WO2014058850A1

WO2014058850A1 - Battery support with modular coupling inserts

Info

Publication number: WO2014058850A1
Application number: PCT/US2013/063832
Authority: WO
Inventors: Stephen Alford; Travis Wayne BAILEY; Phillip Andrew STEWART; Bruce James SILK; Derrick Scott Buck
Original assignee: Enerdel, Inc.
Priority date: 2012-10-08
Filing date: 2013-10-08
Publication date: 2014-04-17

Abstract

Battery assemblies are disclosed including trays and a plurality of battery cells supported by the trays. Adjacent battery cells in each tray may be electrically and physically connected together via modular coupling inserts.

Description

BATTERY SUPPORT WITH MODULAR COUPLING INSERTS

RELATED APPLICATIONS

[0001] This application is related to US Provisional Application Serial No.

61/710,926, filed October 8, 2012, titled BATTERY SUPPORT WITH MODULAR COUPLING INSERTS, docket ENERD-Pl 2-004-01-US-E, the disclosure of which is expressly incorporated by reference herein.

[0002] This application is further related to PCT Application No.

PCT/US 12/40776, filed June 4, 2012, which claims priority from US Provisional Patent Application Serial No. 61/493,275, filed June 3, 2011, and US Provisional Patent Application Serial No. 61/543,781, filed October 5, 2011, all titled ENERGY STORAGE SYSTEM, the disclosures of which are expressly incorporated by reference herein in their entirety.

FIELD

[0003] The disclosure relates in general to methods and systems for storing and providing energy with a plurality of batteries and, more particularly, to methods and systems for storing and providing energy to a stationary energy storage market with a plurality of batteries.

BACKGROUND

[0004] Energy storage systems are known. Exemplary energy storage systems are disclosed in PCT Application No. PCT/US 11/52169, filed September 19, 2011, entitled ENERGY STORAGE SYSTEM, the disclosure of which is expressly incorporated by reference herein in its entirety. SUMMARY

[0005] The present disclosure provides battery assemblies including trays and a plurality of battery cells supported by the trays. Adjacent battery cells in each tray may be electrically and physically connected together via modular coupling inserts.

[0006] According to an embodiment of the present disclosure, a battery assembly is provided including a tray, a support member removably coupled to the tray, a compression member removably coupled to the tray and compressible against the support member, a first prismatic battery cell supported by the tray, the first battery cell having a first terminal, and a second prismatic battery cell supported by the tray, the second battery cell having a second terminal, the first and second terminals being compressed together between the support member and the compression member to electrically and physically couple the first and second terminals.

[0007] According to another embodiment of the present disclosure, a battery assembly is provided that supports a plurality of batteries, each of the plurality of batteries having a terminal. The battery assembly includes a support having a perimeter portion and a middle portion, the middle portion including a plurality of battery pockets to receive the plurality of batteries and a plurality of coupling region receptacles, and a plurality of lower support members positioned in the plurality of coupling region receptacles and removably coupled to the support, each of the plurality of lower support members disposed to support the terminals of at least two adjacent batteries.

[0008] According to yet another embodiment of the present disclosure, a battery assembly is provided including a plurality of batteries, at least two of the plurality of batteries being electrically and physically coupled together in a coupling region, a support that supports the plurality of batteries in a side -by- side configuration, the support including a receptacle in the coupling region, the receptacle spaced apart from a perimeter of the support, and means removably coupled to the receptacle for supporting the at least two batteries in the coupling region. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0010] FIG. 1 is a schematic view of an exemplary battery assembly;

[0011] FIG. 2 illustrates an exemplary battery cell for use in the battery assembly of FIG. 1, the battery cell having a positive terminal and a negative terminal extending from different sides of the battery cell;

[0012] FIG. 2A illustrates another exemplary battery cell for use in the battery assembly of FIG. 1, the battery cell having a positive terminal and a negative terminal extending from a common side of the battery cell;

[0013] FIG. 3 is a partially exploded, perspective view of the battery assembly, the battery assembly including a battery support and a plurality of modular coupling inserts;

[0014] FIG. 4 is a top plan view of the battery support of FIG. 3 shown without the modular coupling inserts;

[0015] FIG. 5 is a bottom plan view of the battery support of FIG. 3 shown without the modular coupling inserts;

[0016] FIG. 6 is a top plan view of the modular coupling insert of FIG. 3;

[0017] FIG. 7 is a side elevational view of the modular coupling insert of FIG. 6; and

[0018] FIG. 8 is a cross-sectional view of the battery assembly of FIG. 3, taken along line 8-8 of FIG. 3. [0019] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

[0020] While the present disclosure primarily involves storing and providing energy for a stationary energy storage market, it should be understood, that the invention may have application to other devices which receive power from batteries. Exemplary applications for a stationary storage market include providing power to a power grid, providing power as an uninterrupted power supply, and other loads which may utilize a stationary power source. In one embodiment, the systems and methods disclosed herein may be implemented to provide an uninterrupted power supply for computing devices and other equipment in data centers. A controller of the data center or other load may switch from a main power source to an energy storage system of the present disclosure based on one or more characteristics of the power being received from the main power source or a lack of sufficient power from the main power source. In one embodiment, the systems and methods disclosed herein may be implemented to provide power to an electric vehicle or a hybrid vehicle.

[0021] In an exemplary embodiment of the present disclosure, a battery assembly is provided. The battery assembly comprising a tray; a support member removably coupled to the tray; a compression member removably coupled to the tray and compressible against the support member; a first prismatic battery cell supported by the tray, the first battery cell having a first terminal; and a second prismatic battery cell supported by the tray, the second battery cell having a second terminal, the first and second terminals being compressed together between the support member and the compression member to at least one of electrically and physically couple the first and second terminals. In one example, the first and second battery cells are arranged in a side -by-side configuration on the tray. In another example, the tray extends under a middle portion of each of the first and second battery cells. In a variation thereof, the middle portions of the first and second battery cells are arranged in a non-overlapping configuration. In a further example, the tray includes a first pocket that receives the first battery cell and a second pocket that receives the second battery cell, a wall of the tray separating the first and second pockets. In a variation thereof, the wall is interrupted to receive the support member and the compression member. In still another example, the first and second terminals are arranged in an overlapping configuration between the support member and the compression member. In yet still another example, the support member is crowned. In yet a further example, the support member includes a plurality of studs, the compression member being compressed against the support member by tightening a plurality of fasteners onto the plurality of studs. In a variation thereof, the support member is overmolded onto the plurality of studs. In another variation thereof, the compression member includes a plurality of apertures to receive the plurality of studs. In still a further example, the tray defines a receptacle that receives the support member and the compression member. In still yet a further example, the support member is part of a modular coupling insert. In a variation thereof, the modular coupling insert includes a rim and at least one foot that frictionally interacts with the tray when the modular coupling insert is coupled to the tray.

[0022] In another exemplary embodiment of the present disclosure, a battery assembly supporting a plurality of batteries is provided. Each of the plurality of batteries has a terminal. The battery assembly comprising a support having a perimeter portion and a middle portion, the middle portion including a plurality of battery pockets to receive the plurality of batteries and a plurality of coupling region receptacles; and a plurality of lower support members positioned in the plurality of coupling region receptacles and removably coupled to the support, each of the plurality of lower support members disposed to support the terminals of at least two adjacent batteries. In one example, the plurality of coupling region receptacles are located between the plurality of battery pockets. In another example, the battery assembly further comprises a plurality of upper compression members compressible against the plurality of lower support members to compress the terminals of the at least two adjacent batteries. In a variation thereof, a plurality of studs extend from each of the plurality of lower support members, the plurality of upper compression members being compressed against the plurality of lower support members by tightening a plurality of fasteners onto the plurality of studs. In a further example, each of the plurality of lower support members includes at least one foot that frictionally interacts with a corresponding coupling region receptacle of the support.

[0023] In a further exemplary embodiment of the present disclosure, a battery assembly is provided. The battery assembly comprising a plurality of batteries, at least two of the plurality of batteries being electrically and physically coupled together in a coupling region; a support that supports the plurality of batteries in a side-by-side configuration, the support including a receptacle in the coupling region, the receptacle spaced apart from a perimeter of the support; and means removably coupled to the receptacle for supporting the at least two batteries in the coupling region.

[0024] In one example, the means holds the at least two of the plurality of batteries in place relative to the support. In another example, the means electrically and physically couples the at least two of the plurality of batteries together. In a varation thereof, a first means electrically and physically couples a first battery and a second battery, a middle portion of the first battery being spaced apart from a middle portion of the second battery in a non-overlapping arrangement, the support extending under the middle portion of the first battery and the middle portion of the second battery. In a refinement thereof, the first means includes a lower support member received in the receptacle of the support and an upper compression member removably coupled to the lower support member. In a further refinement thereof, the receptacle extends completely through the support from a top side of the support to a bottom side of the support. In another refinement, the lower support member is removably coupled to the support.

[0025] Referring to FIG. 1, a battery assembly 1000 is shown. Battery assembly

1000 includes a support 1002 and a plurality of battery cells 104, illustratively six battery cells 104A-104F. Battery support 1002 is also referred to herein as a tray. Battery cells 104A-104F are supported by support 1002 and are connected together to provide a source of power. In FIG. 1, cells 104A-104F are arranged in a generally side -by-side

arrangement. Cells 104A-104F are illustratively arranged in two rows - a first row including three cells 104A-104C and a second row including three cells 104D-104F - although other numbers and arrangements of battery cells 104 are contemplated.

[0026] In the illustrated embodiment, battery assembly 1000 further includes a controller 1012. Controller 1012 is operatively coupled to battery cells 104A-104F to monitor voltage and temperature of battery cells 104A-104F, as discussed further below.

[0027] An illustrative battery cell 104 for use in battery assembly 1000 is shown in FIG. 2. Cell 104 is illustratively a soft prismatic cell. Cell 104 includes a cell pouch 120 containing the battery chemistry and anode-cathode pairs. Cell pouch 120 includes a middle portion 126 and a perimeter portion 128. Perimeter portion 128 may be sealed to contain and protect the components inside cell pouch 120. A negative terminal 122 and a positive terminal 124 extend from the interior of cell pouch 120. In the illustrated embodiment, both negative terminal 122 and positive terminal 124 extend from perimeter portion 128 of cell pouch 120. Negative terminal 122 and positive terminal 124 may extend from opposite sides of cell 104, as shown in FIG. 2. Alternatively, negative terminal 122 and positive terminal 124 may extend from a common side of cell 104', as shown in FIG. 2A.

[0028] Returning to FIG. 1, terminals 122, 124 of adjacent cells 104 may have an overlapping or partially overlapping arrangement on support 1002. This overlapping arrangement may facilitate electrically and physically coupling adjacent cells 104 together, as discussed further below. By contrast, middle portions 126 (FIG. 2) of the adjacent cells 104 are spaced apart from one another in FIG. 1 such that middle portions 126 of the adjacent cells 104 have a non-overlapping arrangement on support 1002. In the illustrated embodiment, the middle portions 126 of adjacent cells 104 are spaced apart in a non-overlapping arrangement while at least one terminal of each cell 104 is electrically coupled together. Illustratively, the terminals of the adjacent cells are overlapping. Cells 104 are illustratively positioned in a single layer having a generally flat configuration on support 1002. Although cells 104 of FIG. 1 form a single layer on support 1002, in one embodiment, multiple layers of cells 104 may be positioned on top of support 1002. In this embodiment, middle portions 126 of cells 104 are still arranged in a non-overlapping arrangement relative to cells 104 within the same layer, but are overlapping with cells 104 of adjacent layers. If a given cell 104 needs replaced, that cell 104 may be removed from support 1002 and replaced with a new cell 104 without disturbing other cells 104 in support 1002.

1. Electrical Arrangement and Control of Battery Assembly

[0029] Referring still to FIG. 1 , the plurality of cells 104A- 104F are electrically coupled together to form a battery group. In the illustrative embodiment of FIG. 1, cells 104A-104F are electrically coupled together in series to form a single battery group. In one embodiment, the total voltage of the single battery group is less than about 50 volts, which complies with the OSHA HV threshold to provide safe assembly and shipping of battery assembly 1000 and groups of battery assemblies 1000 which are not coupled together. It is also within the scope of the present disclosure that at least two of the cells 104A-104F may be electrically coupled together in parallel. In a further embodiment, the battery cells 104A-104F are divided into multiple battery groups.

[0030] As discussed above, each cell 104A-104F includes a negative terminal 122 and a positive terminal 124. In FIG. 1, the side of each cell 104A-104F corresponding to negative terminal 122 is indicated with a "-" and the side of each cell 104A-104F corresponding to positive terminal 124 is indicated with a "+".

[0031] Beginning with cell 104A of FIG. 1 and moving in a counter-clockwise direction around support 1002, positive terminal 124 of cell 104A is electrically connected to positive terminal 1004 of battery assembly 1000 through terminal bar 1006. Negative terminal 122 of cell 104 A is electrically connected to positive terminal 124 of the adjacent cell 104B through an overlapping arrangement of the adjacent terminals 122, 124. Negative terminal 122 of cell 104B is electrically connected to positive terminal 124 of the next adjacent cell 104C through an overlapping arrangement, and so on.

Compression bars 1008 are placed over overlapping terminals 122, 124 to press terminals 122, 124 together, thereby ensuring electrical and physical contact between terminals 122, 124. Between the two rows of battery assembly 1000, cells 104C and 104D are electrically connected through a bussing jumper bar 142 that spans the space between terminals 122, 124 of cells 104C, 104D, without physically overlapping terminals 122, 124 of cells 104C, 104D. Negative terminal 122 of the last cell 104F is electrically connected to negative terminal 1005 of battery assembly 1000 through terminal bar 1006.

[0032] In the illustrated embodiment of FIG. 1, positive terminal 1004 and negative terminal 1005 of battery assembly 1000 extend from and are accessible from the same side of support 1002. However, the position of positive terminal 1004 and negative terminal 1005 may vary. For example, positive terminal 1004 and negative terminal 1005 may extend from opposite sides of support 1002.

[0033] Electrical connections 1010, illustratively electrical connections 1010A-

1010G, are made at each junction between cells 104 and terminals 1004, 1005 of battery assembly 1000. In FIG. 1, electrical connections 1010A-1010G provide voltage readings to controller 1012 through corresponding wiring harnesses 1014A, 1014B, connectors 1016A, 1016B, and cables 1018A, 1018B. It is also within the scope of the present disclosure to wirelessly communicate the voltage readings from electrical connections 1010A-1010G to controller 1012, such as by providing another controller (not shown) on-board support 1002 that communicates wirelessly with controller 1012. In one embodiment, controller 1012 is located in a low voltage tray which is provided as part of the battery assembly 1000.

[0034] Assuming battery cells 104 are functioning properly, controller 1012 should read a voltage at the first electrical connection 1010A that corresponds to the voltage of positive terminal 1004. The voltage at the second electrical connection 1010B should generally be offset from the voltage of the first electrical connection 1010A by the expected voltage of the first cell 104A, and so on through the remaining electrical connections 1010C-1010G.

[0035] A plurality of thermistors 1020, illustratively thermistors 1020A- 1020D, are also provided on support 1002 of FIG. 1, and are positioned to provide an indication of the temperature of cells 104A-104F. Terminals 122, 124 are generally the warmest portions of cells 104A-104F, and as such, thermistors 1020A-1020D may be positioned near terminals 122, 124. In FIG. 1 , thermistors 1020A-1020D are positioned between adjacent cells 104A-104F in a non-overlapping relationship with cells 104A-104F, but it is also within the scope of the present disclosure that thermistors 1020A-1020D may be positioned above or below cells 104A-104F in an overlapping manner. It is also within the scope of the present disclosure that pockets (not shown) may be provided in support 1002 to receive and hold thermistors 1020A-1020D in place. Thermistors 1020A-1020D are illustratively coupled to controller 1012 through corresponding wiring harnesses 1022A, 1022B, connectors 1026A, 1026B, and cables 1028 A, 1028B. It is also within the scope of the present disclosure to wirelessly communicate the temperature readings from thermistors 1020A-1020D to controller 1012, such as by providing another controller (not shown) on-board support 1002 that communicates wirelessly with controller 1012.

2. Physical Arrangement of Battery Assembly

[0036] Referring next to FIGS. 3-5, support 1002 of battery assembly 1000 is shown without cells 104 in place. Support 1002 is a generally tray-shaped, rectangular structure that includes a base 1100, an outer or peripheral wall 1102 extending upward from base 1100, and inner walls 1104 extending upward from base 1100 within peripheral wall 1102. In the illustrated embodiment of FIGS. 3-5, base 1100 of support 1002 has a generally solid construction to support cells 104 thereon. Walls 1102, 1104 cooperate to define a plurality of pockets 1040, illustratively six pockets 1040A-1040F, for receiving corresponding cells 104A-104F (FIG. 1) therein atop the supportive base 1100. In this arrangement, walls 1102, 1104 cooperate to surround and separate adjacent cells 104A-104F in pockets 1040A-1040F.

[0037] Support 1002 of FIGS. 3-5 includes first end 1072 and second end 1074.

First end 1072 and/or second end 1074 of support 1002 may accommodate terminals 1004, 1005 (FIG. 1), electrical connectors 1016A, 1016B that communicate with controller 1012 (FIG. 1), temperature connectors 1026 A, 1026B that communicate with controller 1012 (FIG. 1), and other electrical components, for example. Positioning these electrical components along first end 1072 and/or second end 1074 of support 1002 makes them accessible to a user, even when a plurality of supports 1002 are stacked together. In the illustrated embodiment, first end 1072 of support 1002 may

accommodate terminals 1004, 1005, electrical connectors 1016A, 1016B, and

temperature connectors 1026A, 1026B, making the components accessible to a user from the same side of support 1002.

[0038] Support 1002 of FIGS. 3-5 further includes a plurality of handles 1070.

Handles 1070 define the envelope of support 1002 on first end 1072 and second end 1074. Because handles 1070 define the envelope of support 1002, battery assembly 1000 may be stood on end without stressing terminals 1004, 1005 (FIG. 1), electrical connectors 1016A, 1016B (FIG. 1), temperature connectors 1026A, 1026B (FIG. 1), and other electrical components that are positioned along first end 1072 and/or second end 1074. When a plurality of supports 1002 are stacked together, the handles 1070 of each support 1002 are generally aligned.

[0039] The dimensions of support 1002 may vary. However, an exemplary support 1002 has a length measured between first end 1072 and second end 1074 of about 670 mm and a width of about 560 mm. Support 1002 may also have a low thickness or height, giving support 1002 a low profile design that is electrically safe and low in cost with a friendly mass/volume ratio for battery packaging. In one embodiment, the height of support 1002 is up to about 10 percent, 5 percent, 1.5 percent, or 1 percent of the length of support 1002. For example, the height of support 1002 may be less than about 25 mm, 20 mm, or 15 mm.

[0040] In one embodiment, support 1002 is made of a sheet molded composite

(SMC) dielectric polymer or other suitable electrically insulating materials. Such polymers include fiber-reinforced thermoset polyesters, and more specifically, glass fiber-reinforced thermoset polyesters. An exemplary material for support 1002 is DIELECTRITE E5V-204 SMC, which is available from IDI Composites International of Noblesville, Indiana. Another exemplary material for support 1002 is DIELECTRITE 46-16 BMC, which is also available from IDI Composites International. Additional details regarding DIELECTRITE E5V-204 SMC and DIELECTRITE 46-16 BMC are provided in the above -incorporated US Provisional Patent Application Serial No.

61/543,781. Support 1002 may be manufactured by compression molding or by another suitable molding technique, for example.

[0041] To accommodate electrical connections 1010A-1010G between the separated cells 104A-104F (FIG. 1), coupling regions 1080 are provided in the areas of electrical connections 1010A-1010G (FIG. 1). Coupling regions 1080 may be formed by discrete interruptions, breaks, pockets, and/or recesses in walls 1102, 1104 of support 1002. In FIG. 3, for example, coupling regions 1080 are positioned to accommodate terminals 122, 124, terminal bars 1006, compression bars 1008, and bussing jumper bar 142 (FIG. 1) in and between walls 1102, 1104, for example.

[0042] As shown in FIG. 3, each coupling region 1080 includes a lower support member 1082 and an upper compression member 1084. Upper compression member 1084 may be in the form of a terminal bar 1006 or a compression bar 1008 (FIG. 1), for example. In the assembled state, upper compression member 1084 is compressed against lower support member 1082 to physically and electrically couple desired battery components (e.g., overlapping terminals 122, 124 of FIG. 1) therebetween. In FIG. 3, for example, upper compression member 1084 is compressed against lower support member 1082 by tightening a pair of internally-threaded fasteners 1086 onto a pair of externally- threaded studs 1088 that extend from lower support member 1082. Upper compression member 1084, as well as the battery components being compressed beneath upper compression member 1084 (e.g., overlapping terminals 122, 124 of FIG. 1), may include through-holes 1089 to accommodate the passage of studs 1088. The lower support member 1082 is illustratively crowned to assist in compression, but it is also within the scope of the present disclosure that the upper compression member 1084 may be crowned, for example.

[0043] Lower support member 1082 and upper compression member 1084 may physically couple battery components (e.g., overlapping terminals 122, 124 of FIG. 1) together by holding the battery components in place relative to support 1002. It is within the scope of the present disclosure for the battery components to be pre-attached (e.g., welded, crimped) to one another, in addition to being clamped between lower support member 1082 and upper compression member 1084. In this embodiment, lower support member 1082 and upper compression member 1084 may physically couple the pre- attached battery components together by holding the pre-attached battery components in place relative to support 1002. It is also within the scope of the present disclosure for the battery components to be physically spaced apart. An intermediate electrical connector may span the space between the battery components to electrically couple the battery components together. In this embodiment, lower support member 1082 and upper compression member 1084 may physically couple the spaced-apart battery components together by holding them in place relative to one another and support 1002.

[0044] As discussed above, the overlapping terminals 122, 124 are generally the warmest portions of cells 104A-104F (FIG. 1), so coupling regions 1080 may benefit from heat removal to assist in thermal management. In one embodiment, lower support member 1082 and/or upper compression member 1084 include heat transfer fins or heat transfer channels to facilitate heat removal from coupling region 1080. For example, heat transfer fins may be provided along an upper side of compression member 1084. [0045] According to an exemplary embodiment of the present disclosure, coupling region 1080 is at least partially formed by a modular body, unit, or insert 1090 of support 1002, as shown in FIG. 3. In this manner, the modular coupling insert 1090 may be manufactured separately from the rest of support 1002 and subsequently coupled to support 1002. The modular coupling insert 1090 may also be removable or separable from support 1002.

[0046] The modular nature of coupling insert 1090 presents several benefits.

First, coupling insert 1090 may be constructed of a material different from the rest of support 1002. For example, support 1002 may be constructed of a thermoset polyesters material that is suitable for compression molding, as discussed further above, while lower support member 1082 of coupling insert 1090 may be constructed of a thermoplastic or thermoset polymer material that is suitable for injection molding. An exemplary material for coupling insert 1090 is a polybutylene terephthalate (PBT) / polycarbonate (PC) resin, such as the VALOX^® resin available from S ABIC Innovative Plastics of Pittsfield, Massachusetts. Studs 1088 and upper compression member 1084 may be constructed of electrically conducting materials like hardened steel, which may facilitate conduction in coupling region 1080 and heat removal from coupling region 1080. It is also within the scope of the present disclosure that coupling insert 1090 may be constructed of more than one material in layers. For example, the crowned lower support member 1082 of coupling insert 1090 may be constructed of an electrically conducting material, while the rest of coupling insert 1090 surrounding the crowned lower support member 1082 may be constructed of an electrically insulating material to avoid electrical shorts between adjacent supports 1002. A second benefit is the ability to modify, service, and/or repair coupling insert 1090 without impacting the rest of support 1002. For example, the position or size of studs 1088 on coupling insert 1090 may be changed without impacting the rest of support 1002. Third, the same coupling insert 1090 may be used with supports 1002 of different shapes and sizes to reduce inventory and manufacturing costs. Finally, coupling insert 1090 may be re-used in a new support 1002 to extend its useful life. [0047] Coupling insert 1090 is shown further in FIGS. 6-8. The illustrative coupling insert 1090 includes a crowned lower support member 1082 and a pair of studs 1088 extending therefrom. Coupling insert 1090 may be overmolded around studs 1088 with studs 1088 extending from lower support member 1082 of coupling insert 1090. The illustrative coupling insert 1090 also includes one or more feet 1092 and a rim 1094. As shown in FIG. 8, support 1002 defines a receptacle 1096 in each coupling region 1080 that is sized to receive coupling insert 1090. Receptacle 1096 is also sized to receive upper compression member 1084, such that lower support member 1082 and upper compression member 1084 interface within receptacle 1096. A shoulder 1098 in the receptacle 1096 abuts rim 1094 of coupling insert 1090 to prevent coupling insert 1090 from passing entirely through receptacle 1096. Also, feet 1092 on coupling insert 1090 may abut support 1002 to frictionally stabilize coupling insert 1090 within receptacle 1096. It is also within the scope of the present disclosure for coupling insert 1090 and support 1002 to include a fastener, a snap feature, or another suitable lock feature that locks coupling insert 1090 into support 1002

3. Battery Modules

[0048] As indicated above, a plurality of battery supports 1002 may be stacked or layered together to form a battery module (not shown). Exemplary battery modules are shown and described in the above-incorporated PCT Application No. PCT/US 12/40776. The number of battery supports 1002 in each module may vary. Each battery support 1002 may include nesting features to facilitate stacking of adjacent battery supports 1002. The illustrative support 1002 includes upper bosses 1050 extending from the top side of support 1002, as shown in FIG. 4, and corresponding lower recesses 1052 in the bottom side of support 1002, as shown in FIG. 5. Recesses 1052 are positioned to receive bosses 1050 from the adjacent support 1002 to limit movement between adjacent supports 1002, thereby stabilizing the battery module.

[0049] The assembled battery module may be held together with suitable fasteners. In the illustrated embodiment of FIGS. 3-5, each support 1002 defines a plurality of openings 1054 that align with adjacent openings 1054 to receive fasteners (e.g., bolts, tie rods) through the battery module. It is also within the scope of the present disclosure to wrap fasteners (e.g., bands) around the assembled battery module.

[0050] When adjacent supports 1002 are stacked together to form the module, various regions of support-to-support contact exist where adjacent supports 1002 contact one another. For example, walls 1102, 1104 and handles 1070 of support 1002 may contact adjacent supports 1002. These interfacing regions form a solid material stack in the battery module, thereby increasing the rigidity of the battery module. The solid stack may be spaced apart from pockets 1040A-1040F and the cells 104A-104F (FIG. 1) contained therein. Rather, the solid stack may be located between adjacent pockets 1040A-1040F and around the outer periphery of the module.

[0051] The assembled battery module may be placed in a suitable enclosure (not shown). Exemplary enclosures are shown and described in US Provisional Patent Application Serial No. 61/678,258, filed August 1, 2012, titled MODULAR ENERGY STORAGE SYSTEM, the disclosure of which is expressly incorporated by reference herein in its entirety. The enclosure may store multiple battery modules, as well as a high voltage module, a low voltage module, and a controller, for example. Exemplary high voltage and low voltage modules are disclosed in the above-incorporated US Provisional Patent Application Serial No. 61/486, 151. It is also within the scope of the present disclosure to place individual battery supports 1002 or grouped battery modules on racks in the enclosure. Thermal management systems may also be provided to cool the battery modules with air, liquid, or refrigerant, for example.

[0052] The battery arrangements disclosed herein may be coupled together to form battery strings. The processing sequences disclosed in the above -incorporated US Provisional Patent Application Serial No. 61/486, 151 and PCT Application No.

PCT/USl 1/52169 may be used to monitor and control the operation of the battery arrangements disclosed herein. Also, the trays disclosed herein may replace the drawers in the illustrated embodiment disclosed in the above-incorporated US Provisional Patent Application Serial No. 61/486,151 and PCT Application No. PCT/US11/52169 to provide the battery power of the energy modules.

[0053] While this invention has been described as having exemplary designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A battery assembly comprising:

a tray;

a support member removably coupled to the tray;

a compression member removably coupled to the tray and compressible against the support member;

a first prismatic battery cell supported by the tray, the first battery cell having a first terminal; and

a second prismatic battery cell supported by the tray, the second battery cell having a second terminal, the first and second terminals being compressed together between the support member and the compression member to at least one of electrically and physically couple the first and second terminals.

2. The battery assembly of claim 1, wherein the first and second battery cells are arranged in a side-by-side configuration on the tray.

3. The battery assembly of claim 1, wherein the tray extends under a middle portion of each of the first and second battery cells.

4. The battery assembly of claim 3, wherein the middle portions of the first and second battery cells are arranged in a non-overlapping configuration.

5. The battery assembly of claim 1, wherein the tray includes a first pocket that receives the first battery cell and a second pocket that receives the second battery cell, a wall of the tray separating the first and second pockets.

6. The battery assembly of claim 5, wherein the wall is interrupted to receive the support member and the compression member.

7. The battery assembly of claim 1, wherein the first and second terminals are arranged in an overlapping configuration between the support member and the compression member.

8. The battery assembly of claim 1, wherein the support member is crowned.

9. The battery assembly of claim 1, wherein the support member includes a plurality of studs, the compression member being compressed against the support member by tightening a plurality of fasteners onto the plurality of studs.

10. The battery assembly of claim 9, wherein the support member is overmolded onto the plurality of studs.

11. The battery assembly of claim 9, wherein the compression member includes a plurality of apertures to receive the plurality of studs.

12. The battery assembly of claim 1, wherein the tray defines a receptacle that receives the support member and the compression member.

13. The battery assembly of claim 1, wherein the support member is part of a modular coupling insert.

14. The battery assembly of claim 13, wherein the modular coupling insert includes a rim and at least one foot that frictionally interacts with the tray when the modular coupling insert is coupled to the tray.

15. A battery assembly supporting a plurality of batteries, each of the plurality of batteries having a terminal, the battery assembly comprising:

a support having a perimeter portion and a middle portion, the middle portion including a plurality of battery pockets to receive the plurality of batteries and a plurality of coupling region receptacles; and

a plurality of lower support members positioned in the plurality of coupling region receptacles and removably coupled to the support, each of the plurality of lower support members disposed to support the terminals of at least two adjacent batteries.

16. The battery assembly of claim 15, wherein the plurality of coupling region receptacles are located between the plurality of battery pockets.

17. The battery assembly of claim 15, further comprising a plurality of upper compression members compressible against the plurality of lower support members to compress the terminals of the at least two adjacent batteries.

18. The battery assembly of claim 17, wherein a plurality of studs extend from each of the plurality of lower support members, the plurality of upper compression members being compressed against the plurality of lower support members by tightening a plurality of fasteners onto the plurality of studs.

19. The battery assembly of claim 15, wherein each of the plurality of lower support members includes at least one foot that frictionally interacts with a corresponding coupling region receptacle of the support.

20. A battery assembly comprising:

a plurality of batteries, at least two of the plurality of batteries being electrically and physically coupled together in a coupling region;

a support that supports the plurality of batteries in a side-by-side configuration, the support including a receptacle in the coupling region, the receptacle spaced apart from a perimeter of the support; and

means removably coupled to the receptacle for supporting the at least two batteries in the coupling region.

21. The battery assembly of claim 20, wherein the means holds the at least two of the plurality of batteries in place relative to the support.

22. The battery assembly of claim 20, wherein the means electrically and physically couples the at least two of the plurality of batteries together.

23. The battery assembly of claim 22, wherein a first means electrically and physically couples a first battery and a second battery, a middle portion of the first battery being spaced apart from a middle portion of the second battery in a non-overlapping arrangement, the support extending under the middle portion of the first battery and the middle portion of the second battery.

24. The battery assembly of claim 23, wherein the first means includes a lower support member received in the receptacle of the support and an upper compression member removably coupled to the lower support member.

25. The battery assembly of claim 24, wherein the receptacle extends completely through the support from a top side of the support to a bottom side of the support.

26. The battery assembly of claim 24, wherein the lower support member is removably coupled to the support.