GB2502976A

GB2502976A - A vehicle battery pack, a module for the same, a frame for the module and a method of manufacture

Info

Publication number: GB2502976A
Application number: GB1210277.8A
Authority: GB
Inventors: Stephen Nicholls
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2012-06-11
Filing date: 2012-06-11
Publication date: 2013-12-18
Anticipated expiration: 2032-06-11
Also published as: GB201210277D0; GB2502976B

Abstract

A rechargeable electric battery pack for a vehicle comprising a cell module 36 . The cell module comprises a plurality of rechargeable electrochemical storage cells arranged in frames 92a, 92B. Each frame comprises at least one section structured and configured for accommodating a rechargeable electrochemical storage cell and each frame is affixed to an adjacent frame of the cell module.

Description

A VEHICLE BATTERY PACK, A MODULE FOR THE SAME. A FRAME FOR THE

MODULE AND A METHOD OF MANUFACTURE

TECHNICAL FIELD

The present invention relates to a battery pack, for example, for an electric vehicle (EV) or a hybrid electric vehicle (HEy), for example a plug-in hybrid-electric vehicle (PHEV). The invention also relates to a cell module for the battery pack, a frame for forming the cell module, a method of forming a cell module and a method of assembling a battery pack from one or more cell modules. More particularly, but not exclusively, the invention relates to an improved battery having among many advantageous features a compact and modular construction. Aspects of the invention relate to a frame for a battery pack, a frame for forming a modular frame member, a modular frame member, a cell module for a battery pack, a vehicle and to a method.

BACKGROUND

Electric vehicles are provided with a rechargeable battery pack for providing the power used to drive the vehicle. The performance of the electric vehicle depends upon the power that can be output by the battery pack. As such vehicle characteristics, for example the vehicle's acceleration, top-speed and range (distance that can be travelled between charges) are dependent at least in part, upon the battery pack.

Battery packs typically comprise a series of sealed electrochemical energy storage cells.

Some known cells are Lithium-ion based and the power of the overall battery pack is dependent upon the number of cells contained in the battery pack. The state of charge (SaC), temperature, voltage and other factors may influence the power that can be supplied and/or stored by the cells of a battery pack. Consideration of these and other factors is required in designing rechargeable battery packs.

In W02012/009145A2, to A123 Systems Inc., a battery pack is disclosed in which a retention band is used to exert opposing compressive forces on a stack of cells to maintain the stack of cells together and to maintain the shape of the battery pack when the battery cells are distended due to high temperature and/or high voltage conditions. It is also disclosed that different battery packs for different applications may have different numbers of cells, for example, a system requiring increased charge capacity may have a greater number of cells interposed between the end covers and thus the length of the bands may vary from application to application.

The present invention seeks to provide an improvement in the field of battery packs that may for example be used in vehicles. The invention may be utilised in applications other than for vehicles and passenger vehicles where rechargeable battery packs are used, for example, the rechargeable battery pack of the invention may find advantageous application in: commercial or utility vehicles, such as fork-lift-trucks; electricity grid storage; portable power generators; and back-up power supplies, for example in telecommunications applications.

SUMMARY

Aspects of the invention provide a frame for a battery pack, a modular frame member, a cell module for a battery pack, a vehicle and a method(s).

According to an aspect of the invention for which protection is sought, there is provided a rechargeable electric battery pack for a vehicle comprising a cell module, the cell module comprising a plurality of rechargeable electrochemical storage cells arranged in frames, wherein each frame comprises at least one section structured and configured for accommodating a rechargeable electrochemical storage cell and wherein each frame of the cell module is affixed to an adjacent frame.

Optionally, each frame may comprise more than one section and each frame may accommodate more than one rechargeable electrochemical storage cell, such that the plurality of rechargeable electrochemical storage cells may be arranged in framed rows comprising two or more rechargeable electrochemical storage cells and stacked in columns of frames to form a matrix arrangement of rechargeable electrochemical storage cells.

Optionally, each frame may comprise a top section and a bottom section interconnected by opposed sides and at least one divider for forming said more than one section.

Further optionally, each frame may comprise two dividers and three sections and each frame may accommodate up to three rechargeable electrochemical storage cells.

Additionally or alternatively, one or more of the dividers may be shaped, optionally substantially T'-shaped, in cross-section, for catching or engaging a wing of a rechargeable electrochemical storage cell disposed in a section of the frame that is at least partially defined by the one or more shaped dividers.

Optionally, each section of the frame may comprise at least one pair of apertures formed in the top section of the frame, which apertures may receive terminals of the rechargeable electrochemical storage cell disposed in the sections of the frame.

Further optionally, each section of the frame may comprise an aperture formed in the top section of the frame, through which aperture a temperature sensor may be disposed and positioned for determining the temperature of the cell accommodated by the section.

Additionally, each section of the frame may comprise one or more tabs depending from the top section of the frame for supporting said temperature sensor(s). Further optionally, the tab(s) may comprise a groove or channel for supporting and/or guiding the temperature sensoL Additionally or alternatively, the bottom section of the franie may comprise one or more first parts of a two-part complementary locating mechanism and wherein a cooling plate may comprise one or more second parts of the two-part complementary locating mechanism.

Optionally, the first part may be a notch formed in the front and in the rear face of the bottom section of the frame and the second part is a tab. Further optionally, each section of the is frame may comprise one or more notches formed in the front face and in the rear face of the bottom section of the frame and the number of tabs comprises by the cooling plate is similar to the number of notches formed in the front face or in the rear face of the bottom section of the frame.

Optionally, each frame may comprise a spacing and/or supporting pillar extending upwardly of the top section of the frame above the position of the one or more dividers.

Further optionally, each frame may comprise at least part of an affixing element for affixing the frame to an adjacent frame and wherein said at least part of an affixing element is formed from any one or a combination of: an aperture or hole for receiving a bolt; a clip integrally moulded with the frame; a separate clip moulded with the frame; a notch, indentation or other shaped formation for receiving a snap-fitting clip; a clip over-rnoulded to the frame; and a clip co-moulded with the frame..

Optionally, each side of the frame may comprise a cooling plate inlet/outlet formation and an aperture may be created between the cooling plate inlet/outlet formation of one frame and the cooling plate inlet/outlet formation of an adjacent frame and an inlet or an outlet of a cooling plate of the cell module may be disposed in that aperture.

Optionally, each frame has a front face and a rear face and forms part of either a first modular frame member or a second modular frame member, the first modular frame member may comprise a cooling plate disposed immediately adjacent to the front face of the frame, at least one rechargeable electrochemical cell disposed in a section of the frame and at least one foam cell or foam layer disposed immediately adjacent to the rear face of the frame, and the second modular frame member may comprise at least one foam cell or foam layer disposed immediately adjacent to the front face of the frame, at least one rechargeable electrochemical cell disposed in a section of the frame and a cooling plate disposed immediately adjacent to the rear face of the frame.

Further optionally, the cell module may comprise at least two first modular frame members, at least two second modular frame members and a first end plate wherein the cell module is constructed such that: a first end plate is outermost; a front face of a first one of the first modular frame members is disposed closest to the first end plate such that the cooling plate of the first one of the first modular frame members is in contact with that first end plate; a rear face of a first one of the second modular frame members is disposed closest to the rear face of said first one of the first modular frame members such that the cooling plate of the first one of the second modular frame members is disposed between the cells of the first one of the first modular frame members and the cells of the first one of the second modular frame members; a front face of a second one of the first modular frame members is disposed closest to the front face of said first one of the second modular frame members; and a rear face of a second one of the second modular frame members is disposed closest to the rear face of said second one of the first modular frame members such that the cooling plate of the second one of the second modular frame members is disposed between the cells of the second one of the first modular frame members and the cells of the second one of the second modular frame members.

Optionally, the cell module may further comprise a further cooling plate and a second end plate, wherein the further cooling plate is disposed between the second end plate and the front face of the second one of the second modular frame members such that the further cooling plate is disposed adjacent to the cells of the second one of the second modular frame members and thereby the cells of each frame member of the cell module may be disposed between cooling plates.

Additionally or alternatively, each cooling plate may comprise an inlet and an outlet, the inlet may be disposed on one side of the cooling plate and the outlet may be disposed on the other side of the cooling plate, wherein the inlet is mounted higher than the outlet and wherein inlets of the cooling plates of the cell module are alternately mounted on opposite sides of the cell module.

According to another aspect of the invention for which protection is sought, there is provided a vehicle comprising a rechargeable battery pack according to any preceding paragraph.

According to yet another aspect of the invention for which protection is sought, there is provided a frame for forming a cell module for use in forming a battery pack, the frame may comprise a top section and a bottom section interconnected by opposed sides and at least one divider for forming more than one section, each section for receiving a rechargeable electrochemical cell; at least one pair of apertures formed in the top section of the frame, which apertures are for receiving tab terminals of a cell; and one or more first parts of a two-part complementary locating mechanism disposed in the bottom section for mating with one or more second parts of the two-part complementary locating mechanism formed on a cooling plate.

Optionally, the first part may be a notch formed in the front face and in the rear face of the bottom section of the frame.

Optionally, each frame may comprise a spacing and/or supporting pillar extending upwardly of the top section of the frame above the position of the one or more dividers. The spacing and/or supporting pillar may optionally provide structural support for other components of the battery pack, for example some of the battery's electrical circuitry may be positioned on a platform supported at least in part by the spacing and/or supporting pillar. Additionally, or alternatively, the spacing and/or supporting pillar may ensure that only components intended to contact the tab terminals of the cells can do so and that there is sufficient space above the top section of the frame to house the tabs.

According to a further aspect of the invention for which protection is sought, there is provided a method of forming a first modular frame member for use in forming a cell module for use in forming a battery pack, the method may comprise: providing a cooling plate; positioning a front face of a frame immediately adjacent to the cooling plate and relatively locating first and second complementary locating parts of the cooling plate and frame; positioning a rechargeable electrochemical cell in a section of the frame; and positioning a foam cell or foam layer on top of the rechargeable electrochemical cell and immediately adjacent to the rear face of the frame.

According to yet an even further aspect of the invention for which protection is sought, there is provided a method of forming a second modular frame member for use in forming a cell module for use in forming a battery pack, the method may comprise: positioning at least one rechargeable electrochemical cell in a section of the frame; positioning at least one foam cell or foam layer on top of the at least one rechargeable electrochemical cell and immediately adjacent to the front face of the frame; positioning a cooling plate immediately adjacent to the rear face of the frame.

S Optionally, the method of forming a first modular frame member or the method of forming a second modular frame member may further comprise inserting a temperature sensor into an aperture provided in the top section of the frame and disposing the temperature sensor in thermal contact with the cell.

Optionally either method of the preceding paragraphs may further comprise applying an affixing agent and curing the affixing agent to fix the components of the first modular frame member or second modular frame member.

According to another further aspect of the invention for which protection is sought, there is provided a method of forming a cell module for use in a battery pack, the cell module comprising two or more first modular frame members, two or more second modular frame members and a first end plate, the method may comprise: arranging the first end plate such that it is outermost; positioning a front face of a first one of the first modular frame members closest to the first end plate such that the cooling plate of the first one of the first modular frame members is in contact with that first end plate; positioning a rear face of a first one of the second modular frame members such that it is disposed closest to the rear face of said first one of the first modular frame members and such that the cooling plate of the first one of the second modular frame members is disposed between the cells of the first one of the first modular frame members and the cells of the first one of the second modular frame members; positioning a front face of a second one of the first modular frame members such that it is disposed closest to the front face of said first one of the second modular frame members; and positioning a rear face of a second one of the second modular frame members such that it is disposed closest to the rear face of said second one of the first modular frame members and such that the cooling plate of the second one of the second modular frame members is disposed between the cells of the second one of the first modular frame members and the cells of the second one of the second modular frame members.

Optionally, the cell module may further comprise a further cooling plate and a second end plate, and the method may further comprise: positioning the further cooling plate between the second end plate and the front face of the second one of the second modular frame members such that the further cooling plate is disposed adjacent to the cells of the second one of the second modular frame members and thereby the cells of each frame member of the cell module are disposed between cooling plates; and affixing the end plates, first and second modular frame members and further cooling plate together. Optionally, the method may additionally comprise positioning further pairs of first and second modular frame members between the first end plate and the further cooling plate and second end plate.

Within the scope of this application it is envisaged 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 features thereof, may be taken independently or in any combination. For example, features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIGURE 1 is schematic isometric view of a vehicle comprising a battery pack according to an embodiment of the invention; FIGURE 2A is a schematic perspective view of a battery pack according to an embodiment of the invention; FIGURE 2B is a schematic perspective view of a rechargeable electrochemical storage cell pouch according to an embodiment of the invention; FIGURE 3A is a perspective view showing the top, side and front face of a frame for use in forming a battery pack according to an embodiment of the invention; FIGURE 3B is a perspective view of a frame for use in forming a battery pack according to another embodiment of the invention; FIGURE 4A is an exploded view of the assembly of a first modular frame member for use in forming a battery pack according to an embodiment of the invention; FIGURE 4B is an exploded view of the assembly of a second modular frame member for use in forming a battery pack according to an embodiment of the invention;

S

FIGURE 5A is a perspective view from a first side of the assembled first modular frame member for use in forming a battery pack according to an embodiment of the invention; FIGURE 5B is a perspective view from a first side of the assembled second modular frame member for use in forming a battery pack according to an embodiment of the invention; FIGURE 6 is a perspective view of a cell module formed from six assembled frame members (three of the first modular frame members and three of the second modular frame members) and an end plate; and FIGURE 7 is a perspective, schematic illustration of a cross-section though a module comprising six assembled frame members according to an embodiment of the invention.

To assist in the understanding of the Figures and the components and features shown therein, the following table of reference numerals with a brief description of the referenced feature is provided: Reference Brief Description of Reference Brief Description of Numeral Referenced Feature Numeral Referenced Feature Vehicle 54 Cell wings Battery pack 56 Platform 22 Battery pack cover 58a, 58b, Terminal aperture 158a, 158b 24 Battery pack base 60 Notch 26, 126 Frame 62a, 62b, 62c, Spacing beams 62d End plate 64 Frame notch 32 Inlet manifold 66 Temperature aperture 34 Outlet manifold 68 Temperature support tab 36 Module 70 Temperature groove 38 Temperature sensor 72 Cooling plate location (thermistor) notch 40a Positive cell terminal 74a, 74b Cooling plate inlet/outlet formation 40b Negative cell terminal 76 Manifold fixing apertures 42 Cooling plate 78, 80, 90 Primary module affixing Reference Brief Description of Reference Brief Description of Numeral Referenced Feature Numeral Referenced Feature holes 44 Cell pouch 83 Cooling plate tab 46 Foam block 85 Bolt 48 Foam cell or foam layer 86, 88 Frame sides bOa, 50b Cooling Plate Inlet 92A Assembled A' -frame 52a, 52b Cooling Plate Outlet 92B Assembled B' -frame 82, 84 Dividers 95 Frame body 193 Notch/formation 96, 196 Top section F Frame front face P Frame rear face

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the battery pack, modules, frames and S methods of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the battery pack, modules, frames and methods described herein may be embodied in various and alternative forms.

The figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

In Figure 1 there is shown a vehicle 10 that may optionally be an electric vehicle (EV) having a battery pack 20 for providing electrical power for powering the drive train of the vehicle 10.

The battery pack 20 may optionally comprise two main packs. In other envisaged embodiments, the battery pack 20 may comprise a single pack or more than two main packs. In yet other envisaged embodiments, the vehicle 10 is not a fully electric vehicle, but rather a hybrid electric vehicle (HEy), for example a plug-in hybrid electric vehicle (PHEV).

In yet other envisaged embodiments, the vehicle 10 may not be driven solely or in part by electric power, but may nevertheless comprise a rechargeable electric battery pack 20 for powering electronic components other than the drivetrain of the vehicle 10. Other applications for a battery pack 20 are envisaged, for example, electrical power storage for portable power sources; electric grid; renewable energy generators; and back-up power supply.

An optional battery pack 20 according to an exemplary embodiment of the invention is illustrated schematically in Figure 2A. The battery pack 20 optionally comprises a battery pack base 24 and a battery pack cover 22. The battery pack base 24 provides a surface for supporting the components of the battery pack 20 and the battery pack cover 22 provides a protective barrier to prevent the ingress of, for example dust and dirt, into the battery pack 20. The shape, size, configuration and structure of the base 24 and cover 22 may be altered dependent upon the shape, size, configuration and structure of the battery pack 20 contained therein.

The battery pack 20 comprises a plurality of sealed rechargeable electrochemical energy storage cells 44, an example of which is shown schematically in Figure 2B. The rechargeable electrochemical energy storage cells 44 may also be referred to herein as cells, pouches and cell pouches 44. Optionally, each cell 44 may be a Li-ion (Lithium-ion) based electrochemical energy storage cell 44. In other envisaged embodiments alternative suitable electrochemical storage cells 44 or combinations thereof may be used. Each cell 44 comprises a pair of terminals 40a, 4Db, optionally provided as tabs 40a, 4Db protruding upwardly of the cell 44 when disposed in an generally upright orientation (as shown for example in Figures 2B, 4A and 4B). Each cell 44 may optionally comprise a cell wing 54 on each side thereof, which cell wing 54, may be formed of Aluminium sheet. According to one optional embodiment, the cell 44 may have width (W), depth (D) and height (H) dimensions of about 160mm, about 7mm and about 227mm respectively.

The battery pack 20 additionally comprises electronic circuitry for managing, controlling and balancing the electric charge stored in and taken from the individual cells 44 and a cooling system which optionally may comprise one or more pumps for circulating coolant around the cooling system which is disposed proximate the cells 44.

The power output by an electric battery pack is dependent upon the number and size of cells 44. With the use of an increasing numbers of cells 44 to obtain increased power output, the size of the electric battery pack 20 is increased. It is desirable to have a battery pack 20 that is as densely and compactly packaged as possible in order to minimise the space required by the battery pack 20 for example, within the vehicle 10 body. According to one beneficial aspect, the cells 44 of the battery pack 20 of the present invention are arranged in rows of optionally more than one cell 44, which rows are stacked next to one another to create a matrix of cells 44. In this way, rather than stacking single cells 44 next to one another as disclosed in W02012/009145A2 such that it is always and only the length of the battery pack/cell module that is increased in order to increase the power output, an aspect of the present invention provides a battery pack 20 and/or cell module 36 (for example, see Figure 6) that optionally comprises more than one cell 44 in each row, preferably, but nevertheless optionally disposed side by side. Further beneficially, the modular format of the battery pack described heiein enables vaiiously sized battery packs to be easily formed from the standard components of the battery pack 20 described. As such, no major re-design would be required to produce a battery pack 20 capable of housing a range of numbers and configurations of electrochemical storage cells 44.

Other considerations in the collation of a plurality of cells 44 to create a battery pack 20 of required power output are: the ease of assembly of the cells 44 and other components; the cooling of the cells 44; temperature monitoring of the cells 44 (preferably of each individual cell); protection of the cells 44; and expansion of the cells 44 that can occur when the temperature of the cells 44 increases.

The frame 26, 126 provided by the present invention is beneficial because it optionally allows more than one cell 44 to be disposed next to one another in rows of more than one cell 44 wide, such that the cells 44 can be densely packed together. Once assembled into a frame the more than one cell 44 can be more easily handled for the assembly of a matrix battery pack than would otherwise be the case without the frame. In one optional embodiment, the frame 26 is configured and arranged to house three cells, side-by-side, this is shown in Figure 3A, 5A. In forming a battery pack 20, a plurality of frames 26 each optionally comprising more than one cell 44 are assembled together (as is described below) to form a compact battery pack 20 arrangement.

An optional, exemplary and non-limiting frame 26 according to an embodiment of the invention is illustrated in Figure 3A. A further optional non-limiting frame 126 according to another embodiment of the invention is illustrated in Figure 3B. Optionally, the frame 26, 126 may be about 620mm in length (Dl) and may be about 257mm in height (D2).

One or more cells 44 are affixed, with other components (as described below), to a frame 26, 126 to form first modular frame members 92A (also referred to as A-frames) and second modular frame members 92B (also referred to as B-frames) as shown schematically in Figures 5A and 5B respectively. The first and second modular frame members 92A, 92B are affixed in a stacked alternating arrangement, optionally with additional components (as described below) to form cell modules 36 such as that shown in Figures 6 and 7, wherein each row of one or more cells 44 is disposed between a cooling plate 42 of the cooling system such that each side of the cell pouch 44 can be cooled. The battery cell modules 36 s may be of various size and configuration and various numbers of battery cell modules 36 may be arranged together to form a battery pack 20.

In the optional, illustrated embodiment, the battery pack 20 is split into two units and comprises, in total, one hundred and seventy-four cells 44 arranged in fifty-eight rows of three cells 44 each. The battery pack 20 comprises two separate and independent pumps (now shown) for providing two separate circuits of coolant to each of the two units of the battery pack 20.

Referring now to the cell modules 36, each cell module 36 optionally comprises an alternating sequence of first and second modular frame members 92A, 92B; an additional cooling plate (not shown in Figure 6); and a pair of end plates 30 (only one shown in Figure 6). Each of the first and second modular frame members 92A, 92B comprises (not necessarily in this sequence): a frame 26; a cooling plate 42; one or more rechargeable cells 44 (in this example three cells 44); one or more foam cells or foam layers 48 (in this example three foam cells or foam layers each optionally of about 1.6mm thickness); one or more temperature sensors 38 (in this example three thermistors); and one or more foam blocks 46 (in this example three foam blocks are used for each temperature sensor of each cell 44).

The assembly of each of the first and second modular frame members 92A, 92B is illustrated in Figures 4A and 4B respectively. Before describing the assembly of the first and second modular frame members 92A, 92B, the structural features of the exemplary and frame 26 of Figure 3A will be described in further detail.

Each frame 26 forms the structural foundation of each of the first and second modular frame members 92A, 92B and as such provides a structure onto which the various, aforementioned components can be housed or mounted. The frames 26 may therefore provide for the compact and/or secure housing of one or more cells 44 and preferably, but nevertheless optionally for the housing of more than one adjacently positioned cell 44. The frames 26 additionally, optionally, provide for the compact housing and/or easy assembly of: a cooling plate 42; the temperature sensor 38 for each cell; the inlet and outlet manifolds 50a, 50b, 52a, 52b of the cooling system; and the foam cells or foam layers 48. Additionally, the frames 26 may provide a means for affixing or attaching cells 44 together in stacks or cell modules 36 so that the cells 44 can be compactly, efficiently and securely stacked together in a dense configuration. To achieve these functions, the frame 26 is provided with a number of features, any or all of which may be used in isolation of any of the other features. In other words, the features of the illustrated frame 26 are not necessarily structurally and functionally related to one another unless otherwise explicitly stated. Nevertheless it will be recognised that the features when provided together form the frame 26 according to a preferred, but nevertheless optional embodiment.

The body 95 of the frame 26 of the exemplary embodiment illustrated comprises: a top section 96; a bottom section or platform 56 interconnected by sides 86, 88. Three sections are formed, each for housing an individual cell 44, in part by vertical dividers 82, 84. In other envisaged embodiments a frame 26 may support one or more than one cell 44 and have an appropriate number of separate sections for doing so and is not limited to having three sections as shown. Where a frame 26 for housing only one cell is provided, the frame 26 may be beneficial for assisting the assembly of a battery pack, for ensuring correct alignment and ease of location of a temperature sensor for the cell; for creating a rigid, compact structure in which the cell is securely held and restricted from expanding beyond the dimensions of the frame; and a means for attaching one cell 44 to the next cell 44.

Preferably though nevertheless optionally, the frame 26 comprises three sections and is capable of holding three cells 44 in a row. In this way, the number of cells 44 in a battery can be increased to achieve a desired power output using stacked frames of three cells each whilst maintaining a compact and dense overall battery pack structure. For example, a module comprising sixty cells 44 structured as per the embodiment of Figures 5A and SB in a 3 x 20 configuration may be approximately about 620mm x about 280mm x about 257mm.

In comparison, a battery module structure formed of sixty single cells in a 1 x 60 configuration may be about 200mm x about 840mm x about 257mm.

Referring in more detail to the exemplary and frame 26 of Figure 3A, the substantially rectangular body 95 is optionally moulded from plastics material. Optionally, the frame 26 may be injection moulded as an integral unitary component and optionally from a suitable material such as Nylon® (PAG6). As such the frame may be easy to manufacture and relatively lightweight. The frame has a front face F' (the face shown outermost in Figure 3A and Figure 4A) and a rear face fl' (the face shown outermost in Figure 4B).

The body 95 of the frame 26 of the exemplary illustrated embodiment comprises three sections, defined in part by vertical dividers 82, 84. Each of the three sections is for housing an individual cell 44. The cells 44 to be disposed in the three sections of the body 95 may optionally be supported by the platforms 56. The cell wings 54 (see Figures 2B, 4A and 4B) may be snap-fit or engaged by the physical form or shape of the dividers 82, 84. For example, the dividers 82, 84 may be 1' or + shaped in cross-section which may optionally assist in the mechanical retention of the individual cells 44 in the sections of the frame 26 (see Figures 3A, 4A, 4B and 7). Such mechanical retention may be beneficial during the S construction of an assembled A! or B' frame 92a, 92b (see Figures 5A and SB for the assembled A-frame and the assembled B-frame) and may not necessarily be relied upon as the only way in which the cells 44 are assembled with the frames 26 into the first and second modular frame members 92A, 92B. The method of construction of an assembled frame 92a, 92b is described further below.

Additionally or alternatively, the dividers 82, 84 and to some extent the sides 86, 88 of the frame provide a spacer between one cell wing 54 and an adjacent cell wing 54 and in this way the frame 26 can electrically insulate the aluminium (which is electrically conductive) cell wings 54 from one another to prevent or at least minimise the risk of an unwanted voltage being established between the conductive cell wings 54 of adjacent cells 44.

Referring again to Figure 3A, the frame 26 optionally additionally comprises appropriately shaped, sized and configured pairs of apertures 58a, 58b in the top section 96 of each section, though which the tab terminals 40a, 40b of a cell 44 can be passed such that each tab terminal 40a, 40b is supported by the edge of the aperture 58a, 58b and spaced from the adjacent tab terminal 40b, 40a of the same cell 44 and/or where present, the adjacent cell 44. This at least assists in electrically isolating the terminals 40a, 40b from one another.

Additionally, the apertures 58a, 58b and the edges of those apertures 58a, 58b may provide a further mechanical retention of the cell 44 to assist with securing the cell 44 within the frame 26 and to enable consistent positioning of the cells 44 so that, for example, a temperature sensor 38 (such as a thermistor) can be reliably and accurately coupled to a cell 44, which will be held within the section of the frame at a set position (giving consideration to manufacturing tolerances). In other envisaged embodiments cells having other types of terminal are envisaged and tab terminals are optional.

The top section 96 optionally also comprises appropriately shaped, sized and configured apertures 66 into which a temperature sensor 38 can be inserted, optionally for contacting the cell 44 at a predetermined, optimum temperature sensing location, for determining and monitoring the temperature of the cell 44. Optionally the frame 26 may also comprise integrally formed support tabs 68 for the temperature sensors 38. The support tabs 68 may have an appropriately sized and positioned channel, groove or guide 70 which may assist in supporting and/or aligning the temperature sensor 38.

Optionally the apertures 58a, 58b and 66 are formed substantially centrally of the top section of the frame 26 such that these features are similarly presented when the frame 26 is presented with its front face first or with its rear face first (see Figures 4A and 4B).

S

Upper corner portions 62a, 62d of the frame 26 may be provided with apertures 80 through which a fixing member such as a bolt may be inserted. A bolt or other affixing member of sufficient length may be inserted into multiple apertures (also referred to as optional primary module fixing holes) 80 of separate frames 26 for affixing those frames 26 together to form a cell module 36. The top section 96 may additionally comprise notches 64 or recesses 64 formed in the spacing beams 62a, 62d, which substantially U-shaped notches 64 are aligned with the fixing holes 80. The notches 64 may optionally be formed closer to the rear face of the frame 26 such that in this respect the front and rear faces of the frame 26 are not symmetrical.

Spacing beams 62b, 62c may also additionally project from the top section 96 and may ensure that the tab terminals 40a, 4Db are spaced from and do not undesirably contact any component of the battery pack that may for example be disposed on top of the cell module 36.

The bottom section 56 of the frame 26 optionally comprises one or more formations or cooling plate location notches 72 sized, shaped and/or otherwise configured in complementary manner with an optional formation, shaped portion, projection or cooling plate tab 83 of the cooling plate 42 (see Figures 4A and 4B). The cooling plate tab 83 can be located in a cooling plate location notch 72 to facilitate the assembly of the first and second assembled modular frame members 92A, 92B; to ensure correct positioning and alignment of the cooling plate 42 and optionally to at least temporarily affix the cooling plate 42 to the frame 26 to assist in holding together the components of each first and second modular frame member 92a, 92b during their assembly. Optionally, the location notches 72 are formed on both faces of the bottom section 56 of the frame 26 such that a cooling plate 42 can be located on either face of the frame 26. In this respect the two faces of the frame 26 are symmetrical.

The bottom section 56 of the frame further comprises optional notches 60 through which a an optional primary module fixing hole 78 may be formed. The notches 60 provide a recess into which the head of a bolt or a nut and/or washer may be placed. Such bolts and nuts/washers may be used to affix together two or more of the first and second modular frame member 92a, 92b and/or end plates 30 in forming a module 36. Additional optional primary module fixing holes 90 may be formed in the sides 88, 86 of the frame 26 optionally as illustrated in Figure 3A. Optionally, the notches 60 may be closer to the rear face of the bottom section 56 of the frame 26. In this respect the two faces of the frame 26 are not symmetrical.

Preferably, but nevertheless optionally, the sides 86, 88 of the frame 26 are each provided with one or more shaped formation(s) 74a, 74b. These formations 74a, 74b may also be referred to as cooling plate inlet/outlet formations 74a, 74b. When two frames 26 are placed next to one another (side by side), the formation 74a of one frame 26 mates with the formation 74b of the other frame 26 such that together, the two formations 74a, 74b of the two frames 26 create an aperture appropriately shaped, sized and configured to receive and support an inlet or outlet 50a, SOb; 52a, 52b of the cooling plate 42. Preferably, but nevertheless optionally, the sides 86, 88 of the frame 26 are each provided with four shaped formations 74a, 74b such that a pair of frames 26 can form four apertures (two on either side of the cell module 36), each appropriately shaped, sized and configured to receive and support an inlet or outlet 50a, 50b; 52a, 52b of the cooling plate 42. This and/or the provision of other symmetrically formed features allows for a standard frame 26 to be manufactured that can be used for forming first and second modular frame members 92a, 92b that are of different construction and/or for forming first and second modular frame members 92a, 92b that have differently positioned cooling plate 42 inlets or outlets 50a, SOb; 52a, 52b. The benefit of this may be better understood upon reading the following description of how the frames 26 are used to form first and second modular frame members 92a, 92b and how those first and second modular frame members 92a, 92b are then used to form modules 36.

Turning to the construction of the first modular frame member 92A, reference is made to Figure 4A, which shows, in exploded view, the primary components (cooling plate 42, frame 26, three thermistors 38; three cells 44; three foam blocks 46; and three foam cells or foam layers 48) of the first modular frame member 92A. The first modular frame member 92A may optionally be assembled by placing the components in order on top of one another, for example, the cooling plate 42 may be disposed lower most and with relative movement between the cooling plate 42 and frame 26, the cooling plate 42 is located onto the rear face of the frame 26. A cell 44 may be placed into each section of the frame 26 from the front face thereof. Optionally, each cell 44 may be manipulated into the section by threading the tabs 40a, 40b into the apertures 58a, 58b and then pushing the cell wings 54 past the sides 86, 88 and/or dividers 82, 84, optionally to snap-fit the cell 44 in place. A thermistor 38 is then inserted into each aperture 66 of each section and disposed in contact with a cell 44.

The foam blocks 46 may then be placed between the tabs 40a, 40b of the cells 44 and finally a foam cell or foam layer 48 placed on top of each cell 44. An affixing agent or means, for example a resin, adhesive or mechanical fixing means may be placed within the frame and/or between the primary components and/or applied to the outside of the part-assembled structure. The affixing agent may be any chemical and/or mechanical affixing agent.

Optionally a suitable chemical affixing agent may be a resin which may optionally be, for example a two-part epoxy based resin such as Stycast'. Optionally, the resin of the assembled first modular frame member 92A may be cured by heat, optionally by placing the assembled first modular frame member 92A in an oven. The completed and affixed first modular frame member 92A is shown schematically in Figure 5A.

Turning to the construction of the second modular frame member 92B, reference is made to Figure 4B, which shows, in exploded view, the primary components (cooling plate 42; three foam blocks 46; three cells 44; frame 26; three thermistors 38; and three foam cells or foam layers 48) of the second modular frame member 92B. The second modular frame member 92B may optionally be assembled by placing the components in order on top of one another, for example, the foam cells or foam layers 48 may be disposed lower most and with relative movement between the foam cells or foam layers 48 and frame 26, the foam cells or foam layers 48 located onto the rear face of the frame 26. A cell 44 may be placed into each section of the frame 26 from the front face thereof. Optionally, each cell 44 may be manipulated into the section by threading the tabs 40a, 40b into the apertures 58a, 58b and then pushing the cell wings 54 past the sides 86, 88 and/or dividers 82, 84, optionally to snap-fit the cell 44 in place. A thermistor 38 is then inserted into each aperture 66 of each section and disposed in contact with a cell 44. The foam blocks 46 may then be placed between the tabs 40a, 40b of the cells 44 and finally a cooling plate placed on top of each cell 44 and located into the frame notches 72. An affixing agent or means, for example a resin, adhesive or mechanical fixing means may be placed within the frame and/or between the primary components and/or applied to the outside of the part-assembled structure. The affixing agent may be any chemical and/or mechanical affixing agent. Optionally a suitable chemical affixing agent may be a resin which may optionally be, for example be a two-part epoxy based resin such as Stycast®. Optionally, the resin of the assembled second modular frame member 92B may be cured by heat, optionally by placing the assembled second modular frame member 923 in an oven. The completed and affixed second modular frame member 923 is shown schematically in Figure 53.

To form a cell module 36 from the first and second modular frame members 92A, 92B, the first and second modular frame members 92A, 92B are stacked in an alternating series. In one embodiment a module comprises three first modular frame members 92A and three second modular frame members 92B, two end plates and an extra cooling plate 42. The extra cooling plate 42 is provided so that each cell 44 is disposed or sandwiched between two cooling plates 42. In this way the cooling or temperature management of each cell 44 is optimised. Optionally a cell module 36 may be completed by threading bolts 65 of sufficient length and suitable strength through two or more of the primary module affixing holes 78, 80, 90. Preferably, but nevertheless optionally, bolts 85 are placed though each hole 80 of the top section 96 and each hole 78 of the bottom section 56. Of each of the alternating series of six first and second modular frame members 92A, 92B and the end plates 30. A perspective view of the cell module 36 is shown in Figure 6 and a cross-sectional schematic view is shown in Figure 7. In alternative embodiments, one or both end plates may comprise an integral affixing means of sufficient length and suitable strength for threading through two or more of the primary module affixing holes.

It can be seen that each set or row of three cells 44 is sandwiched between two cooling plates 42. Inlet and outlet manifolds 32, 34 of the cooling system may be connected to a series of three inlets or three outlets 50a, 52a; Sob, 52b which are staggered in their positioning. The first and second modular frame members 92A, 923 are formed and arranged such that their respective cooling plate inlets 50a, 50b and outlets 52a, 52b are disposed on opposite sides of the module 36 from one another. In other words, the inlet 50a of the cooling plate 42 of the first modular frame member 92A is disposed on the opposite side of the cell module 36 to the inlet SOb of the cooling plate 42 of the second modular frame member 923. For example, see Figure 6 where it can be seen that a single inlet manifold 32 may be connected across three cooling plate inlets 50a, each provided by the three first modular frame members 92A. The manifold 32 connects the inlets 50a to the cooling system to provide cooled coolant from the cooling system into the cooling plates 42.

Similarly, a second inlet manifold 32 is disposed on the opposite side of the cell module 36 to serve the three cooling plate inlets SOb provided by the three second modular frame members 923. The outlets 52a of the three cooling plates 42 of the first modular frame members 92A are similarly connected by a single manifold 34 for connecting those outlets 52a to the cooling system for pumping out the warmed coolant from the cooling plates 42.

Similarly, the outlets 52b of the three cooling plates 42 of the second modular frame members 923 are similarly connected by a single manifold 34. The structure and arrangement of the cell module 36 enables the same frames 26 and cooling plates 42 to be used in an alternating assembly to enable, among other things, the manifolds 32, 34 to be fitted to the cell module 36 and despite the size of these components, the manifolds 32, 34 do not cause an increase in the overall dimension of the cell module 36. Despite the size of these components, the manifolds 32, 34 can be filled to the cell module 36, even when the cooling plates 42 are so closely packed together. This is because each inlet is spaced from an adjacent inlet by a frame width. The frame providing the space has its cooling plate inlet on the other side of the cell module. Likewise, each outlet is spaced from an adjacent outlet by a frame width and the frame that provides the spacing has its cooling plate outlet on the other side of the cell module. The alternating formation of the cooling plates 42 by forming s first and second types of modular frame member enables the cells 44 to be very closely packed whilst at the same time providing sufficient room for the manifolds 50a, 50b, 52a, 52b and inletloutlets 32, 34.

Optionally the manifolds 32, 34 may be affixed by screws to the sides 86, 88 of the frame 26.

Optionally, manifold fixing apertures 76 may be formed when the frame 26 is moulded for facilitating the affixing of the manifold using screws to the frames 26. In other envisaged embodiments, other affixing means may be used, for example, self-tapping screws may be directly attached though the manifolds 32, 34 into the frame.

To complete a battery pack 20, the cell module 36 may be stacked with one or more other cell modules 36 (of similar of different modular frame number) to further increase the number of cells 44 and therefore the power capacity of the battery pack 20. The terminals 40a, 40b of each cell 44 are coupled to appropriate electrical circuitry for controlling the electrical charge provided to and taken from each cell 44. A cooling system (not shown) comprising one or more pumps; conduits for coupling the pumps to the manifolds 32, 34; coolant for flowing within the conduits and cooling plates 42; and appropriate electrical circuitry for controlling the volumetric flow-rate from the pump(s) and other characteristics is attached to the cell modules 36. The battery pack 20 optionally may be packaged and housed within a vehicle 10 as shown in Figure 1.

Optionally and beneficially the frames 26 are sufficiently symmetrical that a frame from a single moulding tool is suitable for forming the frames 26 and yet the frames 26 can be used to make the first and second modular frame members 92A, 92B so that a stacked arrangement that sandwiches all cells 44 between two cooling plates 42 can be formed. This is a cost effective and efficient design. In other embodiments however, two distinct and different frames may be used for forming the first and second modular frame members 92A, 92 B. It can be appreciated that various changes may be made within the scope of the present invention, for example, in another envisaged embodiment, such as that shown in Figure 3B, the top section 96 optionally additionally or alternatively comprises a formation or indentation 193 provided for seating a temperature sensor (thermistor) and a foam block for retaining the temperature sensor.

It will be recognised that in other embodiments, the number, format, configuration and/or s position of the optional complementary locating tab 83 and notch 72 may take a variety of formats. For example, in envisaged embodiments, the notch and location tab may be reversed such that the frame may comprise one or more location tabs and the cooling plate complises one or more coriesponding notches. In other envisaged embodiments, the frame may comprise a different number of location tabs to the number of sections for cells such that each section does not necessarily comprise, in its bottom platform a notch or other complementary fitment. Additionally or alternatively, in yet further envisaged embodiments, location fitments (notch/tab) may be formed in the sides 88, 86 of the frame 26 and of the sides of the cooling plate 42. Furthermore in some embodiments all complementary fitments (for example notches 72 and tabs 83) may be of similar shape, size and form. In other embodiments however the frame 26 and cooling plate 42 may comprise a combination of two or more different complementary fitments, for example a notch 72 may be formed in the frame into which a tab 83 of the cooling plate 42 may be located and in addition a notch may be formed in the cooling plate and a tab may be formed as part of the frame 26.

In some embodiments it is envisaged that the frames are placed on their bottom sections 56 and stacked face-to-face; in other embodiments it is envisaged that the frames may be placed with their faces lowermost and stacked upwardly one on top of the next. In yet further envisaged embodiments frames may be affixable together other than in face-contacting relationship, for example the bottom section 56 of one frame may be affixable to spacing beams 62a, 62b, 62c, 62d of another frame. The frames may be affixable together in face-contacting relationship as well, such that a two or more tiered arrangement of cell module can be formed.

In the illustrated embodiment, each frame comprises at least part of an affixing element for affixing the frame to an adjacent frame, which is a hole or aperture for housing a screw or bolt. In other envisaged embodiments a combination of different affixing means may be used. In some embodiments the at least part of an affixing element that is formed in the frame may, for example, be formed from any one or a combination of: an aperture or hole for receiving a bolt; a clip integrally moulded with the frame; a non-moulded clip disposed in the mould during the injection moulding of the frame (a clip may be bi-injection moulded, over-moulded or co-moulded); a notch, indentation or other shaped formation for receiving a snap-fitting clip.

In other embodiments of the invention it is envisaged that adjacent frame members comprise different numbers of cells 44. For example, a first frame member may comprise three cells and the adjacent second frame members may comprise only two cells. In other S embodiments of the invention, a cooling plate may be disposed either side of two or more rows of cells, wherein the two or more rows of cells each comprise one or more cells.

It will be recognised that as used herein, directional references such as "top", "bottom", "front", "back", "end", "side", "inner", "outer", "upper" and "lower" do not limit the features described to such orientation, but merely serve to described and distinguish these features from one another. Any dimensional reference such as "width", "height" and "depth" should not be construed as imparting a directional limitation on the component having any such labelled dimension. Specifically, it will be recognised that whereas in one embodiment of the invention, the cells 44 and frames 26 in the battery pack 20 may be positioned upright relative to a vehicle 10 in which the battery pack 20 is disposed, in other embodiments, the cells 44 and frames 26 may be stacked on their faces, sides or even inverted. The battery pack 20 illustrated is not limited to having a specific orientation within the vehicle 10.

Claims

CLAIMS1. A rechargeable electric battery pack comprising a cell module, the cell module comprising a plurality of frames, each frame comprising at least one section configured and/or arranged for accommodating a rechargeable electrochemical storage cell, wherein each frame is affixed to an adjacent frame of the cell module.
2. A rechargeable electric battery pack according to claim 1 wherein each frame comprises more than one section and each frame accommodates more than one rechargeable electrochemical storage cell, such that the plurality of rechargeable electrochemical storage cells are arranged in framed rows comprising two or more rechargeable electrochemical storage cells and stacked in columns of frames to form a matrix arrangement of rechargeable electrochemical storage cells.
3. A rechargeable electric battery pack according to claim 2 wherein each frame comprises a top section and a bottom section interconnected by opposed sides and at least one divider for forming said more than one section.
4. A rechargeable electric battery pack according to claim 3 wherein each frame comprises two dividers and three sections and each frame accommodates three rechargeable electrochemical storage cells.
5. A rechargeable electric battery pack according to claim 3 or 4 wherein one or more of the dividers are shaped, optionally substantially T'-shaped, in cross-section, for catching a wing (54) of a cell (44) disposed in a section of the frame that is at least partially defined by the one or more shaped dividers.
6. A rechargeable electric battery pack according to any of claims 3, 4 or 5 wherein each section of the frame comprises at least one pair of apertures formed in the top section of the frame, which apertures receive terminals (40a, 40b) of the cell (44) disposed in each of the sections of the frame.
7. A rechargeable electric battery pack according to claim 6 wherein each section of the frame comprises an aperture (66) formed in the top section of the frame, through which aperture a temperature sensor is disposed and positioned for determining the temperature of the cell (44) accommodated by the section.
8. A rechargeable electric battery pack according to claim 7 wherein each section of the frame comprises one or more tabs (68) depending from the top section of the frame for supporting said temperature sensor(s).
9. A rechargeable electric battery pack according to claim 8 wherein the tab (68) comprises a groove or channel for supporting and/or guiding the temperature sensor.
10. A rechargeable electric battery pack according to any of claims 3 to 9 wherein the bottom section of the frame comprises one or more first parts of a two-part complementary locating mechanism and wherein a cooling plate comprises one or more second parts of the two-part complementary locating mechanism.
11. A rechargeable electric battery pack according to claim 10 wherein the first part is a notch (72) formed in the front and in the rear face of the bottom section of the frame and the second part is a tab (83).
12. A rechargeable electric battery pack according to claim 11 wherein each section of the frame comprises a notch (72) formed in the front face and in the rear face of the bottom section of the frame and the cooling plate comprises a number of tabs (83) that is similar to the number of notches formed in the front or rear face.
13. A rechargeable electric battery pack according to any of claims 3 to 12 wherein each frame comprises a spacing and/or supporting pillar extending upwardly of the top section of the frame above the position of the one or more dividers.
14. A rechargeable electric battery pack according to any of claims 3 to 13 wherein each frame comprises at least part of an affixing element for affixing the frame to an adjacent frame and wherein said at least part of an affixing element is formed from any one or a combination of: an aperture or hole for receiving a bolt; a clip integrally moulded with the frame; a clip bi-injection moulded with the frame; a notch, indentation or other shaped formation for receiving a snap-fitting clip; a clip over-moulded to the frame; and a clip co-moulded with the frame.
15. A rechargeable electric battery pack according to any of claims 3 to 13 wherein each side of the frame comprises a cooling plate inlet/outlet formation (74a, 74b) and wherein an aperture is created between the cooling plate inlet/outlet formation (74a) of one frame and the cooling plate inlet/outlet formation (74b) of an adjacent frame and wherein an inlet or an outlet of a cooling plate of the module is disposed in that aperture.
16. A rechargeable electric battery pack according to any of claims 1 to 15 wherein each frame has a front face and a rear face and forms part of either a first modular frame member (92A) or a second modular frame member (92B), wherein the first modular frame member (92A) comprises a cooling plate disposed immediately adjacent to the front face of the frame (26), at least one rechargeable electrochemical cell (44) disposed in a section of the frame and at least one foam cell or foam layer (48) disposed immediately adjacent to the rear face of the frame, and wherein the second modular frame member (923) comprises at least one foam cell or foam layer (48) disposed immediately adjacent to the front face of the frame (26), at least one rechargeable electrochemical cell (44) disposed in a section of the frame and a cooling plate disposed immediately adjacent to the rear face of the frame.
17. A rechargeable electric battery pack according to claim 16 wherein the cell module comprises at least two first modular frame members (92A), at least two second modular frame members (923) and a first end plate wherein the cell module is constructed such that: (i) a first end plate is outermost; (ii) a front face of a first one of the first modular frame members (92A) is disposed closest to the first end plate such that the cooling plate of the first one of the first modular frame members (92A) is in contact with that first end plate; (iii) a rear face of a first one of the second modular frame members (923) is disposed closest to the rear face of said first one of the first modular frame members (92A) such that the cooling plate of the first one of the second modular frame members (92B) is disposed between the cells (44) of the first one of the first modular frame members (92A) and the cells of the first one of the second modular frame members (92B); (iv) a front face of a second one of the first modular frame members (92A) is disposed closest to the front face of said first one of the second modular frame members (92B); and/or (v) a rear face of a second one of the second modular frame members (923) is disposed closest to the rear face of said second one of the first modular frame members (92A) such that the cooling plate of the second one of the second modular frame members (92B) is disposed between the cells (44) of the second one of the first modular frame members (92A) and the cells of the second one of the second modular frame members (92B).
18. A rechargeable electric battery pack according to claim 17 wherein the cell module comprises a further cooling plate and a second end plate, wherein the further cooling plate is disposed between the second end plate and the front face of the second one of the second modular frame members such that the further cooling plate is disposed adjacent to the cells (44) of the second one of the second modular frame members (923) and thereby the cells (44) of each frame member of the cell module are disposed between cooling plates.
19. A rechargeable electric battery pack according to claim 17 or 18 wherein each cooling plate comprises an inlet and an outlet, the inlet being disposed on one side of the cooling plate and the outlet being disposed on the other side of the cooling plate, wherein the inlet is mounted higher than the outlet and wherein inlets of the cooling plates are alternately mounted on opposite sides of the cell module.
20. A vehicle comprising a rechargeable battery pack according to any preceding claim.
21. A frame (26) for forming a cell module for use in forming a battery pack according to any of claims 1 to 19, the frame comprising a top section and a bottom section interconnected by opposed sides and at least one divider for forming more than one section, each section for receiving a rechargeable electrochemical cell (44); at least one pair of apertures formed in the top section of the frame, which apertures are for receiving tab terminals (40a, 40b) of a cell (44); and one or more first parts of a two-part complementary locating mechanism disposed in the bottom section for mating with one or more second parts of the two-part complementary locating mechanism formed on a cooling plate.
22. A trame according to claim 21 wherein the first part is a notch (72) formed in the front face and in the rear face of the bottom section of the frame.
23. A frame according to claim 21 or claim 22 wherein each frame comprises a spacing and/or supporting pillar extending upwardly of the top section of the frame above the position of the one or more dividers.
24. A method of forming a first modular frame member (92A) for use in forming a cell module for use in forming a battery pack according to any of claims 1 to 19, the method comprising: (i) providing a cooling plate; (ii) positioning a front face of a frame (26) optionally according to any of claims 21 to 23 immediately adjacent to the cooling plate and relatively locating first and second complemenatry locating parts of the cooling plate and frame; (iii) positioning a rechargeable electrochemical cell (44) in a section of the frame; and (iv) positioning a foam cell or foam layer (48) on top of the cell (44) and immediately adjacent to the rear face of the frame.
25. A method of forming a second modular frame member (923) for use in forming a cell module for use in forming a battery pack according to any of claims 1 to 19, the method comprising: (i) positioning at least one rechargeable electrochemical cell (44) in a section of the frame; (ii) positioning at least one foam cell or foam layer (48) on top of the at least one rechargeable electrochemical cell (44) and immediately adjacent to the front face of the frame (26); (iU) positioning a cooling plate immediately adjacent to the rear face of the frame.
26. The method of forming a first modular frame member (92A) according to claim 24 or the method of forming a second modular frame member (923) according to claim 25, further comprising inserting a temperature sensor into an aperture provided in the top section of the frame and disposing the temperature sensor in thermal contact with the cell (44).
27. The method of forming a first modular frame member (92A) according to claim 24 or or the method of forming a second modular frame member (923) according to claim 25 or 26, further comprising applying an affixing agent and curing the affixing agent to fix the components of the first modular frame member (92A) or second modular frame member (923).
28. A method of forming a cell module for use in a battery pack according to any of claims 1 to 19, the cell module comprising two or more first modular frame members optionally formed by the method according to claim 24, two or more second modular frame members optionally formed by the method according to claim 25 and a first end plate, the method comprising: (i) arranging the first end plate such that it is outermost; (ii) positioning a front face of a first one of the first modular frame members (92A) closest to the first end plate such that the cooling plate of the first one of the first modular frame members (92A) is in contact with that first end plate; (iii) positioning a rear face of a first one of the second modular frame members (92B) such that it is disposed closest to the rear face of said first one of the first modular frame members (92A) and such that the cooling plate of the first one of the second modular frame members (92B) is disposed between the cells (44) of the first one of the first modular frame members (92A) and the cells of the first one of the second modular frame members (92B); (iv) positioning a front face of a second one of the first modular frame members (92A) such that it is disposed closest to the front face of said first one of the second modular frame members (92B); and/or (v) positioning a rear face of a second one of the second modular frame members (92B) such that it is disposed closest to the rear face of said second one of the first modular frame members (92A) and such that the cooling plate of the second one of the second modular frame members (92B) is disposed between the cells (44) of the second one of the first modular frame members (92A) and the cells of the second one of the second modular frame members (92B).
29. A method of forming a cell module for use in a battery pack according to claim 28, wherein the cell module further comprises a further cooling plate and a second end plate, wherein the method further comprises: (i) positioning the further cooling plate between the second end plate and the front face of the second one of the second modular frame members such that the further cooling plate is disposed adjacent to the cells (44) of the second one of the second modular frame members (923) and thereby the cells (44) of each frame member of the cell module are disposed between cooling plates; and (ii) affixing the end plates, first and second modular frame members and further cooling plate together.
30. The method of claim 29 additionally comprising: (i) positioning further pairs of first and second modular frame members between the first end plate and the further cooling plate and second end plate.
31. A vehicle, battery back, a cell module, a first modular frame member, a second modular frame member, or a frame constructed and/or arranged substantially as described herein with reference to and/or as illustrated by the accompanying Figures.