Battery module construction

Abstract

Described are mechanically robust, thermally managed battery module constructions including a battery case, a reinforcing divider in the case, and battery cells housed by the reinforcing divider. The reinforcing divider defines a plurality of thermal transfer elements externalized of the battery case. A shock dampening material can be provided between the reinforcing divider and the battery case to facilitate a mechanical, shock-dampened, reinforcing integration of the divider and case.

1 . A battery module, comprising:
 a polymeric case defining a plurality of openings in a wall thereof;   a shock dampening material received within the polymeric case;   a monolithic, thermally-conductive, reinforcing divider partially received within the polymeric case;
 the monolithic, thermally-conductive, reinforcing divider structurally reinforcing the polymeric case, with the shock dampening material positioned between the reinforcing divider and the polymeric case and operable to dampen and transfer forces between the polymeric case and the reinforcing divider; 
 the monolithic, thermally-conductive, reinforcing divider including a plurality of dividing wall members defining a plurality of cavities therebetween, with said cavities located within the polymeric case; 
 the monolithic, thermally-conductive reinforcing divider also defining a plurality of thermal transfer projections received through respective ones of the openings of the polymeric case and providing thermal transfer members projecting externally of the polymeric case; 
   a plurality of lithium ion battery pouch cells received within the polymeric case and including lithium ion battery pouch cells received at least partially in respective ones of said cavities of the reinforcing divider;   a conductive material electrically coupling at least some of the lithium ion battery pouch cells in series to provide a battery pouch cell series;   a negative electrical terminal electrically coupled to a first end of the battery pouch cell series; and   a positive electrical terminal electrically coupled to a second end of the battery pouch cell series.   
     
     
         2 - 28 . (canceled) 
     
     
         29 . A battery module, comprising:
 a battery case;   a monolithic divider element at least partially received within the battery case, the monolithic divider element including a plurality of dividing wall members defining a plurality of cavities therebetween;   a plurality of battery cells received within the polymeric case and including battery cells received at least partially in respective ones of said cavities and electrically connected in a battery cell series;   a negative electrical terminal electrically coupled to a first end of the battery cell series; and   a positive electrical terminal electrically coupled to a second end of the battery cell series.   
     
     
         30 . The battery module of  claim 29 , wherein the divider element is composed of extruded aluminum. 
     
     
         31 - 43 . (canceled) 
     
     
         44 . A battery module, comprising:
 a battery case;   a divider element at least partially received within the battery case, the divider element including a plurality of dividing wall members defining a plurality of cavities therebetween;   a plurality of battery cells received within the polymeric case and including battery cells received at least partially in respective ones of said cavities and electrically connected in a battery cell series;   a negative electrical terminal electrically coupled to a first end of the battery cell series; and   a positive electrical terminal electrically coupled to a second end of the battery cell series.   
     
     
         45 . The battery module of  claim 44 , wherein the divider element is a monolithic piece. 
     
     
         46 . The battery module of  claim 45 , wherein the divider element is an extruded material. 
     
     
         47 . The battery module of  claim 44 , wherein the divider element is composed of aluminum. 
     
     
         48 . The battery module of  claim 44 , wherein the divider element also defines a plurality of thermal transfer elements. 
     
     
         49 . The battery module of  claim 48 , wherein the battery case encloses a portion of the divider element in a sealed environment containing at least the battery cells, and wherein the thermal transfer elements extend at least partially from the sealed environment. 
     
     
         50 . The battery module of  claim 49 , wherein the sealed environment is a hermitically sealed environment. 
     
     
         51 . The battery module of  claim 48 , wherein the battery case defines a bottom wall, and wherein at least a portion of the thermal transfer elements extends below the bottom wall. 
     
     
         52 . The battery module of  claim 51 , wherein the battery case also defines a lower lip extending below the bottom wall. 
     
     
         53 . The battery module of  claim 52 , wherein the lower lip extends below the bottom wall a distance at least equal to a distance that the thermal transfer elements extend below the bottom wall. 
     
     
         54 . The battery module of  claim 44 , wherein the battery cells are lithium ion pouch cells. 
     
     
         55 . The battery module of  claim 51 , wherein the thermal transfer elements extending below the bottom wall are the only thermal transfer elements extending from the battery case. 
     
     
         56 . The battery module of  claim 51 , wherein the positive and negative electrical terminals are positioned at or upon a top wall of the battery case opposite the bottom wall. 
     
     
         57 . The battery module of  claim 44 , also comprising electronics for sending a remote reporting or data collection signal.