阅读说明：本技术 电池模块组装方法及电池模块组装装置 (Battery module assembling method and battery module assembling device ) 是由 海纳·费斯 安德里亚斯·特拉克 拉尔夫·迈施 亚历山大·艾希霍恩 约尔格·达马斯克 瓦伦汀 于 2020-02-25 设计创作，主要内容包括：根据一个方面,电池模块通过将第一和第二夹具塔(例如,整体式或模块化/可堆叠夹具塔)安装在表面上来组装。电池单元布置在夹具塔之间并且部分地基于布置在相应夹具塔中的电池单元固定元件而被固定就位。至少一个基于磁性的补充固定元件用于施加磁力(例如磁引力和/或磁斥力)以将电池单元朝向第一夹具塔并远离第二夹具塔(例如,以使得各排中的电池单元彼此齐平)。(According to one aspect, a battery module is assembled by mounting first and second clamp towers (e.g., monolithic or modular/stackable clamp towers) on a surface. The battery cells are disposed between the clamp towers and are secured in place based in part on battery cell securing elements disposed in the respective clamp towers. At least one magnetic-based supplemental securing element is used to apply a magnetic force (e.g., magnetic attraction and/or repulsion) to direct the battery cells toward the first clamp tower and away from the second clamp tower (e.g., such that the battery cells in each row are flush with each other).)

1. A method of assembling a battery module, comprising:

mounting a first fixture tower on a surface;

mounting a second fixture tower on the surface;

arranging a set of battery cells arranged between a first portion of the first clamp tower and a second portion of the second clamp tower, the first portion of the first clamp tower including a first set of battery cell securing elements, the second portion of the second clamp tower opposing the first portion of the first clamp tower and arranged with a second set of battery cell securing elements, each battery cell of the set of battery cells being at least partially secured in place by the first set of securing elements and the second set of securing elements; and

applying a magnetic force to each battery cell in the set of battery cells in a direction toward the first clamp tower and away from the second clamp tower.

2. The method of claim 1, wherein the first set of fixation elements and the second set of fixation elements comprise pins.

3. The method of claim 1,

the first clamp tower includes a first set of stackable clamps, an

The second clamp tower includes a second set of stackable clamps.

4. The method of claim 1,

the first clamp tower comprises a first side plate, a plurality of groups of battery unit fixing elements are arranged at different heights of the first side plate to fix a plurality of rows of battery units at different heights of the first side plate, and

the second jig tower includes a second side plate, and a plurality of sets of battery cell fixing members are provided at different heights of the second side plate to fix the battery cells in different rows.

5. The method of claim 1,

one of the first and second clamp towers comprises a set of stackable clamps, and

the other of the first and second jig towers includes a side plate at which a plurality of sets of battery cell fixing elements are disposed at different heights to fix different rows of battery cells.

6. The method of claim 1, wherein the magnetic force is an attractive force that pulls each cell of the set of cells toward the first fixture tower.

7. The method of claim 1, wherein the magnetic force is a repulsive force that pushes each battery cell of the set of battery cells away from the second clamp tower.

8. The method of claim 1, further comprising:

while applying the magnetic force, the set of battery cells is permanently fixed in place using glue.

9. The method of claim 8, further comprising:

and stopping applying the magnetic force after the glue is cured.

10. The method of claim 9,

the applying comprises switching on at least one electromagnet, an

The stopping includes turning off the at least one electromagnet.

11. The method of claim 1, wherein the applying comprises turning on at least one electromagnet.

12. The method of claim 1, wherein the applying applies the magnetic force via at least one permanent magnet.

13. A battery module assembling apparatus, comprising:

a first clamp tower mounted on a surface;

a second jig tower mounted on the surface;

a set of battery cells disposed between a first portion of the first clamp tower and a second portion of the second clamp tower, the first portion of the first clamp tower including a first set of battery cell securing elements, the second portion of the second clamp tower opposing the first portion of the first clamp tower and disposed with a second set of battery cell securing elements, each battery cell of the set of battery cells being at least partially secured in place by the first set of securing elements and the second set of securing elements; and

at least one magnetic-based supplemental fixation element for applying a magnetic force to each battery cell of the set of battery cells in a direction toward the first clamp tower and away from the second clamp tower.

14. The battery module assembly device of claim 13, wherein the first set of securing elements and the second set of securing elements comprise pins.

15. The battery module assembly device according to claim 13,

the first clamp tower includes a first set of stackable clamps, an

The second clamp tower includes a second set of stackable clamps.

16. The battery module assembly device according to claim 13,

the first clamp tower includes a first side plate, a plurality of sets of cell fixing elements are disposed at different heights of the first side plate to fix different rows of cells, and

the second jig tower includes a second side plate, and a plurality of sets of battery cell fixing members are provided at different heights of the second side plate to fix the battery cells in different rows.

17. The battery module assembly device according to claim 13,

one of the first and second clamp towers comprises a set of stackable clamps, and

the other of the first and second jig towers includes a side plate at which a plurality of sets of battery cell fixing elements are disposed at different heights to fix different rows of battery cells.

18. The battery module assembly device of claim 13, wherein the magnetic force is an attractive force that pulls each battery cell of the set of battery cells toward the first clamp tower.

19. The battery module assembly device of claim 13, wherein the magnetic force is a repulsive force that pushes each battery cell of the set of battery cells away from the second clamp tower.

20. The battery module assembly device according to claim 13, further comprising:

a glue in an uncured, partially cured or fully cured state for permanently fixing the set of battery cells in place when fully cured.

21. The battery module assembly device of claim 13, wherein the at least one magnetic-based supplemental fixation element comprises at least one energized electromagnet.

22. The battery module assembly device of claim 13, wherein the at least one magnetic-based supplemental fixation element comprises at least one permanent magnet.

Technical Field

Embodiments relate to a battery module assembling method and a battery module assembling apparatus.

Background

Energy storage systems may rely on batteries to store power. For example, in certain conventional Electric Vehicle (EV) designs (e.g., all-electric vehicles, hybrid electric vehicles, etc.), a battery housing installed in the electric vehicle houses a plurality of battery cells (e.g., the plurality of battery cells may be individually mounted in the battery housing or alternatively mounted in groups within respective battery modules, each battery module including a group of battery cells, with the respective battery modules being mounted in the battery housing). The battery modules in the battery housing are electrically connected (in series or parallel) to a Battery Junction Box (BJB) via bus bars to distribute electrical energy to the electric motor that drives the electric vehicle, as well as various other electrical components of the electric vehicle (e.g., radios, consoles, vehicle heating, ventilation and air conditioning (HVAC) systems, interior lights, exterior lights such as headlights and brake lights, etc.).

Disclosure of Invention

An embodiment relates to a battery module assembly method comprising mounting a first clamp tower on a surface, mounting a second clamp tower on the surface, arranging a set of battery cells arranged between a first portion of the first clamp tower and a second portion of the second clamp tower, the first portion of the first clamp tower including a first set of battery cell securing elements, the second portion of the second clamp tower opposite the first portion of the first clamp tower and arranged with a second set of battery cell securing elements, each set of battery cells being secured in place at least in part by the first set of securing elements and the second set of securing elements, and applying a magnetic force to each of the set of battery cells in a direction toward the first clamp tower and away from the second clamp tower.

Another embodiment relates to a battery module assembly apparatus including a first jig tower mounted on a surface, a second jig tower mounted on the surface, a set of battery cells disposed between a first portion of the first jig tower and a second portion of the second jig tower, and a magnetic-based supplemental fixation unit; the first portion of the first clamp tower includes a first set of battery cell securing elements, the second portion of the second clamp tower is opposite the first stackable clamp and has a second set of battery cell securing elements disposed thereon, the set of battery cells is secured in place at least in part by the first set of securing elements and the second set of securing elements, the magnetic-based supplemental securing element is configured to apply a magnetic force to each battery cell of the set of battery cells in a direction toward the first clamp tower and away from the second clamp tower.

Drawings

Embodiments of the present disclosure will become more readily apparent and a full understanding thereof may be obtained by referring to the following detailed description in conjunction with the following drawings. The drawings are for illustration purposes only and are not intended to limit the present disclosure. In the drawings:

fig. 1 illustrates an example of a metal-ion (e.g., lithium-ion) battery in which components, materials, methods, other techniques, or combinations thereof described herein may be applied according to various embodiments.

Fig. 2 is a high-level electrical schematic diagram of an exemplary battery module in which P-cell groups (parallel-cell groups) 1 … … N are connected in series according to an embodiment of the present invention.

Fig. 3A shows the battery module after the battery cells are inserted during the assembly process.

Fig. 3B-3D illustrate the general arrangement of the contact plates relative to the battery cells of the battery module.

Fig. 4 to 16B illustrate an assembly process of the battery module according to the embodiment of the present invention.

Figure 17 shows two variations of the pin arrangement in the assembly device.

Fig. 18 illustrates a battery module assembling step according to an embodiment of the present invention.

Fig. 19A-19F each depict a battery module assembly device having a jig tower including respective stackable jig sets based on successive stages of assembly in an exemplary implementation of the process of fig. 18, in accordance with an embodiment of the present invention.

Fig. 20 illustrates a battery module assembling apparatus according to an exemplary embodiment based on the process of fig. 18, according to another embodiment of the present invention.

Detailed Description

Embodiments of the present disclosure will be presented below and in the associated drawings. Alternative embodiments are also contemplated without departing from the scope of the present disclosure. Additionally, well-known elements will not be described in detail or will be omitted so as not to obscure the description of significant details of the present invention.

Energy storage systems may rely on batteries to store power. For example, in certain conventional Electric Vehicle (EV) designs (e.g., all-electric vehicles, hybrid electric vehicles, etc.), a battery housing installed in the electric vehicle houses a plurality of battery cells (e.g., the plurality of battery cells may be individually mounted in the battery housing or alternatively mounted in groups within respective battery modules, each battery module including a group of battery cells, with the respective battery modules being mounted in the battery housing). The battery modules in the battery housing are connected to a Battery Junction Box (BJB) via bus bars to distribute electrical energy to motors that drive the electric vehicle, as well as various other electrical components of the electric vehicle (e.g., radios, consoles, vehicle heating, ventilation and air conditioning (HVAC) systems, interior lights, exterior lights such as headlights and brake lights, etc.).

Fig. 1 illustrates an example of a metal-ion (e.g., lithium-ion) battery in which components, materials, methods, other techniques, or combinations thereof described herein may be applied according to various embodiments. Here, a cylindrical battery cell is shown for illustrative purposes, but other types of batteries including prismatic batteries or pouch cells (sheet type) may also be used as needed. The exemplary battery 100 includes a negative electrode (anode) 102, a positive electrode (cathode) 103, a separator 104 disposed between the anode 102 and the cathode 103, an electrolyte (shown implicitly) impregnating the separator 104, a battery housing 105, and a sealing member 106 sealing the battery housing 105.

Embodiments of the invention relate to various configurations of battery modules that may be deployed as part of an energy storage system. In an example, although not explicitly shown in the figures, a plurality of battery modules according to any of the embodiments described herein can be deployed for an energy storage system (e.g., by providing a higher voltage to the energy storage system in series with one another, or by providing a higher current to the energy storage system in parallel with one another, or a combination thereof).

Fig. 2 is a high-level electrical schematic diagram of a battery module 200 in which P-cell groups (parallel-cell groups) 1 … … N are connected in series according to an embodiment of the present invention. In one example, N may be an integer greater than or equal to 2 (e.g., if N is 2, the middle P battery pack labeled 2 … … N-1 in fig. 1 may be omitted). Each P battery pack includes battery cells 1 … … M connected in parallel (e.g., each battery cell is configured as shown by battery cell 100 of fig. 1). The negative terminal of the first series P-cell stack (or P-cell stack 1) is connected to the negative terminal 205 of the battery module 200, while the positive terminal of the last series P-cell stack (or P-cell stack N) is connected to the positive terminal 210 of the battery module 200. Herein, the battery module may be characterized by the number of P battery packs connected in series therein. Specifically, a battery module having 2P battery packs connected in series is referred to as a "2S" system; a battery module with 3P battery packs connected together in series is called a "3S" system; and so on.

Fig. 3A shows battery module 300A with battery cells 305A inserted during assembly. In some designs, the positive terminal (cathode) and the negative terminal (anode) of the battery cells within the battery module 300A may be disposed on the same side (e.g., top side). For example, the central cell "head" may correspond to the positive terminal, while the cell edge surrounding the cell head may correspond to the negative terminal. In such a battery module, the P battery packs are electrically connected in series with each other via a plurality of contact plates provided above the battery cells 305.

Fig. 3B-3D illustrate a general arrangement of contact plates relative to battery cells of a battery module. As shown in fig. 3B-3D, in some designs, contact plates may be disposed on top of the battery cells in close proximity to the positive and negative terminals of the respective battery cells.

Fig. 4 to 16B illustrate an assembly process of the battery module according to the embodiment of the present invention.

Referring to fig. 4, a battery module is initially constructed on a substrate on which clamps (positive-side clamp and negative-side clamp) are mounted (e.g., via screws). The clips are stackable and will be described in more detail below. The outer frame member of the battery module is disposed between the clamps. As used herein, the "negative side" of a battery cell refers to the side of the battery cell opposite the positive terminal of the battery cell. For some embodiments, cells having positive and negative terminals disposed on the same side may be used (e.g., a positive cell head surrounded by a negative cell edge), in which case the "negative side" does not necessarily have to correspond to the negative terminal of the respective cell.

Referring to fig. 5, the insulation layer is adhered to the outer frame member by a dispenser.

Referring to fig. 6A, a battery cell layer 1 is placed on an insulating layer. In the embodiment shown in fig. 6A, the battery cell layer 1 includes 12 cylindrical battery cells, each of which is part of the same P-cell stack. Fig. 6B-6C show how the position of each cell in cell layer 1 is fixed using pins arranged on the respective clamps. In an example, a magnet may be integrated into each negative side fixture to pull the individual cells of each battery cell layer such that the negative side of each battery cell layer is flush.

Referring to fig. 7A, spacers are added on top of the cell layer 1. The spacers are arranged to define the spacing between the battery cell layers 1 and 2. In an example, the spacer may comprise one or several pieces (e.g., made of plastic).

Referring to fig. 8A, the jigs for the battery cell layer 2 (negative-side jig and positive-side jig) are stacked on the jig for the battery cell layer 1. As shown more clearly in fig. 8B, the notches in the spacer between cell layers 1 and 2 are aligned with the pins on the fixture of cell layer 2.

Referring to fig. 9A, an insulating layer is placed on the spacer between the cell layers 1 and 2. Although not explicitly shown in fig. 9A, glue may be applied to the insulating layer.

Referring to fig. 9B, the battery cell layer 2 is placed on the insulating layer and fixed by glue. In the embodiment of fig. 9B, the battery cell layer 2 includes 12 cylindrical battery cells, each of which is part of the same P-cell stack. The P-cell stack of cell layer 2 may be the same as or different from the P-cell stack of cell layer 3, depending on the configuration of the contact plate used in the battery module (described in more detail below).

In this regard, the process described in fig. 7A-9B may be repeated a given number of times until a desired number of battery cell layers are constructed to form the apparatus depicted in fig. 10, which includes battery cell layers 1-8. As shown in fig. 10, glue is applied to the uppermost insulation layer, and then another outer frame member is attached to the uppermost insulation layer as shown in fig. 11. Referring to fig. 12A-12B, after the top clip is added, the opposing sidewalls are attached by glue. Then, the battery modules are separated from the respective jigs and the substrate, as shown in fig. 13.

Referring to fig. 14A-14B, the base plate is fixed to the battery module via glue.

Referring to fig. 15A, a conductive plate (or a contact plate) is disposed over the battery cells of the battery module (e.g., fixed with glue). Fig. 15B depicts an alternative contact sheet comprising two layers of foil. Examples of contact plates are described with reference to at least fig. 7A-8B of U.S. patent publication No. US 2018/0108886a1 entitled "multilayer contact plate for establishing electrical bonds with battery cells in a battery module," which is hereby incorporated by reference in its entirety. Referring to fig. 15C, the contact plate of fig. 15A may further include a contact pad (e.g., a thermistor) to which the sensor wire may be connected.

Referring to fig. 16A-16B, a cover plate is added to the battery module (e.g., via glue). By now, battery modules have been completed that may be deployed as part of an energy storage system (e.g., for electric vehicles). The external components of the battery module (e.g., the external frame members, the side walls, the bottom plate, and the cover plate) collectively include a battery case for accommodating the battery cells.

Fig. 17 shows two variations of the pin arrangement in the assembly device (i.e., in the negative-side jig and the positive-side jig). In variation a, the pins are fixed on different fixtures and are added as each new fixture is added as shown in fig. 4-16B. In variation B, the pins are placed into either a withdrawn position (not inserted) or an inserted position using a jig tower comprising multiple stacked jigs and/or a single large structure (one large jig comprising multiple layers of cells). In the modification B (1), each pin of the jig tower is extracted. In modification B (2), the pins of the battery cell layer 1 are inserted. In variation B (3), the pins of cell layers 1-2 are inserted. It will be appreciated that the fixture tower may span any number of layers of battery cells, and that multiple fixture towers and/or individual fixtures may also be stacked together.

In some designs, a battery module may be integrated with a cooling plate at one end of a group of cylindrical battery cells (e.g., below the battery cells). In such embodiments, cooling efficiency is improved if the set of cylindrical battery cells are substantially flush with the cooling plate (e.g., although thermal paste may also be used to bridge the gap therebetween). In some designs, electrical terminal connections may be made on one end (or in some designs, both ends) of a group of cylindrical battery cells. In such a design, precise fixation of the battery cell may simplify the process of welding the battery cell terminals to the one or more contact plates.

Conventional methods of achieving the above-described cell fixation uniformity typically rely on mechanical fixation devices (or clamping devices) that secure the cell in place (in addition to fixation pins) while applying glue thereto. Once the glue is cured, the mechanical fixing means are removed. However, the application and subsequent removal of such mechanical securing devices increases the time and complexity of the battery module assembly process. Accordingly, embodiments of the present disclosure relate to a battery module assembling apparatus and a method thereof, whereby the above-described cell position uniformity is achieved using magnetic force without the need to use such mechanical fixing means.

Fig. 18 illustrates a battery module assembly step 1800 according to an embodiment of the present invention. In a step of block 1805, a first jig tower is mounted on a surface (e.g., a base plate). In the step of block 1810, a second jig tower is mounted on a surface (e.g., a floor). Exemplary implementations of the steps of block 1805 and 1810 are shown in fig. 4, 8A and 10.

In an example embodiment, the first clamp tower may be comprised of a first set of stackable clamps, each stackable clamp of the first set of stackable clamps including a first set of battery cell securing elements (e.g., pins, tabs, indentations, pins, etc.). In this case, the first set of stackable fixtures may include any number of stackable fixtures, and the steps of block 1805 may be performed each time a new stackable fixture is added to the first fixture tower. In another example embodiment, the second jig tower may similarly include a second set of stackable jigs, each stackable jig of the second set of stackable jigs including a second set of battery cell securing elements (e.g., pins, tabs, indentations, pins, etc.). In this case, the second set of stackable fixtures may include any number of stackable fixtures, and the steps of block 1810 may be performed each time a new stackable fixture is added to the second fixture tower. 19A-19F depict an example in which each of the first and second clamp towers includes a respective stackable clamp group.

In another example embodiment, the first clamp tower may include a single or "unitary" side panel arranged with multiple sets of cell securing elements (e.g., tabs, indentations, pins, etc.) at different heights of the side panel for securing different rows of cells. In this case, at the beginning of the battery assembling process, the fixing member of the side plate starts to be in the non-inserted state. Then, with the addition of a new layer of battery cells each time, the fixing member for fixing the layer of battery cells is pushed into the inserted state to facilitate the fixing of the battery cells. After all layers of battery cells are added and the fixation of permanent battery cells is achieved (e.g. after the applied glue has sufficiently cured, starting in an uncured state, or reached a partially cured state with sufficient stability, or a fully cured state), all fixation elements may be turned back to a non-inserted state to allow removal of the battery cells, when the battery cells are integrated into a battery module as described above. In another example embodiment, the second clamp tower also includes a single or "integral" side plate arranged with multiple sets of battery cell securing elements of different heights for securing different rows of battery cells. Fig. 20 depicts an example in which each of the first and second clamp towers includes a respective side plate.

In yet another example embodiment, one (or more) of the first and second clamp towers may include a set of stackable clamps, while the other of the first and second clamp towers includes a side plate arranged with sets of battery cell securing elements located at different heights of the side plate to secure different rows of battery cells. This particular embodiment is not explicitly shown in the figures, but can be readily determined from a review of FIGS. 19A-20. For example, the stackable clamps 1905A, 1905C, etc. of FIGS. 19A-19F may be used in conjunction with the side panel 2005 of FIG. 20, or the stackable clamps 1910A, 1910C, etc. of FIGS. 19A-19F may be used in conjunction with the side panel 2000 of FIG. 20.

In the step of block 1815, a set of battery cells is disposed between a first portion of a first clamp tower including a first set of battery cell securing elements and a second portion of a second clamp tower opposite the first portion of the first clamp tower and provided with a second set of battery cell securing elements, each battery cell in the set of battery cells being at least partially secured in place by the first set of securing elements and the second set of securing elements. For example, if the first and second jig towers are configured as stackable jig sets, the first and second portions of the first and second jig towers may correspond to respective topmost jigs of the current stage of battery module assembly. Examples of the steps of block 1815 are shown in fig. 6A and 9B.

In the step of block 1820, a magnetic force is applied to each battery cell in the stack of battery cells in a direction toward the first fixture tower and away from the second fixture tower. The magnetic force applied in the step of block 1820 may be implemented as an attractive force that pulls each battery cell in the cell stack toward the first clamp tower, a repulsive force that pushes each battery cell in the cell stack away from the second clamp tower, or a combination thereof.

In some designs, the magnetic force is applied by using a supplemental magnetic-based fixation element. In some designs, the magnetic-based supplemental fixation element may include one or more permanent magnets that may be integrated into the first and/or second clamp towers or may simply be placed proximate to the first and/or second clamp towers proximate to the battery pack. In other designs, the magnetic-based supplemental fixation element may include one or more electromagnets. One advantage of using electromagnets is that they can be in either an on state (generating a magnetic force) or an off state (eliminating a magnetic force).

In the step of block 1825, optionally, glue is applied while the magnetic force is applied (e.g., in an uncured state, after which the glue cures over time to a partially cured state and eventually to a fully cured state) to permanently secure the battery pack in place. In the step of block 1830, after the glue has sufficiently cured (e.g., to a partially cured state with sufficient stability, or a fully cured state), the application of the magnetic force is optionally stopped. In examples where the magnetic-based supplemental fixation element includes one or more permanent magnets, the cessation of the magnetic force in the step of block 1830 may correspond to a machine or human operator moving the one or more permanent magnets away from the set of battery cells. In examples where the magnetic-based supplemental fixation element includes one or more electromagnets, the cessation of the magnetic force in the step of block 1830 may correspond to the turning off of the one or more electromagnets by a machine or human operator.

An example implementation of the process of fig. 1. An exemplary execution of the steps in fig. 18 will now be described in connection with fig. 19A-19F, each depicting a battery module assembly device having a clamp tower that includes respective stackable clamp sets at successive stages of assembly.

Referring to fig. 19A, the battery module assembly device includes a base plate 1900A on which a first stackable fixture 1905A and a second stackable fixture 1910A are mounted. The first stackable clamp 1905A is arranged with the securing element 1915A in an inserted state, and the first stackable clamp 1910A is arranged with the securing element 1920A in an inserted state. Although not visible in the side view of FIG. 19A, the first and second stackable clamps 1905A-1910A may include other similarly configured securing elements as shown in the various figures above (e.g., FIG. 6B, etc.)

Referring to FIG. 19A, a magnetic attraction is generated at the first stackable fixture 1905A (e.g., by a permanent magnet, an electromagnet, etc.). As noted above, in other designs, magnetic repulsion (or a combination of magnetic attraction at one clamp and magnetic repulsion at another clamp) may be implemented.

Referring to fig. 19B, a battery cell 1925B is added to the battery module assembly device. The magnetic attraction at the first stackable fixture 1905A pulls the battery cell 1925B to remain in flush contact with the first stackable fixture 1905A. Although not explicitly shown in fig. 19B, battery cell 1925B is part of a row of battery cells that includes one or more additional battery cells. In this example, a magnetic attraction is applied to each battery cell in a row of battery cells such that each respective battery cell in the row of battery cells is held in flush contact with a first stackable fixture 1905A, the first stackable fixture 1905A for aligning each battery cell in the row of battery cells.

Referring to FIG. 19C, a third stackable fixture 1905C is mounted on top of the first stackable fixture 1905A and a fourth stackable fixture 1910C is mounted on top of the second stackable fixture 1910A. The third stackable clamp 1905C is arranged with a securing element 1915C in an inserted state, and the fourth stackable clamp 1910C is arranged with a securing element 1920C in an inserted state. Although not visible in the side view of FIG. 19C, the third and fourth stackable clamps 1905C-1910C may include other similarly configured securing elements as shown in the various figures above (e.g., FIG. 6B, etc.).

Referring to fig. 19D, a battery cell 1925D is added to the battery module assembly device. The magnetic attraction at the third stackable fixture 1905C pulls the battery cell 1925D to remain in flush contact with the third stackable fixture 1905C. Although not explicitly shown in fig. 19D, battery cell 1925D is part of a row of battery cells that includes one or more additional battery cells. In this example, a magnetic attraction is applied to each battery cell in the row of battery cells such that each respective battery cell in the row of battery cells is held in flush contact with a third stackable fixture 1905C, the third stackable fixture 1905C for aligning each battery cell in the row of battery cells.

Referring to FIG. 19E, a fifth stackable fixture 1905E is mounted on top of a third stackable fixture 1905C and a sixth stackable fixture 1910E is mounted on top of a fourth stackable fixture 1910C. The fifth stackable clamp 1905E is arranged with the securing element 1915E in an inserted state, and the sixth stackable clamp 1910E is arranged with the securing element 1920E in an inserted state. Although not visible in the side view of FIG. 19E, the fifth and sixth stackable clamps 1905E-1910E may include other similarly configured securing elements as shown in the various figures above (e.g., FIG. 6B, etc.)

Referring to fig. 19F, a battery cell 1925F is added to the battery module assembly device. The magnetic attraction at the fifth stackable fixture 1905E pulls the battery cell 1925F to maintain flush contact with the third stackable fixture 1905E. Although not explicitly shown in fig. 19F, battery cell 1925F is part of a row of battery cells that includes one or more additional battery cells. In this example, a magnetic attraction is applied to each battery cell in the row of battery cells such that each respective battery cell in the row of battery cells is held in flush contact with a fifth stackable fixture 1905E, the fifth stackable fixture 1905E for aligning each battery cell in the row of battery cells.

The assembly process described in fig. 19A-19F may continue because the jig towers grow layer by layer as more jigs (and battery cells) are added.

Fig. 20 illustrates a battery module assembly apparatus according to another embodiment of the present invention based on an exemplary implementation of the process 1800 of fig. 18. Unlike fig. 19A-19F, which use corresponding stackable (or modular) clamp sets to construct a clamp tower, the battery module assembly device of fig. 20 includes two "monolithic" side plates 2000 and 2005. As shown in fig. 20, a magnetic attraction force is generated (e.g., by a permanent magnet, an electromagnet, etc.) at each unit layer (or row) of the side plate 2000. Although not specifically shown in fig. 20, side panels 2000 and 2005 may be mounted on a surface (e.g., substrate 1900A of fig. 19A).

In the embodiment of fig. 20, the securing elements 2015 and 2020 are disposed within corresponding holes (or openings) of the side plates 2000 and 2005, respectively, so as to be movable (e.g., configured in an inserted state to secure the battery cell, or a non-inserted state to allow the battery cell to be movable). At the beginning of the battery assembly process, the fixing elements 2015 and 2020 are in an uninserted state. Then, as each new battery cell layer is added, a fixing member for fixing the battery cell layer is pushed into an inserted state to facilitate fixing of the battery cell. After all cell layers are added and permanent cell fixation is achieved (e.g., after the applied glue has sufficiently cured, or to a partially cured state with sufficient stability, or to a fully cured state), all fixation elements may be turned back to a non-inserted state to allow removal of the cells, at which point the cells are integrated into a battery module as described above. As shown in fig. 19A-19F, each battery cell of each layer (or row) of battery cells may be flush with respect to the side plates 2000 such that each battery cell of each layer (or row) of battery cells is aligned with each other.

Any numerical range recited herein with respect to any embodiment of the invention is not only intended to define the upper and lower limits of the relevant numerical range, but also to implicitly disclose the unit or increment of each discrete value within the range, consistent with the level of accuracy in characterizing the upper and lower limits. For example, a numerical distance range from 7nm to 20nm (i.e., precision level in units of 1 or increments) encompasses the set [7, 8, 9, 10.., 19, 20] (in nm) as if the intermediate numbers 8 to 19 in units or increments of 1 were explicitly disclosed. In another example, the range of percentage values from 30.92% to 47.44% (i.e., a level of precision in hundredths or a step size that is graded) encompasses the set [30.92, 30.93, 30.94, … …, 47.43, 47.44] in% as if the median values 30.92-47.44 in percentage units or increments were explicitly disclosed. Thus, any intermediate value encompassed by any range of values disclosed is intended to be understood as meaning that the value is equivalent to what has been explicitly disclosed, and any such intermediate value can therefore itself constitute the upper and/or lower limit of the subrange that it falls within that range of values. Thus, each subrange (e.g., each smaller range having at least one intermediate numerical value of the larger range as an upper and/or lower limit) is intended to be understood as being implicitly disclosed by virtue of the explicit disclosure of the larger range.

While the embodiments described above relate primarily to electric vehicles on the ground (e.g., automobiles, trucks, etc.), it should be understood that other embodiments may implement various battery-related embodiments for any type of electric vehicle (e.g., boats, submarines, airplanes, helicopters, unmanned planes, space vehicles, rockets, etc.).

The previous description is intended to enable any person skilled in the art to make or use embodiments of the present invention. It should be understood, however, that various modifications to these embodiments will be readily apparent to those skilled in the art, and that the invention is not limited to the specific formulations, process steps, and materials disclosed herein. That is, the general principles presented herein may be applied to other embodiments without departing from the spirit or scope of the embodiments of the present disclosure.