Technical field

The present invention relates to a cell holder for a battery housing of an electrical vehicle, in particular of an electrical bike, or a power tool.

Background of the invention

From Korean patent KR101948319B1 there is known a battery holder comprising a bridging portion which is brought into contact with inner side plates of a battery casing, when the battery holder is put into the casing. The bridging portion is made of elastic and deformable material, such that when impact is applied to the side plates of the battery casing and transmitted to the bridging portion, that portion is elastically deformed so as to absorb the impact. Furthermore, the battery holder comprises curved projections which are brought into contact with inclined portions located in the bottom part of the battery casing. What is more, they perform similar function to bridging portions, i.e. absorbing impact applied to the bottom part of the battery housing.

American patent US11177526B2 discloses a battery housing for an electrical vehicle comprising a frame formed of multiple profile segments mutually connected by angle pieces and a bottom plate inserted into the lower frame opening. The battery housing also comprises a longitudinal strut and transverse struts arranged at distance from one another and parallel to one another. The transverse struts are connected with the longitudinal struts to jointly form nodes. Furthermore, the battery housing comprises tolerance-compensating elements corresponding to the number of the nodes and fitted to the nodes. The tolerance-compensating elements are provided as a stamped and shaped sheet metal part.

Although the above-cited patent literature discloses cell holders for electric vehicles either arranged to compensate for dimensional tolerance of a battery housing or cell holders for electric vehicles allowing them to be positioned inside the battery cell housing, there is still a need to provide cell holders for a battery housing of an electrical vehicle or a power tool that could be arranged to compensate for dimensional tolerance of the battery housing and to allow longer-term positioning of the cell holder in the battery cell housing comparing to the solution known from the prior art. Therefore, the object of the invention is to provide a cell holder for a battery housing of an electrical vehicle or a power tool arranged to compensate for dimensional tolerance of the battery housing and to allow longer-term positioning of the cell holder in the battery cell housing comparing to the solution known from the prior art. The Essence of the Invention

The object of the invention is a cell holder for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool comprising a body, and at least two elements compensating dimensional tolerance of a battery housing. Said elements compensating dimensional tolerance of a battery housing and the body form a monolithic structure. Said elements compensating dimensional tolerance of a battery housing are configured to have lower bending stiffness, such that they can be bent when said cell holder is placed inside a battery housing thereby compensating dimensional tolerance of the battery housing.

The application of said elements compensating dimensional tolerance of a battery housing and the body forming the monolithic structure, wherein said elements compensating dimensional tolerance of a battery housing are configured to have lower bending stiffness, such that they can be bent when said cell holder is placed inside a battery housing thereby compensating dimensional tolerance of the battery housing provides a cell holder for a battery housing of an electrical vehicle or a power tool arranged to compensate for dimensional tolerance of a battery housing and to allow longer-term positioning of the cell holder in the battery housing comparing to the solution known from the prior art.

Preferably, said elements compensating dimensional tolerance of a battery housing are arranged such that they compensate dimensional tolerance of the battery housing in x axis. Such an arrangement of said elements limits the movement of the cell holder within the battery housing in one of the axes namely axis x, and as a result, increases the durability of the cell holder as well as reduces a shaking degree of cells placed in such holder.

Preferably, said elements compensating dimensional tolerance of a battery housing are arranged such that they compensate dimensional tolerance of the battery housing in y axis. Such an arrangement of said elements limits the movement of the cell holder within the battery housing in one of the axes, namely axis y, and as a result, further increases the durability of the cell holder as well as reduces shaking degree of cells placed in such holder.

Preferably, said elements compensating dimensional tolerance of a battery housing are located on opposite sides of the body.

The location of said elements on the opposite sides of the body improves distribution of stresses acting on said elements and ensures efficient clamping of the cell holder in the battery housing while minimizing the risk of the cell holder locking into the battery housing. Preferably, at least one side of the body comprises a plurality of said elements compensating dimensional tolerance of a battery housing.

The presence of a plurality of said elements on the at least one side of the body leads to improvement in compensation of dimensional tolerance of the battery housing.

Preferably, said elements compensating dimensional tolerance are located on surface of the body.

The presence of said elements located on surface of the body reduces the risk of denting such elements inside the body and as a consequence damaging of a battery cell or battery cells, especially when the battery housing is within its minimum dimensional tolerance limit and the cell holder is within its maximum dimensional tolerance limit. This is particularly important not only when pressing the cell holder into the battery housing during manufacturing process, but also during normal usage of said cell holder and battery housing. Further, the presence of said elements located on surface of the body ensures maintenance of proper contact between the cell holder and the battery housing, and therefore their proper fit and resulting stability, even when the battery housing is within its maximum dimensional tolerance limit and the cell holder is within its minimum dimensional tolerance limit.

Preferably, said elements compensating dimensional tolerance of a battery housing have a form of arched projections and/or inclined projections.

The application of arched projections and inclined projections allows the use of the body of the cell holder of different shapes and sizes, so a result the cell holder can be used in battery housings of different shapes and sizes.

Preferably, arched projections have a form of a section of a truncated cone cut along the height of the cone.

The application of the arched projections having the form of the section of the truncated cone cut along the height of the cone provides an increased compensation range of dimensional tolerance of the battery housing.

Preferably, the arched projections have through-holes extending along the longitudinal axis of the cell holder.

Preferably, at least one of the arched projections is chamfered towards at least one of its ends.

The application of at least one of the arched projections chamfered towards at least one of its ends ensures that the cell holder does not permanently lock into the battery housing. It can be inserted and removed from said housing. Consequently, it enables maintenance of a battery system contained in the battery housing. Therefore, it is also possible to remove and insert the cell holder during a manufacturing process of a battery pack when an assembler makes a mistake in assembling of those parts.

Preferably, the inclined projections are angled at 30-90°.

Preferably, the inclined projections are angled at 45°.

The application of the inclined projections angled at 30-90°, especially at 45°, reduces the possibility of damage of such projections due to the resulting stresses and consequently leads to an additional increase in positioning time of the cell holder within the battery housing.

Preferably, the upper surface of the inclined projections is chamfered towards at least one of its ends.

The application of the inclined projections with the chamfered upper surface towards at least one of its ends ensures that the cell holder does not permanently lock into the battery housing. It can be inserted and removed from said housing without damaging the inclined projections due to plastic deformations acting on these projections. Consequently, it enables maintenance of a battery system contained in the battery housing. Therefore, it is also possible to remove and insert the cell holder during a manufacturing process when an assembler makes a mistake in assembling of those parts.

Preferably, the body comprises recesses and the inclined projections are located inside the recesses.

The application of the recesses limits the possibility of bending the inclined projections, and consequently limits the stresses arising in those projections, leading to an increase in their durability, and as a result even longer-term positioning of the cell holder in the battery housing.

Preferably, the arched projections and/or inclined projections are longitudinal elements.

The application of the arched projections and/or inclined projections that are longitudinal elements leads to an increase in their strength and, consequently, their service life. Increasing the service life of the arched projections and/or inclined projections leads to an increase in the service life of the entire cell holder.

Advantages of the invention

The cell holder according to the invention ensures reduction of costs of materials used to compensate dimensional tolerance of a battery housing as a body and elements compensating dimensional tolerance form a monolithic structure. As a result it leads to a reduction in manufacturing costs of a battery pack and increases the efficiency of said manufacturing process compared to solutions known in the state of the art. The cell holder according to the invention eliminates an additional operation of placing paste, glue or silicon in a battery housing during assembly of said cell holder inside the battery housing, thus simplifies the whole manufacturing process of a battery pack.

The cell holder according to the invention allows to compensate for dimensional differences occurring during manufacturing of a batter housing, as a result less accurate battery housings may be a part of a battery pack.

The arrangement of elements compensating dimensional tolerance of a battery housing prevents movement of the cell holder according to the invention in the battery housing, especially its movement in X and Y axes.

The cell holder according to the invention increases a level of mechanical stability of a cell arrangement, for example against vibrations, shocks or impact loads, and improves a battery system performance.

The cell holder according to the invention allows maintenance of a battery system during exploitation of a battery pack.

Description of the drawings

The subject of the invention is shown in the embodiments in a drawing, in which:

Fig.lA presents a cell holder according to the first embodiment of the invention in a perspective view;

Fig.lB presents a cell holder according to the first embodiment of the invention placed in a battery housing in a front view;

Fig.2A presents a cell holder according to the second embodiment of the invention in a perspective view;

Fig.2B presents a cell holder according to the second embodiment of the invention placed in a battery housing in a front view;

Fig.3A presents a cell holder according to the third embodiment of the invention in a perspective view;

Fig.3B presents a cell holder according to the third embodiment of the invention placed in a battery housing in a front view;

Fig.4A presents a cell holder according to the fourth embodiment of the invention in a perspective view; Fig.4B presents a cell holder according to the fourth embodiment of the invention placed in a battery housing in a front view;

Fig.5A presents a cell holder according to the fifth embodiment of the invention in a perspective view;

Fig.SB presents a cell holder according to the fifth embodiment of the invention placed in a battery housing in a front view;

Fig.6A presents a cell holder according to the sixth embodiment of the invention in a perspective view;

Fig.SB presents a cell holder according to the sixth embodiment of the invention placed in a battery housing in a front view.

Detailed description of the invention

The first embodiment of the invention

A cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool comprises a body 2, and elements 3 compensating dimensional tolerance of a battery housing. Said elements 3 compensating dimensional tolerance have a form of arched projections. The arched projections 3 are longitudinal elements. The application of the arched projections 3 that are longitudinal elements leads to an increase in their strength and, consequently, their service life. Increasing the service life of the arched projections leads to an increase in the service life of the entire cell holder.

The arched projections 3 and the body 2 form a monolithic structure made of material being acrylonitrile-butadiene-styrene and polycarbonate mixture. The arched projections 3 are located on the opposite sides of the body 2 and, moreover, on surface of the body 2. The location of the arched projections 3 on the opposite sides of the body 2 improves distribution of stresses acting on the arched projections 3 and ensures efficient clamping of the cell holder 1 in the battery housing while minimizing the risk of the cell holder 1 locking into the battery housing. In turn, the presence of the arched projections 3 located on surface of the body 2 reduces the risk of denting such projections inside the body 2 and as a consequence damaging of a battery cell or battery cells, especially when the battery housing is within its minimum dimensional tolerance limit and the cell holder 1 is within its maximum dimensional tolerance limit. This is particularly important not only when pressing the cell holder 1 into the battery housing during manufacturing process, but also during normal usage of said cell holder 1 and battery housing. Further, the presence of the arced projections 3 located on surface of the body 2 ensures maintenance of proper contact between the cell holder 1 and the battery housing, and therefore their proper fit and resulting stability, even when the battery housing is within its maximum dimensional tolerance limit and the cell holder is within its minimum dimensional tolerance limit.

Furthermore, the body 2 comprises a plurality of the arched projections 3. The presence of a plurality of arched projections 3 on the body 2 leads to improvement in compensation of dimensional tolerance of the battery housing. The arched projections 3 have through-holes 5 extending along the longitudinal axis of the cell holder 1.

The arched projections 3 are configured to have lower bending stiffness, such that they can be bent when said cell holder 1 is placed inside a battery housing thereby compensating dimensional tolerance of the battery housing. Bending of the arched projections 3 is possible e.g. as a thickness of the arched projections 3 is significantly smaller than a thickness of the body 2. The thickness of the arched projections 3 is half the thickness of the body 2 but in the other embodiments of the invention the thickness of the arched projections 3 might be even smaller. For instance, the thickness of the arched projections 3 is the range from 0.6 to 1.5 mm, and the thickness of the body 2 is the range of 1 to 2 mm, wherein the thickness of the body 2 should be uniform. For example, where the thickness of the arched projections 3 is 0.65 mm, the thickness of the body 2 is 1.5 mm. Furthermore, in some embodiments of the invention the arched projections 3 have a constant thickness along their length. When the mentioned thickness is constant it is, for example, 0.65 mm. The application of the arched projections 3 of the disclosed configuration, which form the monolithic structure with the body 2, provides a cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool arranged to compensate for dimensional tolerance of a battery housing and to allow longer-term positioning of the cell holder 1 in the battery housing comparing to the solution known from the prior art. As a consequence there is no need to place paste, glue or silicon in the battery housing during assembly of the cell holder 1 inside the battery housing, what simplifies the whole manufacturing process of a battery pack.

The arched projections 3 are arranged such that they compensate dimensional tolerance of the battery housing in x and y axes. The disclosed arrangement of the arched projections 3 limits the horizontal and vertical movement of the cell holder 1 within the battery housing. The result of the horizontal movement limitation is an increase of the durability of the cell holder 1 as well as a reduction of shaking degree of cells placed in such holder and as a result improvement of a battery system performance. In turn, vertical movement limitation further increases the durability of the cell holder 1 as well as reduction of shaking degree of cells placed in such holder and as a result improvement of a battery system performance.

The second embodiment of the invention

The second embodiment of a cell holder 1 for a battery housing of an electrical vehicle, in particular in an electrical bike, or a power tool as in the second embodiment, but with the difference that the arched projections 3 have a form of a section of a truncated cone cut along the height of the cone. The application of the arched projections 3 having the form of the section of the truncated cone cut along the height of the cone provides an increased compensation range of dimensional tolerance of the battery housing.

Furthermore, one of the arched projections 3 having the form of the section of the truncated cone cut along the height of the cone is chamfered towards one of its ends. In the other embodiments of the invention each of the arched projections 3 might be chamfered towards one or both of their ends. In still the other embodiments only some of the arched projections 3 might be chamfered towards one or both of their ends. Chamfering of the ends of the arched projections 3 is especially important if the cell holder 1 is to be mounted in a battery housing in which the free spaces between the cell holder 1 and the battery housing, resulting from the dimensional deviation exceeding the tolerance range and subject to compensation, are so small that, when an attempt is made to remove the cell holder 1 from the battery housing, the resulting plastic deformations lead to damage of the arched projections 3. The application of the arched projection 3 chamfered towards one or both of its ends, as it might happen in the other embodiments of the invention, ensures that the cell holder 1 does not permanently lock into the battery housing. It can be inserted and removed from said housing without damaging the arched projections 3 due to plastic deformations acting on these projections. Consequently, it enables maintenance of a battery system contained in the battery housing. Therefore, it is also possible to remove and insert the cell holder 1 during a manufacturing process when an assembler makes a mistake in assembling of those parts. The application of more than one of the arched projections 3 chamfered towards one or both of its ends leads to even easier insertion and removal of the cell holder 1 from the battery housing.

In yet another embodiments of the invention, all of the arched projections 3 may have a form of a cone without said chamfers. It is especially possible if the cell holder 1 is to be mounted in a battery housing in which the free spaces between the cell holder 1 and the battery housing, resulting from the dimensional deviation exceeding the tolerance range and subject to compensation, are large enough that, when an attempt is made to remove the cell holder 1 from the battery housing, the possible plastic deformations do not lead to damage of the arched projections 3. In yet another embodiment of the invention, the arched projections 3 may have a form of a cylinder chamfered towards one or both of its ends. In these embodiments of the invention, the chamfers play the same role in the case of the arched projections 3 in the form of the section of a truncated cone cut along the height of the cone.

The third embodiment of the invention

The third embodiment of a cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool as in the first or the second embodiment, but with the difference that the cell holder 1 comprises elements 4 compensating dimensional tolerance of the battery housing having a form of inclined projections instead of the elements 3 having the form of the arched projections. As with arched projections 3 so also the inclined projections 4 are configured to have lower bending stiffness, such that they can be bent when said cell holder 1 is placed inside a battery housing thereby compensating dimensional tolerance of the battery housing. Bending of the inclined projections 4 is possible e.g. as a thickness of the inclined projections 4 is significantly smaller than a thickness of the body 2. The thickness of the inclined projections 4 is half the thickness of the body 2 and it narrows in the direction from the molding. For instance, the thickness of the inclined projections 4 is the range from 0.6 to 0.9 mm, and the thickness of the body 2 is the range of 1 to 2 mm, wherein the thickness of the body 2 should be uniform. For example, where the thickness of the inclined projections 4 is 0.65 mm, the thickness of the body 2 is 1.5 mm. Furthermore, in some embodiments of the invention the inclined projections 4 have a constant thickness along their length. When the mentioned thickness is constant it is, for example, 0.65 mm. The application of the inclined projections 4 of the disclosed configuration, which form the monolithic structure with the body 2, provides a cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool arranged to compensate for dimensional tolerance of a battery housing and to allow longer-term positioning of the cell holder 1 in the battery housing comparing to the solution known from the prior art.

The inclined projections 4 are angled at 45° in relation to the body 2 surface. Furthermore, in other embodiments the inclined projections 4 may be angled at other angle in the range of 30-90°. The application of the inclined projections 4 angled at 30-90°, in particular 45°, reduces the possibility of damage of such projections due to the resulting stresses and consequently leads to an additional increase in positioning time of the cell holder 1 within the battery housing. Furthermore, the body 2 comprises recesses 7 and the inclined projections 4 are located inside those recesses 7. The application of the recesses 7 limits the possibility of bending the inclined projections 4, and consequently limits the stresses arising in those projections, leading to an increase in their durability, and as a result even longer-term positioning of the cell holder 1 in the battery housing.

The inclined projections 4 are arranged such that they compensate dimensional tolerance of the battery housing in x and y axes. The disclosed arrangement of the inclined projections 4 limits the horizontal and vertical movement of the cell holder 1 within the battery housing. The result of the horizontal movement limitation is an increase of the durability of the cell holder 1 as well as a reduction of shaking degree of cells placed in such holder and as a result improvement of a battery system performance. In turn, vertical movement limitation further increases the durability of the cell holder 1 as well as reduction of shaking degree of cells placed in such holder and as a result improvement of a battery system performance.

The fourth embodiment of the invention

The fourth embodiment of a cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or in a power tool as in the third embodiment, but with the difference that the upper surface 5 of the inclined projections 4 is chamfered towards one of its ends. Chamfering of the inclined projections 4 is especially important if the cell holder 1 is to be mounted in a battery housing in which the free spaces between the cell holder 1 and the battery housing, resulting from the dimensional deviation exceeding the tolerance range and subject to compensation, are so small that, when an attempt is made to remove the cell holder 1 from the battery housing, the resulting plastic deformations lead to damage of the inclined projections 4. The application of the inclined projections 4 with the chamfered upper surface towards one, or both of its ends as it might happen in the other embodiments of the invention, ensures that the cell holder 1 does not permanently lock into the battery housing. It can be inserted and removed from said housing without damaging the inclined projections 4 due to plastic deformations acting on these projections. Consequently, it enables maintenance of a battery system contained in the battery housing. Therefore, it is also possible to remove and insert the cell holder 1 during a manufacturing process when an assembler makes a mistake in assembling of those parts.

The fifth embodiment of the invention

The fifth embodiment of a cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool as in the first or third embodiment, but with the difference that the cell holder 1 comprises both kinds of elements compensating dimensional tolerance of a battery housing i.e. the arched projections 3 and inclined projections 4, wherein the arched projection 3 is placed on the top of the body 2. The application of arched projections 3 and inclined projections 4 allows the use of the body of the cell holder 1 of different shapes and sizes, so a result the cell holder 1 can be used in battery housings of different shapes and sizes.

As is was mentioned the thickness of the inclined projections 4 is, for example, in the range from 0.6 to 1.5 mm and the thickness of the arched projections 3 is, for example, the range from 0.6 to 0.9 mm. In some embodiments of the invention only the thickness of the inclined projections 4 varies along their length in the given range. In the other embodiments of the invention only the thickness of the arched projections 3 varies along their length in the given range. In still other embodiments of the invention both the inclined projections 4 and the arched projections 3 varies thickness along their length in the given ranges, and in further embodiments of the invention both the inclined projections 4 and the arched projections 3 have a constant thickness along their length. When the mentioned thickness is constant, for both the inclined projections 4 and for the arched projections 3 it is 0.65 mm. The sixth embodiment of the invention

The fifth embodiment of a cell holder 1 for a battery housing of an electrical vehicle, in particular an electrical bike, or a power tool as in the fifth embodiment, but with the difference that the arched projections 3 are placed not only on the top but also on the bottom of the body 2.