C.R.F. Società Consortile per Azioni Patente

An electric battery pack (1) comprises a container (2) and a frame (3) inside the container (2), defining a plurality of compartments (4) that receive a plurality of stacks (50) of battery cells (5). Each compartment (4) is defined by two end walls (40, 40') and by two side walls (41). In each compartment (4) at least one of said end walls (40') of the compartment is supported by the inner frame (3) in such a way as to be movable in a direction orthogonal to said end wall (40'). An actuator device (9) is associated with the movable wall (40') of each compartment, configured to move the movable wall (40') from a retracted position, further away from the opposite end wall (40) of the same compartment (4), towards an advanced position, in which it applies a pressure on the cell stack (50) in the respective compartment (4).

A device for joining and welding tab terminals (3) of electric battery cells (1), comprises a single tool (6) configured to perform an operating stroke in a direction (Y) orthogonal to the longitudinal direction (X) of the cells and parallel to the planes of the tab terminals (3), so as to progressively engage a pair of tab terminals (3) starting from a position on one side of the tab terminals (3). The tool (6) comprises a first tool section (7), which progressively engages the two tab terminals (3) from one side, forcing them to bend and join each other, a second tool section (8), which enables the engagement of a clamp element (10) over the joined portions (30) of the two tab terminals (3), and a third tool section (9), for the execution of a weld of the joined portions (30) of the two tab terminals (3) and of the clamp element (10) over the two tab terminals (3).

An electric battery unit (1) comprises a container (2) and a plurality of battery cells within the container (4) spaced apart from each other by one or more spacer frames (11) such as to define spaces (7) between the cells (2). The battery cells (2) come into direct contact with a flow of a temperature-regulating liquid that passes through the container (4) from an inlet collector chamber (5) below, or above, the battery cells (2), through the spaces (7) between the battery cells (2), up to an outlet collector chamber (6) above, or respectively below, the battery cells (2). The inlet collector chamber (5) communicates with the spaces (7) between the battery cells via a plurality of relatively restricted passages (9), configured to offer the flow of the temperature-regulating liquid a sufficient resistance to prevent the temperature-regulating liquid from tending to flow to a greater extent in the spaces that are closer to an inlet and/or an outlet for the temperature-regulating liquid. The spacer frames (11) define a plurality of parallel paths (13) in each of the spaces (7) between the cells (2) configured so as to further uniform the temperature of each cell along the vertical direction.

Control software storable and executable by an electronic processing unit (20) of an electric vehicle (10), said electric vehicle (10) including a battery pack (8) and an electric propulsion system (2) comprising a converter (4), an electric motor (3) coupled to the converter (4) and a propulsion control unit (15) configured to control the converter (4) and the electric motor (3) through a FOC, "Field-Oriented Control", control technique as a function of torque values and of motor revolution numbers. The control software is configured in such a way that, when the software is executed by the electronic processing unit (20), the electronic processing unit (20) becomes configured to: drive (50) the propulsion control unit (15) on the basis of a first torque (τ1) and of a real motor revolution number (VREAL), in such a way that the electric motor (3) provides a torque equal to the first torque (τ1) and turns at a revolution number equal to said real motor revolution number (VREAL), in such a way that the electric propulsion system (2) has a first efficiency (η1); acquire (21, 22) an initial temperature (Ti) of the battery pack (8) and a set temperature (TSET) to be reached by the battery pack (8), the set temperature (TSET) being greater than the initial temperature (Ti); determine (25) a motor revolution number correction (Δv) as a function of the difference between the set temperature (TSET) and the initial temperature (Ti); determine (24) a virtual motor revolution number (VVRT) which is a function of the sum of the real motor revolution number (VREAL) and the motor revolution number correction (Δv); and drive (50) the propulsion control unit (15) on the basis of the first torque (τ1) and of the virtual motor revolution number (VVRT), in such a way that the electric motor (3) provides a second torque (τ2), substantially equal to the first torque (τ1), and turns at a revolution number still equal, substantially, to the real motor revolution number (VREAL), in such a way that the electric propulsion system (2) has a second efficiency (η2), which is less than the first efficiency (η1), thereby causing an increment of power losses of the electric propulsion system (2) and the consequent heating of the battery pack (8).

Control software storable and executable by an electronic processing unit (20) of an electric vehicle (10), said electric vehicle (10) including a battery pack (8) and an electric propulsion system (2) comprising a converter (4), an electric motor (3) coupled to the converter (4) and a propulsion control unit (15) configured to control the converter (4) and the electric motor (3) through a FOC control technique as a function of torque values and of motor revolution numbers. When the software is executed, the electronic processing unit (20) becomes configured to: drive (50) the propulsion control unit (15) on the basis of a first torque (τ1) and of a real motor revolution number (VREAL), in such a way that the electric motor (3) provides a torque equal to the first torque (τ1) and turns at a revolution number equal to said real motor revolution number (VREAL), in such a way that the electric propulsion system (2) has a first efficiency (η1) which corresponds to a first power loss of the electric propulsion system (2); acquire thermal status signals (TH) indicative of an initial temperature (Ti) of the battery pack (8) and of a set temperature (TSET) to be reached by the battery pack (8), the set temperature (TSET) being greater than the initial temperature (Ti); determine (30), on the basis of the thermal status signals (TH), an additional power loss of the electric propulsion system (2) which brings the temperature of the battery pack (8) from the initial temperature (Ti) to the set temperature (TSET); store (35) at least one power loss map indicative of the power losses of the electric motor (3) and of the converter (4) as a function of the torque values and of the motor revolution numbers; determine (24) a virtual motor revolution number (VVRT) such that the power loss indicated by the power loss map for the first torque (τ1) and for said virtual motor revolution number (VVRT) is equal to the sum of said first power loss and said additional power loss; and drive (50) the propulsion control unit (15) on the basis of the first torque (τ1) and of the virtual motor revolution number (VVRT), in such a way that the electric motor (3) provides a second torque (τ2), substantially equal to the first torque (τ1), and turns at a revolution number still equal, substantially, to the real motor revolution number (VREAL), in such a way that the electric propulsion system (2) has a second efficiency (η2), which is less than the first efficiency (η1) and corresponds to the sum of the first power loss and of the additional power loss, thereby causing an increment of power losses of the electric propulsion system (2) and the consequent heating of the battery pack (8). Figure 6

A battery pack (1) comprises a plurality of battery cells (2) arranged within a container configured to define one or more passages for a forced flow of temperature-regulating air that maintains the battery cells (2) within a predetermined temperature range. The cells (2) of the battery pack (1) are divided into a plurality of separate blocks (5), each provided with a respective container (5A) isolated from the containers (5A) of the other blocks (5). In the container (5A) of each block (5) is arranged at least one group (3) of battery cells (2). Most, or all, of the temperature-regulating air flow is supplied cyclically only to one of the blocks (5) of battery cells, for a determined time, while the other blocks (5) of cells receive a relatively reduced or null flow of temperature-regulating air, such that, at the end of each cycle, all the blocks (5) of battery cells have received in turn, for a determined time interval, a major flow of temperature-regulating air. In this way it is possible to obtain a much higher heat exchange efficiency compared to the case where the flow rate of the temperature-regulating air were constantly distributed equally among the different blocks of cells. During a warm-up phase, after a cold activation of the battery pack (1), the air flow is supplied in turn only to the blocks (5) of a part of the battery pack (1), so as to make the heating of this part of the battery pack (1) faster. During a charging phase of the battery pack (1), the charging electric current can be supplied only to the block (5) of the battery pack (1) that in turn receives the major air flow, so as to make the cooling more effective where it is most necessary.

An electric battery pack (100) comprises a plurality of stacks (101) of battery cells arranged within a container (4). In each cell stack (101), a temperature-regulating liquid flows from an inlet collecting chamber (13A), which extends below the cell stacks, through the spaces between the cells (2) and up to an outlet collecting chamber (13B) that extends above the cells (2) of the stack (101). The battery pack (1) includes a distribution system (D) configured to enable a major flow of the temperature-regulating liquid, corresponding to most or all of the incoming flow into the battery pack, to be cyclically supplied only to one of the cell stacks (101), or only to a group of cell stacks (101), while the other cell stacks (101) receive a reduced or no flow of the temperature-regulating liquid, such that, at the end of each cycle, a plurality of cell stacks (101) have in turn received, for a determined time interval, most or all of the incoming flow of thermal management liquid into the battery pack (1).

An electric battery pack (1) comprises one or more groups of battery cells (2) arranged inside a container (4). The battery cells (2) are cylindrical cells (2) or pouch cells arranged horizontally and immersed in a flow of a temperature-regulating liquid that maintains them within a predetermined temperature range. The temperature-regulating liquid flows from an inlet collector chamber (5), situated below the battery cells (2), through spaces (7) defined between the cells (2), into an outlet collector chamber (6) arranged above the cells. The spaces between the cells communicate with the inlet collector chamber (5) via a plurality of restricted passages (9). The battery cells (2) each have their respective positive and negative poles (P, N) situated at a same end, or on opposite ends, of the cell, facing a respective vertical side wall (40) of the container (4). All the poles (P, N) of the cells that are facing a respective vertical side wall (40) of the container (4) of the battery pack (1) are contained in one or more lateral chambers (C). The temperature-regulating liquid can flow from the inlet collector chamber (5) to the outlet collector chamber (6) also passing through the lateral chambers (C), which are isolated from the spaces (7) between the cells (2) by means of a separation wall (D) including a sealing panel (10) of elastomeric material, for example of silicone material, mounted on the ends of the cells (2) bearing the poles (P, N). Associated with the sealing panel (10) and/or with a rigid support frame (11) of the sealing panel are one or more rigid tubular elements (12) for the communication of the inlet collector chamber (5) with each lateral chamber (C).

An electric battery pack comprises a container (2) including a bottom wall (2A), side walls (2C) and an upper lid (2B). Within the container are disposed assemblies of battery cells (4) arranged side by side and spaced apart from one another. A temperature-regulating system uses a temperature-regulating liquid that flows from an inlet collector chamber (11) located below the battery cells (4), through the spaces (9) defined between the battery cells (4), into an outlet collector chamber (13) arranged above the battery cells (4). The temperature-regulating system includes a heat exchanger (6) to maintain the temperature of the temperature-regulating liquid within a determined range. The heat exchanger consists of a heat exchange plate (6), including one or more passages (15) for a secondary fluid, which is associated with the lid (C) or the bottom wall (2A) of the container (2), so that the flow of the temperature-regulating liquid comes into contact with the heat exchange plate (6) inside the container (2). In a preferred example, the heat exchange plate (6) is associated with the lid (C) of the container (2), in such a way as to constitute a lower wall of the outlet collector chamber (13) of the temperature-regulating liquid, and is furthermore arranged in contact with upper surfaces of the battery cells (4), in such a way that the heat exchange plate (6) is able to exchange heat both with the flow of the temperature-regulating liquid and with the battery cells (4) that are in contact with it.

A vehicular control system (1) for an electric traction system (ET) of a vehicle (V) with electric or hybrid propulsion, the vehicle (V) with electric or hybrid propulsion comprises a vehicular powertrain (GM) comprising the electric traction system (ET) and a transmission system (T) interposed between the electric traction system (ET) and driving wheels (W) of the vehicle with electric or hybrid propulsion (V). The electric traction system (ET) comprises at least one multiphase electric motor (ME) and is electronically controllable to selectively operate in different operating modes comprising at least one electric mode, wherein the vehicle (V) with electric or hybrid propulsion is propelled by the electric motor (ME). The vehicular control system (1) is designed to determine (10) the presence of a possible critical condition of the electric traction (ET) system of the vehicle (V) with electric or hybrid propulsion; in case a possible critical condition of the electric traction system (ET) of the vehicle (V) with electric or hybrid propulsion is determined to be present, inhibit (11) first phases of the electric motor (ME) of the vehicle (V) with electric or hybrid propulsion; verify (12) that the position of a rotor of the electric motor (ME) of the vehicle (V) with electric or hybrid propulsion meets a proprietary criterion; and if the position of a rotor of the electric motor (ME) of the vehicle (V) with electric or hybrid propulsion meets the proprietary criterion, inhibit (13) the remaining second phases of the electric motor (ME) of the vehicle (V) with electric or hybrid propulsion.

A prismatic-type electric battery cell (1) has a housing (2) having two opposite main walls (2A), an upper wall (2B), a lower wall (2C) and two end walls (2D). The cell incorporates an anti-swelling device, including at least one internal connecting member (4), acting as a tie rod, arranged inside the housing (2) and having two opposite sides connected to the two main walls (2A) of the housing (2), so as to tend to prevent an outward swelling of the main walls (2A). The internal connecting member (4) divides the space inside the housing (2) into two chambers in which two or more wound electrode sheet rolls (JR) are arranged, with the winding axis (5) directed vertically or horizontally. In this way, the swelling of the cell during the operation of a battery pack is significantly reduced, or eliminated altogether, without the use of limiting elements arranged outside the cell and with consequent savings in space, weight and production cost, and with a consequent increase in the energy density of the battery pack.

An electric battery pack comprises one or more electric battery units (1), each including an array of battery cells (2) arranged inside a container (4) and kept spaced apart from each other by respective spacer frames (8). A temperature-regulating liquid distribution system includes an inlet collector chamber (5) disposed below the array of battery cells (2) and an outlet collector chamber (6) disposed above the array of battery cells (2) and communicating with the inlet collector chamber (5) through the spaces (7) defined between the battery cells (2). Each space (7) between the cells (2) communicates with the inlet collector chamber (5) via one or more relatively narrow passages (9). The cells (2) each have a positive pole (3P) and a negative pole (3N) on a vertical end wall of the cell, facing a vertical side wall (40) of the container (4). The positive poles (3P) and negative poles (3N) of the cells are contained in one or more lateral chambers (CP, CN) of the battery unit (1), which are isolated from the space of the container occupied by the cells (2) by a separation wall (D) including a sealing panel (10) made of elastomeric material, for example silicone material, mounted on the ends of the cells (2) bearing the positive poles (3P) and negative poles (3N), and a rigid support frame (11) for the sealing panel (10), rigidly connected to the container (4). One or more rigid tubular elements (12) are associated with the sealing panel (10) for communication between the inlet collector chamber (5) and the lateral chambers (CP, CN).

An electric battery pack (1) comprises a plurality of electric battery groups. Each group comprises a plurality of battery cells (4), arranged side by side along a first horizontal direction (X). The different groups of battery cells (4) are arranged in at least one row along a second horizontal direction (Y) orthogonal to the first horizontal direction (X). The battery pack (1) is configured to receive a flow of a temperature-regulating liquid that passes through the battery pack (1) so as to come into direct contact with the battery cells (4). A system for distributing the temperature-regulating liquid includes a longitudinal feeding channel (6) and a plurality of transverse channels (7) extending beneath each group of battery cells (4) along said first horizontal direction (X). The transverse channels (7) are defined by a lower support structure (5) on which the battery cells (4) are supported and including a lower wall (50), an upper wall (51) parallel to and spaced above the lower wall (50) and formed integrally, or rigidly connected, with said lower wall (50), and a plurality of internal ribs (5B) parallel to and spaced apart from each other extending along the first horizontal direction (X) between the lower wall (50) and the upper wall (51). Each transverse channel (7) has a closed cross-section, defined by the lower wall (50), the upper wall (51), and two of the internal ribs (5B) of the lower support structure (5). In the upper wall (51) of the lower support structure (5) are formed relatively narrow apertures (9) for communication with the spaces between the cells (4).

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