WO2017063855A1

WO2017063855A1 - An apparatus comprising battery cells and a method of assembling

Info

Publication number: WO2017063855A1
Application number: PCT/EP2016/072849
Authority: WO
Inventors: Stephen Nicholls
Original assignee: Jaguar Land Rover Limited
Priority date: 2015-10-14
Filing date: 2016-09-26
Publication date: 2017-04-20
Also published as: GB201518173D0; GB2543489B; DE112016004704T5; GB2543489A

Abstract

An apparatus (101), a vehicle (1001) and an electrical system (1006) comprising an apparatus (101) and a method of assembly are disclosed. The apparatus comprises a plurality of sets (102A, 102B) of battery cells (102), and each battery cell comprises a first electrode (103), a second electrode (104) and an electrolyte (105). The apparatus also includes a plurality of bodies (106), where each body (106) contains a respective one of the sets (102A, 102B) of battery cells (102) and the battery cells (102) have first electrodes (103) electrically connected to the respective body (106). A plurality of connector plates (107) are each connected to the second electrodes (104) of the battery cells (102) in a respective one of the bodies (106), and each of the connector plates (107) is insulated from the respective body (106). A first one of the connector plates (107A) is connected to the second electrodes (104) of a first one of the sets (102A) of battery cells (102) located in a first one of the bodies (106A), and the first connector plate (107A) is directly attached to a second body (106B) containing a second one of the sets (102B) of battery cells (102).

Description

AN APPARATUS COMPRISING BATTERY CELLS AND A METHOD OF ASSEMBLING

TECHNICAL FIELD

The present disclosure relates to an apparatus comprising battery cells and a method of assembling. In particular, but not exclusively, it relates to an apparatus comprising battery cells and a method of assembling for use in a vehicle. Aspects of the invention relate to an apparatus, an electrical system, a vehicle and a method.

BACKGROUND It is known to locate sets of battery cells within containers or bodies to form modules. Cables and connectors or busbars and bolts are used to electrically connect the modules together to provide the required voltage and power.

It is an aim of the present invention to eliminate the need for cables and connectors or busbars and bolts to connect together sets of battery cells.

SUMMARY OF THE INVENTION

Aspects of the embodiments of the invention provide an apparatus, a vehicle, an electrical system and a method as claimed in the appended claims.

According to an aspect of the invention there is provided an apparatus comprising: a plurality of sets of battery cells, each battery cell comprising a first electrode, a second electrode and an electrolyte; a plurality of container means, each container means containing a respective one of the sets of battery cells, and the battery cells having first electrodes electrically connected to the respective container means; a plurality of connector plates, each of the connector plates connected to the second electrodes of the battery cells in a respective one of the container means, and each of the connector plates being insulated from the respective container means; and wherein a first one of the connector plates is connected to the second electrodes of a first one of the sets of battery cells located in a first one of the container means, and the first connector plate is directly attached to a second container means containing a second one of the sets of battery cells.

This provides the advantage that no additional cables or busbars are required to connect the sets of battery cells together.

Each of the container means may be a body formed of an electrically conducting material.

In some embodiments, the first electrode is a negative electrode and the second electrode is a positive electrode.

In some embodiments, the first connector plate forms a part of, or is permanently directly connected to, the second container means. The first connector plate may be permanently directly connected to the second container means by a weld joint.

The second container means may define holes containing battery cells and a plate may extend across the holes to close one end of the holes in the second container means and provides the first connector plate.

This provides a simple structure for manufacture because the second container means may be formed for example by extrusion and one end of the holes may be closed and the first connector plate attached by one process.

In some embodiments, the second container means is permanently attached to the connector plate by braze material or a weld.

In some embodiments, each container means defines a plurality of holes, and each said hole contains one of the battery cells. Each of the battery cells may have a structure comprising a layer of positive electrode material, a layer of electrolyte material and a layer of negative electrode material, and at least one of the positive electrode material, the electrolyte material and the negative electrode material is in direct contact with the respective container means. Thus, the layered structure is in direct contact with the container means because the layered structure is not encapsulated in a can prior to being positioned in a hole. The absence of the can provides the advantages of saving on space that would otherwise have been taken up by the cans, and saving on weight.

In some embodiments, each container means defines a plurality of holes, and each said hole contains one of the battery cells. The apparatus may comprise an insulating member located between one of the bodies and a respective connector plate, and the insulating member is shaped to provide engagement with the holes defined by said container means. The insulating member may have features on a surface which mechanically engage with features on a surface of the respective connector plate. The features on the surface of the respective connector plate may comprise an array of apertures. In some embodiments, a connecting face of a first one of the bodies is attached to a connecting face of a second one of the bodies by an insulating sheet, and the insulating sheet and connecting faces of the first and second bodies are provided with interlocking features. Thus, the insulating sheet provides the function of insulating one body from another and may also provide the function of holding the two bodies together by the interlocking features.

The interlocking features of the insulating sheet may be configured to interlock with the features of the first one of the bodies by sliding together. This provides for an easy method of assembly.

The insulating sheet may form part of the insulating member which insulates a connecting plate from a container means.

In some embodiments, at least one of the connector plates comprises an array of apertures, and each aperture of the array of apertures is provided with a lid to which a respective one of the second electrodes of the battery cells is connected. This provides for an easy method of connection between the second electrodes and the connector plate. According to another aspect of the invention there is provided an electrical system for a vehicle comprising an apparatus according to any one of claims 1 to 16.

According to a further aspect of the invention there is provided a vehicle comprising an apparatus according to any one of claims 1 to 16.

According to a further aspect of the invention there is provided a method of assembling battery cells comprising: locating a first set of battery cells within a first body; locating a second set of battery cells within a second body; connecting a first electrode of each of the battery cells to the respective one of the bodies; positioning a respective connector plate relative to each one of the bodies so that each of the connector plates is insulated from the respective body; connecting a first one of the connector plates to the second electrodes of the first set of battery cells; and connecting a second one of the connector plates to the second electrodes of second set of battery cells, wherein the first one of the connector plates is formed as a part of, or is direct attached to, the second body.

In some embodiments, said connecting a first electrode comprises connecting a negative electrode of each of the battery cells to the respective one of the bodies. In some embodiments, the first connector plate forms a part of the second body.

In some embodiments, the method comprises connecting the first connector plate directly to the second body by a weld joint. In some embodiments, the second body defines holes for receiving battery cells and the first connector plate is part of a larger plate and the method comprises permanently attaching the plate to the body to close one end of the holes.

In some embodiments, each of the battery cells has a structure comprising a layer of positive electrode material, a layer of electrolyte material and a layer of negative electrode material, and the method comprises placing at least one of the positive electrode material, the electrolyte material and the negative electrode material in direct contact with the respective body. In some embodiments, the method comprises positioning an insulating member between one of the bodies and a respective one of the connector plates. The method comprises bringing together features of the insulating member with corresponding mating features of the respective connector plate and/or body. At least one of the connector plates may comprise an array of apertures, and the method comprises connecting a respective one of the second electrodes of the battery cells to a respective lid and positioning the lids over the holes. In some embodiments, the method comprises connecting features on one side of an insulating sheet to interlocking features of the first body and connecting features on the other side of the insulating sheet to interlocking features of the second body. The process of connecting features on one side of an insulating sheet to interlocking features of the first body may comprise sliding together the features on one side of the insulating sheet and the interlocking features of the first body.

According to a further aspect of the invention there is provided an apparatus comprising: a plurality of sets of battery cells, each battery cell comprising a first electrode, a second electrode and an electrolyte; a plurality of bodies, each body containing a respective one of the sets of battery cells, and the battery cells having first electrodes electrically connected to the respective body; a plurality of connector plates, each of the connector plates connected to the second electrodes of the battery cells in a respective one of the bodies , and each of the connector plates being insulated from the respective body; and wherein a first one of the connector plates is connected to the second electrodes of a first one of the sets of battery cells located in a first one of the bodies, and the first connector plate is directly attached to a second body containing a second one of the sets of battery cells.

According to a still further aspect of the invention there is provided an apparatus comprising: a first set of battery cells, each battery cell comprising a first electrode, a second electrode and an electrolyte; a first body containing the battery cells, the body being electrically connected to the first electrodes of the battery cells; a first connector plate electrically connected to the second electrodes of the battery cells; and a first insulating member extending between the body and the connector plate, wherein the first insulating member is shaped to provide engagement with features defined by the body and/or the connector plate.

In some embodiments, the first insulating member is provided with raised ridges to provide engagement with holes defined by the body. The holes may be provided in the body for receiving battery cells.

According to a still further aspect of the invention there is provided an apparatus comprising: a plurality of sets of battery cells; a plurality of bodies, each body containing a respective one of the sets of battery cells, and the battery cells having first electrodes electrically connected to the respective body; a plurality of connector plates, each of the connector plates connected to the second electrodes of the battery cells in a respective one of the bodies, and each of the connector plates being insulated from the respective body; and wherein a first one of the connector plates is connected to the second electrodes of a first one of the sets of battery cells located in a first one of the bodies, and the first connector plate is directly attached to a second body containing a second one of the sets of battery cells

According to a still further aspect of the invention there is provided an apparatus comprising: a first plurality of battery cells located in a first electrically conductive body and a second plurality of battery cells located in a second electrically conductive body, wherein an electrode of each of the first plurality of battery cells are connected to an electrical conductor and the electrical conductor is directly attached to the second electrically conductive body.

In an embodiment the electrical conductor comprises a conductor plate which is directly attached to the second electrically conductive body.

The apparatus may be used to provide a battery for use in a vehicle.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

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

Fig. 1 shows a schematic cross sectional view of an apparatus 101 according to an embodiment of the present invention;

Fig. 2 shows a cross-sectional view of an apparatus 101 B according to an embodiment of the present invention;

Fig. 3 shows a cross-sectional view of an apparatus 101 C according to an embodiment of the present invention;

Fig. 4 shows the second body 106B, second connector plate 107B and the integrally formed second insulating member 308B and body insulating member 312, partially disassembled;

Figs. 5A and 5B show alternative perspective views of an example of an apparatus 101 D comprising more than two bodies 106;

Fig. 6 shows a flow chart outlining a method 600 for assembling battery cells;

Fig. 7 shows a cross-sectional view of an alternative apparatus 101 E according to an embodiment of the present invention;

Fig. 8 shows a perspective view of the apparatus 101 E of Fig. 7 with the connector plate 107R and insulating member 108R removed from the body 106R;

Fig. 9 shows a flow chart outlining a method 900 for assembling battery cells; and

Fig. 10 shows schematically a vehicle 1001 comprising a battery 1002 including at least one apparatus 101 , 101 B, 101 C, 101 D or 101 E.

DETAILED DESCRIPTION

The Figures illustrate an apparatus 101 comprising: a plurality of sets 102A, 102B, 102P, 102Q, 102R of battery cells 102, each battery cell 102 comprising first electrodes 103, second electrodes 104 and electrolyte 105; a plurality of container means 106, each container means 106 containing a respective one of the sets 102A, 102B, 102P, 102Q, 102R of battery cells 102 and the battery cells 102 having first electrodes 103 electrically connected to the respective container means 106; a plurality of connector plates 107, each of the connector plates 107 connected to the second electrodes 104 of the battery cells 102 in a respective one of the container means 106, and each of the plates 107 being insulated from the respective container means 106; and wherein a first one of the plates 107A, 107P is connected to the second electrodes 104 of a first one of the sets 102A, 102P of battery cells 102 located in a first one of the container means 106A, and the first plate 107A, 107P is directly attached to a second container means 106B containing a second one of the sets 102B, 102Q of battery cells 102.

Each of the container means 106 may be a body 106 formed of an electrically conducting material. An apparatus 101 embodying the present invention is shown in a schematic cross section in Fig. 1 . The apparatus 101 of Fig. 1 comprises two sets 102A and 102B of battery cells 102. The apparatus 101 also comprises two bodies 106, each body 106 containing a respective one of the sets of battery cells 102. A first set 102A of the battery cells 102 is positioned in a first one of the bodies 106A, and the second set 102B of the battery cells is positioned within the second body 106B. Three battery cells are shown in each of the sets 102A and 102B of battery cells 102 in Fig. 1 , but the sets of battery cells may comprise more than just three battery cells. As is shown, for example in Fig. 4, the battery cells may be arranged in a two dimensional array, and therefore for example, the array may be three battery cells wide but several battery cells long. (Of course the array may have a width comprising more or fewer than three battery cells.)

The bodies 106 may each define a plurality of holes 109 and each one of the holes may be configured to receive at least one of the battery cells 102. In the apparatus 101 of Fig. 1 , each hole 109 contains a single battery cell 102. The holes 109 may be cylindrical in shape so that a cylindrical battery cell 102 is a good fit within its hole.

Each battery cell 102 comprises a first electrode 103, a second electrode 104 and an electrolyte 105. The first electrodes 103 may be negative electrodes and the second electrodes 104 may be positive electrodes. The battery cells 102 have first electrodes 103 electrically connected (for example by conducting element 121 ) to the respective body 106, which is electrically conductive. The apparatus also comprises a plurality of connector plates 107 and each of the connector plates 107 is connected (for example by conducting element 122) to the second electrodes 104 of the battery cells 102 in a respective one of the bodies 106. Thus, the battery cells 102 in the first set 102A have first electrodes 103 connected to the first body 106A and second electrodes 104 connected to a first one of the connector plates 107A. Similarly the battery cells 102 in the second set 102B have first electrodes 103 connected to the second body 106B and second electrodes 104 connected to a second one of the connector plates 107B.

Each of the connector plates 107 is insulated from the respective body 106. In the present example, each of the connector plates 107 is insulated from the respective body 106 by an insulating member 108. The first connector plate 107A is insulated from the first body 106A by a first insulating member 108A and the second connector plate 107B is insulated from the second body 106B by a second insulating member 108B. The insulating members 108 may be provided with apertures 1 12 to enable electrical connection between the second electrode 104 of each of the battery cells 102 and the respective connector plates 107.

Insulating member 108A extends over the holes 109 such that the apertures 1 12 in the insulating member are aligned with the holes 109. The first plate 107A extends over the insulating member 108A to close off the apertures 1 12 in the insulating member 108A, so that the insulating member 108A in combination with the first connector plate 107A closes off one end 123 of the holes 109.

The two bodies 106A and 106B are insulated from one another by a body insulating member 1 13. The body insulating member 1 13 may be separately formed from the insulating members 108A and 108B or may be integrally formed.

The first one of the connector plates 107A is connected to the second electrodes 104 of a first one of the sets 102A of battery cells 102 located in a first one of the bodies 106A, and the first connector plate 107A is directly attached to a second body 106B containing the second one of the sets 102B of battery cells 102. Consequently the first set 102A of battery cells 102 is connected in series with the second set 102B of the battery cells 102 without the need for any additional connectors. The first one of the connector plates 107A may be formed separately from the second body 106B and attached to it, for example by welding or brazing, so that the first plate is permanently directly connected to the second body 106B. Alternatively, the second body 106B may be formed with the first one of the connector plates 107A attached to the body 106B.

The bodies 106 may be formed by extruding a metal, such as aluminium or aluminium alloy, and the holes 109 may be formed in the extrusion process. One end 124 of the holes may be closed by a conductive material. In the case where the bodies are formed as an extrusion, the end 124 of the holes 109 may be closed by a metal plate fixed across the end of the extrusion. For example, an aluminium or aluminium alloy plate may be brazed or welded to the end of the extrusion. In the case of the second body 106B, the plate may be made sufficiently long to close the end 124 of the holes 109 and also to provide the first connector plate 107A. For example, with reference to Fig. 1 , a first portion 1 10 of a plate (to the right of dashed line 1 1 1 ) may be attached to the end of the extrusion while a second portion of the plate provides the connector plate 107A.

Alternatively, the bodies 106 may be formed by machining a solid block of material or by machining a metal casting. In which case, for example, the first connector plate 107A and the second body 106B may be integrally formed as part of single metal casting.

It may be noted that the second connector plate 107B unlike first connector plate 107A, is not directly attached to a body. Instead, the second connector plate 107B is provided with a terminal part 1 14 extending away from the second body 106B. The terminal part 1 14 may be configured to provide a means for connecting the connector plate 107B to another electrical component such as a connecting cable (not shown). Similarly the first body 106A, unlike the second body 106B, is not directly attached to a connector plate 107, but instead is provided with a terminal part 1 15 which may be configured to connect the first body 106A to another electrical component such as a connecting cable (not shown). An apparatus 101 B embodying the invention is shown in cross section in Fig. 2, the apparatus 101 B of Fig. 2 may be have the same features as those described above with respect to the apparatus 101 of Fig. 1 . However, Fig. 2 provides more detail of an example apparatus 101 B.

Thus, like the apparatus 101 of Fig. 1 , the apparatus 101 B of Fig. 2 comprises two bodies 106A and 106B, each of which contains a plurality of battery cells 102. The battery cells 102 in a first set 102A are located within the first body 106A and have first electrodes 103 connected to the body 106A and second electrodes 104 connected to a first plate 107A. Similarly, the battery cells 102 in a second set 102B are located within the second body 106B, have first electrodes connected to the second body 106B and second electrodes connected to a second plate 107B. The battery cells 102 may have a layered structure comprising layers of first electrode material and second electrode material separated by electrolyte material. The layers of material may be coiled up to form a coiled structure that is commonly referred to as a "jelly roll" or "Swiss roll".

Each coiled structure may be positioned within a metal can which is sealed to form a conventional battery cell that is then located in a body 106. However, in the present embodiment, the layered structures forming the battery cells 102 are not encapsulated in individual cans. Instead, the layered structures are positioned in an uncovered form within the holes 109 formed in the bodies 106. Consequently, the outermost layers of the layered structures are in direct contact with the inner surfaces 201 defining the holes 109 of the bodies 106. The layered structures forming the battery cells 102 are arranged such that they all have the first electrode 103 providing the outermost layer.

An advantage of positioning the layered structures of the battery cells within the bodies without first encapsulating in individual cans is that the space that would have been taken up by the cans is saved. In addition, in use, the battery cells generate heat which must be conducted away through the bodies 106, and any resistance to this conduction that would have been provided by the cans is avoided. As shown in Fig. 2 a conductive tab 202 is provided on the first electrode 103 of each of the battery cells 102. The conductive tab 202 is attached to the body 106, for example by a weld 203. This may be achieved by arranging the tab 202 to extend across the end of a hole 204 which extends along the length of the coiled layered structure of the battery cells. After positioning the coiled layered structure within its hole 109 in a body 106 a welding electrode may be extended through the hole 204 to spot weld the tab to the body 106. In an alternative the layered structure may be positioned within a hole 109 in a body so that the tab is nearest to the open end 123 of the hole 109. The tab may then be welded to a side wall (inner surface 201 ) of the hole.

A second conductive tab 205 is provided on the second electrode 104 of each battery cell 102. The second conductive tab 205 may be used to provide electrical connection between the second electrode 104 and the respective connector plate 107. The second conductive tab 205 and the connector plate 107 may be electrically connected by a conductor 206, such as a metal wire. The conductor 206 may be attached to the tab 205 and to the connector plate 107, for example by welding.

To simplify assembly, the connector plates 107 are provided with a plurality of apertures 207, each aperture being aligned with a respective aperture 1 12 in the insulating member 108 and with a respective hole 109 in the body 106. Each aperture 207 in a connector plate 107 is provided with a lid 208 to cover the aperture 207. In this arrangement, the second electrodes 104 of the battery cells 102 are connected to a respective one of the lids 208 of the connector plate 107. For example, the conductors 206 attached to the second electrode 104 may be connected to the lids 208, for example by welding.

During assembly, the conductors 206 may firstly be attached to tabs 205. All of the battery cells 102 in a set 102A or 102B may then be positioned in their holes 109 in a body 106. The conductors 206 may be configured to extend out from the ends of the holes 109. The insulating member 108 and connector plate 107, without lids 208 in place, may then be positioned over the holes 109. A lid 208 may then be attached to each of the conductors 206 before welding the lids in place over the aperture 207. An apparatus 101 C embodying the present invention is shown in the cross sectional view of Fig. 3. The apparatus 101 C may be identical to the apparatus 101 B of Fig. 2 except for the configuration of the insulating members 308 which insulate the bodies 106A and 106B from their respective connector plates 107A and 107B.

In the apparatus 101 C, a first insulating member 308A separates the first body 106A from the first connector plate 107A and a second insulating member 308B separates the second body 106B from the second connector plate 107B. The insulating member 308A has a first face 301 having first features 302 configured to mechanically engage with features of the connector plate 107A and a second face 303 having second features 304 configured to mechanically engage with features of the first body 106A. In the present embodiment, the first features 302 are raised circular ridges which surround the apertures 1 12 formed in the insulating member 308A, and the features 302 are configured to be a good fit within the apertures 207 formed in the connector plate 107A. Similarly, the second features 304 are raised circular ridges which surround the apertures 1 12 formed in the insulating member 308A, and the second features 304 are configured to be a good fit within the ends of the holes 109 formed in the body 106A.

The insulating member 308B may have the same configuration as the insulating member 308A, having first features 302 configured to locate within apertures 207 formed in the connector plate 107B and second features 304 configured to locate within holes 109 formed in the body 106B. However, in the present example, the second insulating member 308B is integrally formed with the body insulating member 312. The second body 106B, second connector plate 107B and the integrally formed second insulating member 308B and body insulating member 312 are shown partially disassembled in Fig. 4. The second body 106B has opposing side faces 401 and 402 that are provided with a plurality of parallel slots 403. The slots 403 are configured to have a relatively narrow opening at the faces 401 and 402 and relatively wide bottoms spaced from the faces 401 , 402. In the present case, the slots have a dovetail-shaped cross section, but alternative shaped slots, such as T-shaped slots or L-shaped slots may be used instead. The body insulating member 312 comprises a sheet of insulating material on which are provided parallel ridges 404 on each of its two faces 405 and 406. The ridges 404 on each of the faces of the body insulating member 312 have a cross-section and a spacing to match the cross section and spacing of the slots 403 formed on the faces of the body 401 . Thus, as shown in Fig. 4, the body insulating member 312 may be attached to one face 402 of the body 106B by sliding the ridges 404 on one face 405 into the slots 403. The first body 106A (not shown in Fig. 4) may be provided with slots 403 like those of the second body 106B. Consequently the first body 106A may be attached to the body insulating member 312 by sliding the ridges 404 on the second face 406 of the body insulating member 312 into the slots 403 of the first body 106A.

The above-described apparatuses comprise only two bodies 106 and a corresponding number of connecting plates 107. However, in alternative embodiments more than two bodies 106 and connecting plates 107 are included. An example of an apparatus 101 D comprising more than two bodies 106 is shown in the alternative perspective views of Fig. 5A and 5B. The apparatus 101 D in this example comprises five bodies 106 and a corresponding number of connecting plates 107. Four of the bodies 106C, 106D, 10E and 106F may be identically configured to each other and like body 106B of Figs. 1 to 4. Thus, they are each attached directly to a connector plate 107A. The fifth body 106A may be configured identically to the body 106A of Figs. 1 to 4, and therefore is provided with a terminal plate 1 15 rather than a connector plate 107.

In Figs. 5A and 5B the bodies are connected together by body insulating members 312 as described above with respect to Fig. 4. An end one of the bodies 106F and the respective connector plate 107B are shown prior to assembly to the rest of the bodies 106A, 106C, 106D and 106E in Figs. 5A and 5B. In addition, only three of the holes 109 in the end one of the bodies 106F have been provided with battery cells 102. To complete the assembly of the apparatus 101 D, a battery cell 102 is positioned in each of the empty holes 109 and the end one of the bodies 106F may then be attached to the neighboring body 106E by sliding the ridges 404 of the body insulating member 312 into the slots 403 provided in the body 106F. In doing this, the insulating member 308B is positioned over the open ends of the holes 109 in the body 106F, and the conductors 206 attached to the tabs 205 of the battery cells 102 will be positioned within the apertures 1 12 provided in the insulating member 308B. The connector plate 107B may also be located on the insulating member 308B and then the conductors 206, which are attached to each of the battery cells 102, may be connected to a respective one of the lids 208 before the lids are welded in place over respective apertures 207 in the connector plate 107B.

A flow chart outlining a method 600 for assembling battery cells is shown in Fig. 6. The method 600 comprises at blocks 601 and 602 positioning a first set of battery cells within a first body and a second set of battery cells within a second body. For example, with reference to Fig. 1 , a first set 102A of battery cells 102 are positioned within the first body 106A and a second set 102B of battery cells 102 are positioned within the second body 106B. At block 603 the first electrodes of each of the battery cells are connected to the respective body. Thus for example, with reference to Fig. 1 , the first electrode 103 of the battery cells in the first body 106A are connected to the first body and the first electrodes of the battery cells in the second body 106B are connected to the second body 106B.

At block 604 a respective connector plate, such as connector plates 107A and 107B of Fig. 1 are positioned relative to each body, such that each connector plate is insulated from the respective body. Thus, for example, the connector plate 107A of Fig.1 is positioned with respect to the body 106A with the insulating member 108A positioned between the connector plate and the body 106A. Similarly, the connector plate 107B is positioned with respect to the body 106B with the insulating member 108B insulating the connector plate 107B from the body 106B. The process at block 604 may include connecting features on one side of an insulating sheet to interlocking features of the first body and connecting features on the other side of the insulating sheet to interlocking features of the second body. For example, with reference to Figs. 5A and 5B this process of connecting features on one side of an insulating sheet to interlocking features of the first body may comprises sliding together the features, such as ridges 404, on one side of the insulating sheet 312 to the interlocking features, such as slots 403, of the first body. At block 605 a first one of the connector plates (such as first connector plate 107A of Fig.1 ) is connected to the second electrodes of the first set of battery cells. In the present method the first one of the connector plates is already attached to the second body. As described above, the connector plate may be integrally formed with the body, for example by casting the body and the connector plate as a single item. Alternatively the connector plate may be permanently attached to the body by brazing or welding. This process of permanently attaching the plate to the body may result in closing one end of the holes formed in the body, for example, where the body is formed as an extrusion. At block 606 a second one of the connector plates is connected to the second electrodes of second set of battery cells. For example, with reference to Fig. 1 the connector plate 107B is connected to the second electrodes 104 of the second set 102B of battery cells 102.

It will be understood that this method may also be used in the assembly of apparatuses having more than two bodies. For such apparatuses a respective set of battery cells is positioned within a respective body, in a similar manner to blocks 601 and 602. Also, several connector plates that are connected to the second electrodes of the corresponding sets of battery cells in the corresponding body will be directly attached to a body that neighbors the corresponding body. For example, with reference to Figs. 5A and 5B, the connector plates 107A are each connected to the second electrodes of the battery cells in the corresponding sets in the bodies 106A, 106C, 106D and 106E and each of these connector plates 107A is directly attached to bodies neighboring the bodies 106A, 106C, 106D and 106E. For example, the connector plate 107A that is connected to second electrodes of the battery cells in body 106A is directly attached to the neighboring body 106C. Similarly, the connector plate 107A that is connected to second electrodes of the battery cells in body 106C is directly attached to the neighboring body 106D, and so on.

An alternative apparatus 101 E embodying the present invention is shown in cross-section in Fig. 7 and in a perspective view partially disassembled in Fig. 8. Like the previously describe apparatuses, the apparatus 101 E comprises a plurality of sets 102P, 102Q, 102R of battery cells 102, each battery cell comprising a first electrode 103, a second electrode 104 and an electrolyte 105. The apparatus also comprises a plurality of bodies 106, each body 106 containing a respective one of the sets 102P, 102Q, 103R of battery cells 102. The battery cells 102 have first electrodes 103 electrically connected to the respective body 106. The apparatus also includes a plurality of connector plates 107, and each of the connector plates 107 is connected to the second electrodes 104 of the battery cells 102 in a respective one of the bodies 106.

Each of the connector plates 107 is insulated from the respective body 106. In the present embodiment, this is achieved by an insulating member 108 located between each body 106 and its respective connector plate 107. For example, an insulating member 108P is positioned between a first body 106P and the respective connector plate 107P. Similarly, a second insulating member 108Q is positioned between a second body 106Q and a second connector plate 107Q and a third insulating member 108R is positioned between a third body 106R and the third connector plate 107R.

The first one of the connector plates 107P is connected to the second electrodes 104 of a first one of the sets 102P of battery cells 102 located in a first one of the bodies 106P. In the present embodiment, where there are three bodies, the second one of the connector plates 107Q is connected to the second electrodes 104 of a second one of the sets 102Q of battery cells 102 located in the second one of the bodies 106Q, and the third one of the connector plates 107R is connected to the second electrodes 104 of a third one of the sets 102R of battery cells 102 located in the third one of the bodies 106R.

The first connector plate 107P is directly attached to a second body 106Q, which contains the second one of the sets 102Q of battery cells 102. Thus, the battery cells of the first set 102P located in the first body 106P are connected in series with the battery cells of the second set 102Q located in the second body 106Q, without the need for any additional connectors. In the present embodiment, the attachment of the first connector plate 107P to the second body 106Q is due to one or more welds 701 .

In the present embodiment, the second connector plate 107Q is directly attached to the third body 106R, which contains the third one of the sets 102R of battery cells 102. Again the attachment is provided by welds 701 . It should be understood that the present embodiment comprises three bodies each containing a set of battery cells but in other embodiments, more or fewer than three bodies may be provided. In the present embodiment, the connector plates 107P, 107Q and 107R and the insulating members 108P, 108Q and 108R have a similar construction to the connector plate 107B and insulating member 308A of Fig. 3. Thus, the connector plates 107P, 107Q and 107R each define apertures 207 that are provided with lids 208. The lids 208 are connected to the second electrodes 104 of the battery cells 102 via a conductor 206 which passes through an aperture 1 12 in the insulating member 108.

Each of the bodies 106 along with their respective sets of battery cells 102, connector plate 107 and insulating member 108 may be regarded as a separate one of three modules that are connected together by the welds 701 to form the apparatus 101 E. For example, the body 106P, the set 102P of battery cells 102 located in the body 106P, the connector plate 107P and the insulating member 108P may be consider to form a single module 720. Because the body is formed of an electrically conducting material, this module 720 may then be connected to other such modules, as shown in Fig. 7 by simply abutting the body of one module against the connector plate of another module and fixing together by, for example a weld (such as weld 701 ). Although three modules are connected together in Fig. 7 and 8, it will be understood that any number of such modules may be connected together in this way. A flow chart outlining a method 900 for assembling battery cells is shown in Fig. 9. The method 900 comprises at blocks 901 and 902 positioning a first set of battery cells within a first body and a second set of battery cells within a second body. For example, with reference to Fig. 7, a first set 102P of battery cells 102 are positioned within the first body 106P and a second set 102Q of battery cells 102 are positioned within the second body 106Q. The battery cells may be individually encapsulated in cans, but alternatively, as shown in Fig. 7, the battery cells may not be encapsulated and so at blocks 901 and 902, at least one of the positive electrode material, the electrolyte material and the negative electrode material is placed in direct contact with the respective body. At block 903 the first electrodes of each of the battery cells are connected to the respective body. Thus for example, with reference to Fig. 7, the first electrode 103 of the battery cells in the first body 106P are connected to the first body and the first electrodes of the battery cells in the second body 106Q are connected to the second body 106Q. At block 904 a respective connector plate, such as connector plates 107P and 107Q of Fig. 7 are positioned relative to each body, such that each connector plate is insulated from the respective body. Thus, for example, the connector plate 107P of Fig.7 is positioned with respect to the body 106P with the insulating member 108P positioned between the connector plate 107P and the body 106P. Similarly, the connector plate 107Q is positioned with respect to the body 106Q with the insulating member 108Q positioned between the connector plate 107Q and the body 106Q. In instance where the insulating member (such as insulating member 108P of Figs. 7 and 8) is provided with features configured to engage with features of the connector plate (107P) and/or the body (106P), this process (at block 904) may include bringing together features of the insulating member with corresponding mating features of the respective plate and/or body.

At block 905 a first one of the connector plates (such as first connector plate 107P of Fig.7) is connected to the second electrodes (104) of the first set (107P) of battery cells.

At block 906 a second one of the connector plates is connected to the second electrodes of second set of battery cells. For example, with reference to Fig. 7 the connector plate 107Q is connected to the second electrodes 104 of the second set 102Q of battery cells 102.

At block 907, the first connector plate is directly attached to the second body. For example, with reference to Fig. 7, the first connector plate 107P is directly attached to the second body 106Q.

Method 900 therefore differs from the method 600 in that it includes the process of attaching the first plate to the second plate at block 907. However, in instances where the first plate is already attached to the second body, for example, where these two items are integrally formed, the process at block 907 is not necessary.

A vehicle 1001 comprising a battery 1002 including at least one apparatus 101 , 101 B, 101 C, 101 D or 101 E is shown schematically in Fig. 10. The battery 1002 may be located within an insulating case 1003 to electrically insulate the bodies 106 and connector plates 107 of the apparatuses from other parts of the vehicle.

The battery 1002 forms a part of an electrical system 1006 of the vehicle 1001 . The electrical system 1006 may also comprise an electrical generator 1004 and/or an electric motor 1005. Alternatively, the vehicle 1001 may be a hybrid vehicle 1001 and the electrical generator 1004 may be a starter generator.

The blocks illustrated in the Figs. 6 and 9 may represent steps in a method. The illustration of a particular order to the blocks does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the block may be varied. Furthermore, it may be possible for some steps to be omitted.

Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed.

Features described in the preceding description may be used in combinations other than the combinations explicitly described.

Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not.

Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

1 . An apparatus comprising:

a plurality of sets of battery cells, each battery cell comprising a first electrode, a second electrode and an electrolyte;

a plurality of container means, each container means containing a respective one of the sets of battery cells, and the battery cells having first electrodes electrically connected to the respective container means;

a plurality of connector plates, each of the connector plates connected to the second electrodes of the battery cells in a respective one of the container means, and each of the connector plates being insulated from the respective container means; and

wherein a first one of the connector plates is connected to the second electrodes of a first one of the sets of battery cells located in a first one of the container means, and

the first connector plate is directly attached to a second container means containing a second one of the sets of battery cells.

2. An apparatus according to claim 1 , wherein each of the container means comprises an electrically conductive body.

3. An apparatus according to claim 1 or claim 2, wherein the first electrode is a negative electrode and the second electrode is a positive electrode.

4. An apparatus according to any one of claims 1 to 3, wherein the first connector plate forms a part of, or is permanently directly connected to, the second container means.

5. An apparatus according to any one of claims 1 to 3, wherein the first connector plate is permanently directly connected to the second container means by a weld joint.

6. An apparatus according to any one of claims 1 to 3, wherein the second container means defines holes containing battery cells and a plate extends across the holes to close one end of the holes in the second container means and provides the first connector plate.

7. An apparatus according to claim 6, wherein the second container means is permanently attached to the connector plate by braze material or a weld.

8. An apparatus according to any one of claims 1 to 7, wherein each container means defines a plurality of holes, and each said hole contains one of the battery cells.

9. An apparatus according to claim 8, wherein each of the battery cells has a structure comprising a layer of positive electrode material, a layer of electrolyte material and a layer of negative electrode material, and at least one of the positive electrode material, the electrolyte material and the negative electrode material is in direct contact with the respective container means.

10. An apparatus according to any one of claims 1 to 9, wherein the apparatus comprises an insulating member located between one of the container means and a respective connector plate.

1 1 . An apparatus according to claim 8 or claim 9, wherein the apparatus comprises an insulating member located between one of the container means and a respective connector plate, and the insulating member is shaped to provide engagement with the holes defined by said container means.

12. An apparatus according to claim 10 or claim 1 1 , wherein the insulating member has features on a surface which mechanically engage with features on a surface of the respective connector plate.

13. An apparatus according to claim 12, wherein the features on the surface of the respective connector plate comprise an array of apertures.

14. An apparatus according to any one of claims 1 to 13, wherein a connecting face of a first one of the container means is attached to a connecting face of a second one of the container means by an insulating sheet, and the insulating sheet and connecting faces of the first and second container means are provided with interlocking features.

15. An apparatus according to claim 14, wherein the interlocking features of the insulating sheet are configured to interlock with the features of the first one of the container means by sliding together.

16. An apparatus according to any one of claims 1 to 15, wherein at least one of the connector plates comprises an array of apertures, and each aperture of the array of apertures is provided with a lid to which a respective one of the second electrodes of the battery cells is connected.

17. An electrical system for a vehicle comprising an apparatus according to any one of claims 1 to 16.

18. A vehicle comprising an apparatus according to any one of claims 1 to 16.

19. A method of assembling battery cells comprising:

locating a first set of battery cells within a first body;

locating a second set of battery cells within a second body;

connecting a first electrode of each of the battery cells to the respective one of the bodies; positioning a respective connector plate relative to each one of the bodies so that each of the connector plates is insulated from the respective body;

connecting a first one of the connector plates to the second electrodes of the first set of battery cells; and

connecting a second one of the connector plates to the second electrodes of second set of battery cells,

wherein the first one of the connector plates is formed as a part of, or is direct attached to, the second body.

20. A method according to claim 19, wherein said connecting a first electrode comprises connecting a negative electrode of each of the battery cells to the respective one of the bodies.

21 . A method according to claim 19 or claim 20, wherein the first connector plate forms a part of the second body.

22. A method according to claim 19 or claim 20, wherein the method comprises connecting the first connector plate directly to the second body by a weld joint.

23. A method according to claim 19 or claim 20, wherein the second body defines holes for receiving battery cells and the first connector plate is part of a larger plate and the method comprises permanently attaching the plate to the body to close one end of the holes.

24. A method according to any one of claims 19 to 23, wherein each of the battery cells has a structure comprising a layer of positive electrode material, a layer of electrolyte material and a layer of negative electrode material, and the method comprises placing at least one of the positive electrode material, the electrolyte material and the negative electrode material in direct contact with the respective body.

25. A method according to any one of claims 19 to 24, wherein the method comprises positioning an insulating member between one of the bodies and a respective one of the connector plates.

26. A method according to claim 25, wherein the method comprises bringing together features of the insulating member with corresponding mating features of the respective connector plate and/or body.

27. A method according to claim 25 or claim 26, wherein at least one of the connector plates comprises an array of apertures, and the method comprises connecting a respective one of the second electrodes of the battery cells to a respective lid and positioning the lids over the apertures.

28. A method according to any one of claims 19 to 27, wherein the method comprises connecting features on one side of an insulating sheet to interlocking features of the first body and connecting features on the other side of the insulating sheet to interlocking features of the second body.

29. A method according to claim 28, wherein the process of connecting features on one side of an insulating sheet to interlocking features of the first body comprises sliding together the features on one side of the insulating sheet to the interlocking features of the first body.

30. An apparatus, an electrical system, a vehicle or a method substantially as herein described with reference to the accompanying figures.