the second concave surface is arranged opposite the first concave surface.

In one or more embodiments, the kit includes a first elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface, opposed to the first surface, configured to abut the second row of battery cells; wherein the first elongate barrier comprises a cooling barrier that includes at least one channel therein for receiving a flow of coolant for cooling the first and second rows of battery cells when in use.

In one or more embodiments, each of at least the spacers include a first part of a snap-fit coupling; and the kit further includes a second elongate barrier having a first surface configured to abut a side of a row of battery cells and a second surface opposed the first surface, wherein the second elongate barrier includes a plurality of complementary second parts of the snap-fit coupling to engage with respective first parts of the snap-fit coupling present on the spacers.

While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail.

The figures and Detailed Description that follow also exemplify various example embodiments. Various example embodiments may be more completely understood in consideration of the following Detailed Description in connection with the accompanying Drawings.

Brief of the

One or more embodiments will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 shows an example embodiment of a first row of battery cells; and

Figure 2 shows an example embodiment of a spacer and its configuration to fit between two battery cells;

Figure 3 shows an example of how a first and second row of battery cells with example elongate barriers are affixed together to form a double-rowassembly;

Figure 4 shows an example snap-fit coupling;

Figure 5 shows an example of how a plurality of double-row-assemblies may be coupled together to form a quad-row-assembly and a cell block;

Figure 6 shows an example flow chart illustrating the formation of the cell block;

Figure 7 shows the cell block of Figure 5 being enclosed to form a battery assembly; and

Figure 8 shows an example battery module assembly.

Detailed Description

A battery assembly typically comprises a plurality of cylindrical battery cells. A battery assembly may comprise hundreds of cylindrical battery cells. The efficient handling of the plurality of battery cells during assembly of the battery assembly is therefore important. The battery assembly may comprises a battery module sub-assembly, a battery module or a battery pack.

Cylindrical battery cells, as will be familiar to those skilled in the art, comprise a curved side wall, forming a tubular casing, separating two ends. In a battery assembly, the cylindrical cells are typically stacked together side-by-side, such that their curved side wall abut or are adjacent one another. One of the two ends of each of the plurality of battery cells may therefore lie in a plane providing for electrical connection of the cells. In addition to the battery cells, a battery assembly typically includes one or more elongate barriers that extend between groups of battery cells and are configured to lie against the curved side walls. The elongate barriers may provide for cooling of the side walls of the battery cells or may provide a thermal barrier.

It will be appreciated that effective handling of the battery cells and elongate barriers presents a challenge.

The embodiments described herein illustrate how the plurality of battery cells may be grouped, in one or more stages, during assembly into a battery assembly.

With reference to Figures 1 and 2, a first row of battery cells 100 is shown formed from a first plurality of battery cells 101, 102 (etc) and a first plurality of individual, spacers 103. The first row of battery cells 100 may also be referred to as the "first row" in the description that follows for brevity.

Thus, the first plurality of the battery cells 101, 102 and individual, spacers 103 are arranged in a mount or jig (not shown) and secured together to form the first row 100. The mount may be configured to support the battery cells 101, 102 while the steps described below are performed. In some examples, the mount may have features to assist in one or both of positioning and supporting the cells.

The spacers 103 comprises a body 104 having a first concave surface 105 to receive one of the battery cells and a second concave surface 106 to receive a further one of the battery cells. Thus, each spacer 103 is configured to receive one battery cell in each of its concave surfaces 105, 106. In the present example, adhesive is used to secure a first battery cell 101 to the first concave surface 105 and a second battery cell 102 to the second concave surface 106. The first and the second concave surfaces 105, 106 are arranged opposite one another. The body 104 further comprises a plurality of ribs 107 between the first and the second concave surfaces 105, 106 to support them. In other examples, the body 104 may be solid, or may be hollow and have side surfaces that connect edges of the concave surfaces. In other examples, the spacer may have a H-shaped or I-shaped cross-section rather than the arcuate concave surfaces shown in example figure 2. In such an example, the adhesive may be applied at two or three contact points that would be present when the curved side wall of the battery cell is received in the recesses of the H-shape or I-shape.

The first and/or second concave surfaces may include one or more ridges 108. The one or more of ridges 108 may be configured to engage with complementary channels in the battery cells or ends of the battery cells that are to be received by the concave surfaces 105, 106 and may therefore act to locate the battery cells in a predetermined position relative to the spacer 103. In one or more examples, the one or more of ridges 108 may be configured to retain the adhesive in one or more predetermined regions of the first concave surface 105 and/or one or more predetermined regions of the second concave surface 106. Accordingly, the ridges 108 may perform an adhesive locating function. The ridges 108 may be of a predetermined height above the concave surface and may thereby act to control the thickness of the adhesive applied to the concave surface 105, 106. In some examples, the one or more ridges 108 may provide the battery cell positioning function and other ridges may provide the adhesive locating function or adhesive thickness control function. In other examples, one or more of the ridges 108 may perform one or more of the battery cell positioning function and the adhesive locating function and the adhesive thickness control function.

The adhesive 110 may be provided as a film which is applied to one or both of the curved side walls of the cylindrical cells or the first/second concave surfaces 105, 106. In other examples, the adhesive may be provided on a carrier film and which is applied similarly. The film 110 may therefore have adhesive on both sides, wherein one side secures it to the battery cell 101 (in Figure 2) and the other side secures it to the first concave surface 105 of a respective spacer 103. In other examples, the adhesive 110 may be dispensed from a dispensing head onto one or both of the curved side walls of the cylindrical cells or the first/second concave surfaces 105, 106. The adhesive 110 may take the form of a double-sided tape. Thus, a plurality of different ways may be used to apply the adhesive 110.

However the adhesive is applied, the first row of battery cells 100 is thus formed of a linear arrangement of battery cells such that directly adjacent battery cells in the row have one of said spacers 103 therebetween and wherein the adhesive 110 is configured to adhere the battery cells 101, 102 of the first plurality of battery cells and the spacers 103 together to form the first row 100.

In a first example, a first battery cell may be provided to the mount and a first spacer may be secured to it by its first concave surface using the adhesive 110. Then a second battery cell may be secured to the second concave surface 106 of the first spacer using further adhesive 110. A second spacer may then be secured to the second battery cell and so on until a row of a desired length is created. In a second example, pairs of battery cells may be coupled to a respective spacer 103 and then the pairs may then be coupled together by further spacers 103. Whichever order the steps are performed, the row 100 may comprise a linear arrangement of battery cells having discrete spacers 103 between each and every adjacent pair of battery cells. In the present example, the first row of battery cells 100 is one battery cell wide and a predetermined number of battery cells long (thirty-five cells long in the example of Figure 1). It will be appreciated that the predetermined number may be any desired number but may be at least four battery cells, in one or more examples.

Once the adhesive 110 has cured the first row of battery cells 100 may be provided for further assembly to form part of the battery assembly. It will be appreciated that the adhesive may be cured to a strength that allows for handling of the first row of battery cells 100 without disassembly (due to the handling) of the battery cells and the spacers or the adhesive may be fully cured or cured to a degree therebetween. The adhesive 110 may be a structural adhesive. The adhesive may be a semi- structural adhesive. Thus, the adhesive 110 may firmly bond the battery cells 101, 102 and spacers 103 together to a degree that the first row of battery cells 100 may be handled without the row disassembling in subsequent assembly steps. Thus, the row may be sufficiently rigid that the first row of battery cells 100 may be handled without having to support each and every constituent battery cell 100. In one or more examples, the adhesive 110 (and optionally other adhesives mentioned herein) comprise an adhesive with an elastic modulus greater than 100 MPa and/or a lap shear strength (LSS) greater than 2MPa. It will be appreciated that adhesives with other values of elastic modulus and lap shear strength may be used depending on the size of the row and/or the required resilience for subsequent handling steps. In one or more examples, the adhesive 110 (and optionally other adhesives mentioned herein) may comprise an epoxy-based adhesive, a urethane based adhesive, or an acrylic based adhesive, although other adhesive types may be suitable.

The formation of the rigid row of battery cells 100 is advantageous because the row can be easily handled. Once formed, the rigid row of battery cells 100 comprises a unit part for further assembly steps in the assembly of a cell block and the battery assembly.

Turning to example figures 3 and 4, the first row of battery cells 100 is shown ready to be assembly with a second row of battery cells 200.

The second row of battery cells 200 may be formed in a similar way to the first row of battery cells 100 using the same mount or a different mount. In this example, the second row of battery cells 200 has the same number of battery cells as the first row of battery cells 100. However, in other embodiments, there may be different numbers of battery cells in each of the first row 100 and the second row of battery cells 200.

The second row of battery cells 200 may also be referred to as the "second row" in the description that follows for brevity. Figure 3 and figure 4 show a first elongate barrier 300 that is configured to extend between the first and second rows 100, 200. Thus, the first elongate barrier 300 may have a first surface 301 configured to abut a side of the first row of battery cells 100 and a second surface 302, opposed to the first surface 301, configured to abut the second row of battery cells 200.

The first and second surfaces 301, 302, in the present example are configured complementary in shape to the rows of cylindrical battery cells in the first row 100 and the second row 200. Thus, the first surface 301 and/or the second surface 302 may have an undulating profile.

Arrow 303 indicates the first row of battery cells 100 and the second row of battery cells 200 and the first elongate barrier 300 (and optionally the second elongate barrier 350), as shown in exploded view, coming together to form a first double-row-assembly 400.

Thus, the first double-row-assembly 400 is formed by affixing the first row of battery cells 100 to the first surface 301 of the first elongate barrier 300 and affixing the second row of battery cells 200 to the second surface 302 of the first elongate barrier 300. One or both of the aforementioned affixing steps may comprise affixing by use of adhesive (not shown).

In the present example, the first elongate barrier 300 comprises a cooling barrier that includes at least one channel therein for receiving a flow of coolant for cooling the first and second rows of battery cells 100, 200 when in use. At least in part due to the undulating profile of the surfaces 301, 302, such cooling barriers may be known as cooling snakes. The cooling snakes therefore snake around the partially interleaved curved side walls of the cylindrical battery cells in each of the first and second rows 100, 200.

In examples where the first elongate barrier 300 comprises a cooling barrier, a thermally conductive paste or potting may be applied between the sides of the rows and the elongate barrier 300 to improve thermal conductivity between the battery cells and the cooling barrier. The thermal paste or potting may be applied in addition to the adhesive. In other examples, the first elongate barrier 300 may comprise a thermal barrier comprising a material having a thermal conductivity below a predetermined threshold. In one or more examples, the thermal barrier may have a thermal conductivity of less than 0.3 W/mK. Put another way, the thermal barrier is a thermal insulator configured to prevent the transfer of heat between the first row 100 and the second row 200. The thermal barrier may be of mica, which is typically used for such thermal barriers, although other materials will be familiar to those skilled in the art.

Figure 3 also shows an example of affixing of a second elongate barrier 350 to the first row of battery cells 100. In other examples, the second elongate barrier 350 may be affixed to the second row of battery cells 100. Also, the order in which the first elongate barrier 300 and the second elongate barrier 350 are affixed to the two rows of battery cells 100, 200 may differ between examples. Thus, in one or more examples, the second elongate barrier 350 may be affixed to the first (for example) row of battery cells 100, followed by the affixing of the first elongate barrier 300 and the second row of battery cells 200 to the assembly of the first row of battery cells 100 and the second elongate barrier 350. In other examples, the formation of the assembly of the first row 100, the second row 200 and the first elongate barrier 300 may be created first, with the second elongate barrier 350 added thereto. The disclosure is not limited to any one particular order of assembly of the first row 100, the second row 200, the first elongate barrier 300 and the second elongate barrier 350. However, the double-row-assembly 400 at least comprises two rows 100, 200 of battery cells and at least one elongate barrier.

In one or more examples, adhesive 351 may be applied between the second elongate barrier 350 and the row of battery cells 100, 200 to which it is affixed.

In one or more examples, one or both of the elongate barriers 300, 350 may include part of a snap-fit coupling. Likewise, the spacers 103 present in one or both of the first row 100 and the second row 200 may include a complementary part of the snap-fit coupling to provide for, or assist in, the affixation of the elongate barriers 300, 350 to the rows of battery cells 100, 200. An example of the snap-fit coupling will be described with reference to figures 2, 3 and 4.

The snap-fit coupling, in general, comprises a first part that is configured to engage with a complementary second part. The engagement may be releasable or may be non-releasable. When non-releasable, separation of the snap-fit coupling may require breaking of the snap-fit coupling.

Figure 2 shows an example first part 111 of the snap-fit coupling comprising a cantilevered hook that projects from the spacer 103. In the present example, a second, first part 112, also comprising a cantilevered hook is provided that also projects from the spacer 103. The first part(s) 111, 112 are configured to project in a direction perpendicular to a side of the row 100 or the row 200 out from between the curved walls of adjacent battery cells 101, 102 in the row 100, 200.

In one or more examples, further first parts may be present on the opposite side of the spacer 103 projecting in the opposite direction. In one or more examples, assembly may be more straightforward if the spacer 103 is symmetrical in terms of the location of the parts of the snap fit coupling because then it does not have to be orientated before use.

With reference to figure 4, a second part 352 of the snap-fit coupling comprising a recess within the elongate barrier 350. In the present example, a second, second part 353, also comprising a recess, is provided. The second part(s) 352, 353 are configured to receive the hook 111, 112 therein. In the present example, the spacing between the hooks 111, 112 and the spacing between the recesses 352, 353 is such that the hooks 111, 112 are configured to ride over opposite edges of the elongate barrier 350 and snap into the recesses provided on an opposite side of the elongate barrier 350.

The elongate barrier 350 also includes first and second further recesses 354, 355 that face an opposite direction to the recesses 352, 353. The first and second further recesses 354, 355 will be described later. To summarize, the first parts of the snap fit couplings may be provided on one or two opposite sides of some or all of the spacers 103. The complementary second parts of the snap fit couplings may be provided on one side or both sides of one or both of the elongate barriers 300, 350. The snap fit coupling is configured to retain an elongate barrier against the side of a row of battery cells, possibly while adhesive also therebetween cures. While we have used "first part" to refer to a hook and "second part" to refer to a recess, it will be appreciated that provided that there are complementary parts available to inter-engage, the spacers 103 may have recesses and/or hooks and the elongate barriers may have the other of recesses and/or hooks or a mixture thereof. Further, it will be appreciated that snap fit couplings having a configuration other than hook-and-recess may be used. For example, a pin, which may be part of the spacer 103, may be configured to snap into or provide an interference fit with a complementary hole in the elongate barrier. Other interference fit type coupling may be used. In other examples, the first part and the second part may comprise structures that receive a third part that interconnects the first part and the second part.

With further reference to Figure 3, the method of assembly may comprise receiving the second elongate barrier 350 having a first surface 356 configured to abut a side of the first row of battery cells 100 and a second surface 357 opposed the first surface. The plurality of complementary second parts 352, 353 of the snap-fit coupling on the second elongate barrier 350 are aligned to engage with at least some of the respective first parts 111, 112 of the snap-fit coupling present on the first plurality of spacers 103 of the first row of battery cells 100. When the parts are brought together and the snap fit coupling engages (possibly with adhesive 351 therebetween the rows and barriers), the second elongate barrier 350 is affixed to the first row of battery cells 100 at least by snap-fitting the first parts 111, 112 and the second parts 352, 353 together.

Thus, the first double-row-assembly 400 in one or more examples comprises the first row 100, second row 200, first elongate (e.g. cooling) barrier 300 therebetween and the second elongate (e.g. thermal) barrier 350 on one side. The first double-row-assembly 400 may be provided with any further rows or further double-rows for further assembly based on the intended assembled size of the battery assembly.

We will now describe further method of assembly steps that include forming a second double-row-assembly 500 (shown in Figure 5) from a third row 501 and a fourth row 502 of battery cells with a third elongate barrier 503 and a fourth elongate barrier 504. The second double-row-assembly 500 may be assembled as described above for the first double-row-assembly 400. The first doublerow-assembly 400 may be substantially identical to the second double-rowassembly 500. Thus, the third elongate barrier 503 may be a cooling barrier or "cooling snake". Likewise, the fourth elongate barrier 504 may comprise a thermal barrier, similar to the second elongate barrier 350.

As shown in Figure 5, the assembly method may include the forming a first quad-row-assembly of four rows of battery cells by affixing the first doublerow-assembly 400 and the second double-row-assembly 500 together. The affixation of the double-row-assemblies 400, 500 may be effected by adhesive 505 and by snap-fitting the further first parts 511 of at least some of the fourth plurality of spacers (that is those in the fourth row of battery cells 502) of the second double-row-assembly 500 with the second parts (at least first further recess 354) of the second elongate barrier 350 of the first double-rowassembly 400.

The first quad-row-assembly formed of first double-row-assembly 400 and the second double-row-assembly 500 may be provided with any further rows or further double-rows assemblies or further quad-row assemblies for further assembly based on the intended assembled size of the battery assembly.

Figure 5 also shows a cell block 512 formed at least of the first quad-row- assembly. However, it will be appreciated that once a double-rowassembly 400, 500 is formed, they can be coupled together, such as by snap- fit or snap-fit with adhesive, with other double-row-assemblies 400, 500 to form the cell block 512 of the desired size. In general, the first quad-row-assembly may be assembled further by affixing it to any one or two of a further quad-row-assembly, a further double-rowassembly or a single row of battery cells. The affixing may use the snap-fit coupling where possible and/or adhesive.

Example figure 6 illustrates a method which comprises: forming rows of battery cells 100, 200, 502, 503 in step 601 as described herein; forming double-rowassemblies 400, 500 in step 602 as described herein; optionally forming at least one quad-row-assembly in step 603; and forming a cell block 512 in step 604 from the double-row-assemblies and/or quad-row-assemblies. The steps 601-604 may be achieved following the process described above.

Figures 7 and 8 show an optional further step of placing the cell block 512 in a housing to form a battery assembly 800, which may comprise a battery module or battery pack. In other examples, the cell block 512 may not have a housing and may be inserted directly into a vehicle chassis or other device.

In one or more examples, the cell block 512 is provided on a base plate 701. The battery cells of the cell block 512 are electrically connected by connections 702, such that a first and second terminal are electrically connected to the battery cells and can thus be connected to a load, such as via a battery management system. Side walls 702, 703, 704, 705 are provided at sides of the cell block 512 and a top plate 706 is provided over the cell block to thereby enclose it.

It will be appreciated that the methodology described allows modular components to be used to build a cell block 512 and a battery assembly 800. Thus, we also disclose a kit of parts for arranging a plurality of battery cells for forming a battery assembly comprising a mount configured to hold a row of battery cells 100, 200, 501, 502 in place during an adhesive curing process. The kit further includes a plurality of the individual spacers 103, each spacer configured to be located between directly adjacent battery cells in the row. The kit of parts may further include the first elongate barrier 300, 503, wherein the first elongate barrier may comprise a cooling barrier that includes at least one channel therein for receiving a flow of coolant for cooling the rows of battery cells to which it is affixed, when in use. In other examples, the first elongate barrier may be a thermal barrier of mica for example.

The kit of parts may further includes a second elongate barrier, such as a thermal barrier or another cooling barrier. One or both of the first elongate barrier and the second elongate barrier may include complementary parts of the snap-fit coupling.

In any of the examples herein the battery cells 101 comprise cylindrical cells. However, the disclosure is not limited to an implementation that uses cylindrical cells.

Claims

1. A method of arranging battery cells, comprising cylindrical battery cells, for forming a battery assembly, the method comprising: forming a first row of the battery cells by stacking a first plurality of the battery cells and a first plurality of individual, spacers in a mount such that directly adjacent battery cells of the first plurality of the battery cells have one of said first plurality of spacers therebetween and wherein adhesive applied to one or both of said first plurality of spacers and said first plurality of battery cells is configured to adhere the battery cells of the first plurality of battery cells and the spacers of the first plurality of spacers together to form the first row of battery cells; providing the first row of battery cells, once the adhesive has cured, for assembly to form at least part of the battery assembly.

2. The method of claim 1, comprising: forming a second row of the battery cells by stacking a second plurality of the battery cells and a second plurality of the spacers in a mount such that directly adjacent battery cells of the second plurality of battery cells have one of said second plurality of spacers therebetween and wherein adhesive applied to one or both of said second plurality of spacers and said second plurality of battery cells is configured to adhere the battery cells of the second plurality of battery cells and the spacers of the second plurality of spacers together to form the second row of battery cells; and arranging the first row of battery cells together with the second row of battery cells.

3. The method of claim 2 comprising: forming a first double-row-assembly by: receiving a first elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface, opposed to the first surface, configured to abut a side of the second row of battery cells; affixing the first row of battery cells to the first surface of the first elongate barrier and affixing the second row of battery cells to the second surface of the first elongate barrier.

4. The method of claim 3, wherein the first elongate barrier comprises one of: a cooling barrier that includes at least one channel therein for receiving a flow of coolant for cooling the first and second rows of battery cells when in use; and a thermal barrier.

5. The method of claim 3, wherein the affixing of the first row of battery cells to the first surface of the first elongate barrier and the affixing of the second row of battery cells to the second surface of the first elongate barrier comprises affixing by applying adhesive to one or more of the first surface, the second surface, the first row of battery cells and the second row of battery cells and allowing said adhesive to cure.

6. The method of claim 2, wherein the battery cells are cylindrical battery cells and each of the first plurality of spacers and/or each of the second plurality of spacers comprises a body having a first concave surface to receive one of the battery cells; a second concave surface to receive a further one of the battery cells, wherein the second concave surface is arranged opposite the first concave surface.

7. The method of any preceding claim, wherein each of at least the first plurality of spacers include a first part of a snap-fit coupling and wherein the method comprises: receiving a second elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface opposed the first surface, wherein the second elongate barrier includes a plurality of complementary second parts of the snap-fit coupling to engage with at least some of the respective first parts of the snap-fit coupling present on the first plurality of spacers of the first row of battery cells; and affixing the second elongate barrier to the first row of battery cells at least by snap-fitting the first parts and the second parts together.

8. The method of claim 3, forming a second double-row-assembly by: forming a third row of the battery cells by stacking a third plurality of the battery cells and a third plurality of spacers in a mount such that directly adjacent battery cells of the third plurality of the battery cells have one of said third plurality of spacers therebetween and wherein adhesive applied to one or both of said third plurality of spacers and said third plurality of battery cells is configured to adhere the battery cells of the third plurality of battery cells and the spacers of the third plurality of spacers together to form the third row of battery cells; forming a fourth row of the battery cells by stacking a fourth plurality of the battery cells and a fourth plurality of the spacers in a mount such that directly adjacent battery cells of the fourth plurality of battery cells have one of said fourth plurality of spacers therebetween and wherein adhesive applied to one or both of said fourth plurality of spacers and said fourth plurality of battery cells is configured to adhere the battery cells of the fourth plurality of battery cells and the spacers of the fourth plurality of spacers together to form the fourth row of battery cells; forming the second double-row-assembly by: receiving a third elongate barrier having a first surface configured to abut a side of the third row of battery cells and a second surface, opposed to the first surface, configured to abut the fourth row of battery cells; affixing the third row of battery cells to the first surface of the third elongate barrier and affixing the fourth row of battery cells to the second surface of the third elongate barrier; and wherein each of at least the fourth plurality of spacers include a first part of the snap-fit coupling and wherein the method further comprises: forming a first quad-row-assembly by: affixing the first double-row-assembly and the second doublerow-assembly together at least by snap-fitting the first parts of at least some of the fourth plurality of spacers of the second double-row-assembly with the second parts of the second elongate barrier of the first double-row-assembly.

9. The method of claim 8, comprising forming a cell block by affixing the first quad-row-assembly to further assemblies comprising one or more of: four rows of the battery cells; two rows of the battery cells; and single rows of the battery cells.

10. The method of claim 9, further comprising forming the battery assembly by: providing the cell block on a base plate; electrically connecting the plurality of battery cells of the cell block; assembling side walls at sides of the cell block and a top plate over the cell block to thereby enclose the cell block.

11. A battery assembly formed by the method of any preceding claim.

12. A kit of parts for arranging a plurality of battery cells, comprising cylindrical battery cells, for forming a battery assembly, comprising a mount configured to hold a row of battery cells in place during an adhesive curing process and a plurality of individual spacers, each spacer configured to be located and adhered between directly adjacent battery cells in the row.

13. The kit of parts of claim 12, wherein each of the spacers comprises a body having a first concave surface to receive one of the battery cells; a second concave surface to receive a further one of the battery cells, and wherein the second concave surface is arranged opposite the first concave surface.

14. The kit of parts of claim 13, wherein the kit includes a first elongate barrier having a first surface configured to abut a side of the first row of battery cells and a second surface, opposed to the first surface, configured to abut the second row of battery cells; wherein the first elongate barrier comprises a cooling barrier that includes at least one channel therein for receiving a flow of coolant for cooling the first and second rows of battery cells when in use.

15. The kit of parts of claim 13 or claim 14, wherein each of at least the spacers include a first part of a snap-fit coupling; and the kit further includes a second elongate barrier having a first surface configured to abut a side of a row of battery cells and a second surface opposed the first surface, wherein the second elongate barrier includes a plurality of complementary second parts of the snap-fit coupling to engage with respective first parts of the snap-fit coupling present on the spacers.