Description:FIELD
The present disclosure relates to a field of battery pack, and particularly relates to a battery pack with venting provisions for routing of gas that may be produced internal to the battery pack.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, the battery pack used in the vehicles is a rechargeable type of battery pack i.e., a plurality of lithium-ion battery cells is packed in a battery module of the battery pack assembly to provide sufficient power to operate the electric vehicle or for other applications.
During operation as well as while charging and discharging, the battery cells are known to generate gas. These gas when gets collected inside the battery module, results in a pressurized condition within the battery pack. There is no passage provided in battery module or the battery case to allow gas to escape. Hence, when the pressure exceeds beyond the strength of the battery pack or the battery module, there is a possibility that the battery pack or the battery module may rupture or explode.
Thus, there is felt a need for an assembly for a battery module or a battery pack that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present invention is to provide a ladder frame assembly for a battery module.
Another object of the present invention is to provide a ladder frame assembly that mitigates thermal runway.
Still another object of the present invention is to provide a ladder frame assembly that provides support to a battery module.
Yet another object of the present invention is to provide a ladder frame assembly that ensures uniform sealing between each adjacent cell.
Still another object of the present invention is to provide a ladder frame assembly that provides self-alignment of each adjacent cell of the battery module.
Yet another object of the present invention is to provide a ladder frame assembly that provides positive locking for a battery module.
Still another object of the present invention is to provide a ladder frame assembly that offers ease of assembly.
Yet another object of the present invention is to provide a ladder frame assembly that provides a space for the escape of gas.
Yet another object of the present invention is to provide a ladder frame assembly that optimizes the packaging space of a battery module in a battery pack.
Still another object of the present invention is to provide a ladder frame assembly that offers anti-fire properties to a battery module.
SUMMARY
The present disclosure envisages a ladder frame assembly for a battery module. The battery module has an array of battery cells wherein each battery cell has a vent thereon. The battery module is configured to be received by a slot defined in a battery case. The battery case is configured with a plurality of venting valves around the outer boundary of the battery case. The ladder frame assembly comprises at least one glue with mica sheet pad, a plurality of first openings, an enclosure cover, a plurality of second openings, at least one pair of recesses, and at least two brackets.
In an embodiment, the side plates and the brackets are selected from a group of materials consisting of pure metals, or alloys or a combination thereof.
In an embodiment, the enclosure cover is selected from a group of materials consisting of metals, alloys, composite or a combination thereof.
In an embodiment, the enclosure cover, the brackets and the glue with mica sheet pad are made as an integral component.
The at least one glue with mica sheet pad is configured to be attached to an operative module bottom surface of the battery module. The plurality of first openings is configured on the glue with mica sheet pad. The enclosure cover is configured to be attached on the top surface of the glue with mica sheet pad. The plurality of second openings is configured on the enclosure cover. The at least one pair of recesses are configured along sides of the enclosure cover, and extends along the length of the enclosure cover. Each of the brackets are configured to be received by each of the recesses, and further configured to secure the enclosure cover on the battery module.
In an embodiment, the glue with mica sheet pad is a structural mica sheet with layers of glue on both side of the mica sheet.
The ladder frame assembly is configured to define a vent pathway between the battery module and the battery case. Therefore, the defined vent pathway facilitates gas to escape from the vents towards the venting valves of the battery case.
In an embodiment, the plurality of first openings, and the plurality of second openings are configured to be in-line with the vent provided on each of the battery cell, to form a gas escape path from the vent towards the venting valves of the battery case.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A ladder frame assembly for a battery module, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a perspective bottom isometric view of a ladder frame assembly mounted on a bottom surface of a battery module in accordance with an embodiment of the present disclosure;
Figure 2 illustrates an exploded perspective bottom isometric view of a ladder frame assembly with a battery module in accordance with an embodiment of the present disclosure;
Figure 3a illustrates a perspective bottom view of mounting of a frame case with a plurality of battery modules in accordance with an embodiment of the present disclosure;
Figure 3b illustrates a perspective top side of a battery module and a venting valve in accordance with an embodiment of the present disclosure;
Figure 4 illustrates an isometric view of enclosure cover in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a front view and a side view of mounting of an enclosure cover in accordance with an embodiment of the present disclosure;
Figure 6 illustrates a sectional view of a battery module with a ladder frame assembly mounted in accordance with an embodiment of the present disclosure;
Figure 7 illustrates a perspective view of a battery cell and a sectional view of a battery module with a ladder frame assembly attached thereon in accordance with an embodiment of the present disclosure; and
Figure 8 illustrates a perspective sectional view of a battery case with a vent pathway defined therebetween in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING
100 ladder frame assembly
20 array of battery cells
20a battery cell
20b vent
20c battery terminal
22 battery module
22a compression pad or double-sided tape
24 battery case
24a slot for mounting battery module
24b venting valves
24c slot for mounting BMS and electrical components
26 glue with mica sheet pad
26a first openings
28 enclosure cover
28a second openings
28b recesses
28c rib
28d lug
30 brackets
30a flange
32 side plate
34 vent pathway
50a module bottom surface
50b module top surface
50c module side surface
52 dowel pin and dowel bracket
54 supporting bracket
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known grader structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, and “having”, are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being “mounted on”, “engaged to”, “connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region or section from another component, region, or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Typically, the battery pack used in the vehicles is a rechargeable type of battery pack i.e., a plurality of lithium-ion battery cells is packed in a battery module of the battery pack assembly to provide sufficient power to operate the electric vehicle or for other applications. During operation as well as while charging and discharging, the battery packs or batteries are known to liberate gas. There is a possibility that the liberated gas may escape into neighbouring cells and may trigger the thermal event. .However, there is no passage provided in battery module or the battery case to allow gas to escape.
In order to address the aforementioned problems, the present disclosure envisages a ladder frame assembly (100) for a battery module (22) of a battery pack assembly. The ladder frame assembly (100) is configured to be mounted on an operative surface of a battery module (22) according to an embodiment which is described with reference to FIGS. 1 and 2. FIG. 1 illustrates a perspective bottom isometric view of a ladder frame assembly (100) mounted on a module bottom surface of a battery module. FIG. 2 illustrates an exploded perspective bottom isometric view of a ladder frame assembly with a battery module in accordance with an embodiment.
As shown in FIGS. 1 and 2, the battery module (22) has an array of battery cells (20), arranged in a stack. The arrangement of the array of the battery cells (20) defines an operative module top surface (50b), an operative module bottom surface (50a), and two module side surfaces (50c) of the battery module (22). Each of the side surface (50c) is provided with a side plate (32). Each adjacent cell (20a) is provided with a pre-defined play by means of a compression pad or double-sided tape (22a) therebetween to accommodate residual stresses, if any. Each of the battery cell (20a) is configured with a vent (20b) on the operative bottom surface (50a). These vents (20b) are configured to release harmful gas during the chemical reaction taking place within the battery cells (20a). Each of the battery modules (22) is mounted in a slot (24a) by means of different dowel pins and dowel brackets (52) and supporting brackets (54), defined in a battery case (24), and electrical components such as Battery Management System (BMS) are mounted to a slot (24c). Therefore, the module top surface (50b) of the battery module (22) touches an operative surface of a cooling plate, whereas the module bottom surface (50a) of the battery module (22) abuts on a base surface of the battery case (24). The outer boundary of the battery case (24) is provided with a plurality of venting valves (24b). Each of the venting valves (24b) is operatively in fluid communication with each of the slots (24a) defined in the battery case (24). The ladder frame assembly (100) of the battery module (22) comprises at least one glue with mica sheet pad (26), a plurality of first openings (26a), an enclosure cover (28), a plurality of second openings (28a), at least one pair of recesses (28b), and at least two brackets (30). The glue with mica sheet pad (26) is provided with a plurality of first openings (26a). Each of the first openings (26a) extends along the width of the glue with mica sheet pad (26). The glue with mica sheet pad (26) is attached to the module bottom surface (50a) of the battery module (22) in such a way that each of the first openings (26a) is aligned with each vent (20b) of the battery cells (20a). Figure 3a illustrates a perspective bottom view of mounting of the frame case with a plurality of battery modules, and Figure 3b illustrates a perspective top side of mounting of a battery module and a venting valve of the frame case.
In an embodiment, the glue with mica sheet pad (26) is a structural mica sheet pad with layers of glue on both surfaces of the mica sheet pad.
In another embodiment, the glue with mica sheet pad (26) is a structural mica sheet pad with layers of glue on an operative bottom surface of the mica sheet pad.
In an embodiment, the thickness of the glue with mica sheet pad (26) is in the range of 1.5 to 3.0 mm based on the vent flow of battery cell.
In an embodiment, the glue with mica sheet pad (26) is selected from a group of materials selected from mica with structural glue layer on either side.
In an embodiment, the side plate (32) is selected from a group of materials selected from metals, or alloys.
Further, the enclosure cover (28) is configured with a plurality of second openings (28a), extending along the width of the enclosure cover (28). The enclosure cover (28) is further configured with at least two lugs (28d) at the extreme ends and at least one rib (28c), extending along the width of the enclosure cover (28). The enclosure cover (28) is mounted on an operative top surface of the glue with mica sheet pad (26). The enclosure cover (28) is integrally provided with at least one pair of recesses (28b). Each of the recesses (28b) is extending longitudinally with the enclosure cover (28) to abut the top surface of the glue with mica sheet pad (26). The enclosure cover (28) is mounted in such a way that each of the second openings (28b) is configured to align with each of the first openings (26a) of the glue with mica sheet pad (26). Therefore, each of the first openings (26a), and each of the second openings (28b) are configured to be in-line with the vent (20b) provided on each of the battery cell (20a), thus it forms the pathway (34) from the vent (20b) towards the venting valves (24b) of the battery case (24). Each lug (28d) of the enclosure cover (28) is allowed to be received by an operative surface of the side plates (32) in an operative configuration. The rib (28c) is allowed to be received within the play defined by means of a compression pad or double-sided tape (22a), defined between each adjacent cells of the battery module (22). Figure 4 illustrates an isometric view of enclosure cover and Figure 5 illustrates a front view and a side view of mounting of an enclosure cover in accordance with an embodiment of the present disclosure.
In an embodiment, the enclosure cover (28) is selected from a group of material consisting of plastic, composite, metal, alloy or combinations thereof.
Further, each of the brackets (30) is defined by a strip of metals or alloys, extending along the length of the enclosure cover (28) and the extreme ends of the brackets (30) are provided with a flange portion (30a). Each bracket (30) is allowed to be received within the recess (28b) of the enclosure cover (28) in such a way that the flanges (30a) provided on each bracket (30) slides on an operative surface of the side plates (32). Thereby, each bracket (30) secures the enclosure cover (28) with the battery module (22) rigidly. Figure 6 illustrates a sectional view of battery module with a ladder frame assembly mounted in accordance with an embodiment of the present disclosure.
In an embodiment, each flange (30a) of the brackets (30) is welded to the operative surface of the side plates (32).
In an embodiment, the enclosure cover (28), the brackets (30) and the glue with mica sheet pad (26) are made as an integral component.
Further, the sequential geometrical arrangement of the glue with mica sheet pad (26), the enclosure cover (28), and the brackets (30) of the ladder frame assembly (100) over the module bottom surface (50a) of the battery module (22) facilitates to define the vent pathway (34) between the battery module (22) and the battery case (24). Therefore, the vent pathway (34) allows gas to escape from the vents (20b) towards the venting valves (24b) of the battery case (24). Figure 7 illustrates a perspective view of a battery cell and a sectional view of a battery module with a ladder frame assembly attached thereon and Figure 8 illustrates a perspective sectional view of a battery case with a pathway defined therebetween in accordance with an embodiment of the present disclosure.
In an embodiment, the vent pathway (34) is in fluid communication with the venting valves (24b) of the battery case (24).
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of the ladder frame assembly for a battery module, that:
• mitigates thermal runway, since it defines a pathway between the battery module and the battery case to facilitate gas escape;
• provides support and secures each cell of the battery module rigidly;
• ensures uniform sealing between each adjacent cell;
• provides self-alignment of each adjacent cell of the battery module;
• provides positive locking for a battery module;
• offers ease of assembly;
• provides a space for the escape of gas;
• optimizes the packaging space of a battery module in a battery pack; and
• offers anti-fire properties and stops thermal propagation in a battery module.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
, Claims:WE CLAIM:
1. A ladder frame assembly (100) for a battery module (22), said battery module (22) having an array of battery cells (20) wherein each battery cell (20a) has a vent (20b) thereon, said battery module (22) configured to be received by a slot (24a) defined in a battery case (24), said case (24) configured with a plurality of venting valves (24b), said ladder frame assembly (100) comprising:
• at least one glue with mica sheet pad (26), configured to be attached to an operative bottom surface (50a) of said battery module (22);
• a plurality of first openings (26a), configured on said glue with mica sheet pad (26);
• an enclosure cover (28), configured to be attached on the top surface of said glue with mica sheet pad (26);
• a plurality of second openings (28a), configured on said enclosure cover (28);
• at least one pair of recesses (28b), configured along sides of said enclosure cover (28), and extending along the length of said enclosure cover (28); and
• at least two brackets (30), each of said brackets (30) configured to be received by each of said recesses (28b), and further configured to secure said enclosure cover (28) on said battery module (22);
said ladder frame assembly (100) being configured to define a vent pathway (34) between said battery module (22) and said battery case (24) to facilitate gas to escape from said vents (20b) towards said venting valves (24b) of said battery case (24).
2. The ladder frame assembly (100) as claimed in claim 1, wherein each of said first openings (26a), and each of said second openings (28a) are configured to be in-line with each of said vents (20b) provided on each of the battery cell (20a), to form said vent pathway (34) from said vent (20b) towards said venting valves (24b).
3. The ladder frame assembly (100) as claimed in claim 1, wherein said enclosure cover (28) is configured with at least one rib (28c), extending along the width of said enclosure cover (28).
4. The ladder frame assembly (100) as claimed in claim 3, wherein said rib (28c) is configured to be received within a play defined by means of a compression pad or double-sided tape (22a), defined between each adjacent battery cells of said battery module (22).
5. The ladder frame assembly (100) as claimed in claim 1, wherein said battery module (22) is provided with at least two side plates (32), wherein each of said side plates (32) is configured to be mounted on an operative side surface (50c) of said battery module (22).
6. The ladder frame assembly (100) as claimed in claim 5, wherein said enclosure cover (28) is configured with at least two lugs (28d), each of said lugs (28d) is configured at extreme end of said enclosure cover (28).
7. The ladder frame assembly (100) as claimed in claim 6, wherein each of said lugs (28d) is configured to be received by the operative side surfaces (50c) of said side plates (32).
8. The ladder frame assembly (100) as claimed in claim 5, wherein each of said brackets (30) is provided with a flange portion (30a) at extreme ends, said flange portion (30a) is configured to be welded to the operative side surfaces (50c) of said side plates (32).
9. The ladder frame assembly (100) as claimed in anyone of claims 1 to 8, wherein said side plates (32) and said brackets (30) are selected from a group of materials consisting of pure metals, or alloys or a combination thereof.
10. The ladder frame assembly (100) as claimed in claim 1, wherein said enclosure cover (28) is selected from a group of materials consisting of metals, alloys, composite or a combination thereof.
11. The ladder frame assembly (100) as claimed in claim 1, wherein said vent pathway (34) is in fluid communication with said venting valves (24b) of said battery case (24).
12. The ladder frame assembly (100) as claimed in anyone of claims 1 to 10, wherein said enclosure cover (28), said brackets (30) and said glue with mica sheet pad (26) are integral component.

Dated this 14th day of March, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI