Battery module and method for manufacturing the battery module

#Battery modules have been designed with battery cells having cell tabs encapsulated in a potting compound. The inventors herein have recognized that a drawback with the above battery modules is that when the potting compound is being applied around the battery cell tabs, the potting compound can leak in the battery module and undesirably contact battery portions or battery pouches. Also, the potting compound can undesirably fill in cooling passages between the battery portions.

#A battery module in accordance with an exemplary embodiment is provided. The battery module includes a plurality of battery cells having electrical terminals extending from battery portions. The battery module further includes an interconnect board having a plurality of apertures extending therethrough for receiving the electrical terminals therethrough. The battery module further includes an elastomeric layer having a plurality of apertures extending therethrough. The elastomeric layer is disposed proximate to the interconnect board such that the electrical terminals extend through the plurality of apertures of the interconnect board and further extend through the plurality of apertures of the elastomeric layer. The battery module further includes a potting compound disposed on the elastomeric layer such that the elastomeric layer prevents the potting compound from contacting the battery portions.

#A method of manufacturing a battery module in accordance with another exemplary embodiment is provided. The method includes disposing a plurality of battery cells in a plurality of frame members. The plurality of battery cells have electrical terminals extending from battery portions. The electrical terminals extend through apertures in the frame members. The method further includes disposing an interconnect board proximate to the plurality of battery cells such that a plurality of apertures extending through the interconnect board receive the electrical terminals therethrough. The method further includes disposing an elastomeric layer proximate to the interconnect board such that the electrical terminals extend through the plurality of apertures of the interconnect board further extend through a plurality of apertures of the elastomeric layer. The method further includes disposing a potting compound on the elastomeric layer and the electrical terminals such that the elastomeric layer prevents the potting compound from contacting the battery portions.

#FIG. 1 is a schematic of a battery module in accordance with an exemplary embodiment;

#FIG. 2 is an exploded view of the battery module of FIG. 1;

#FIG. 3 is a schematic of a portion of the battery module of FIG. 1;

#Referring to FIGS. 1-4, a battery module 10 having an elastomeric layer 100 in accordance with an exemplary embodiment is provided. The battery module 10 includes a plurality of battery cells 20, a plurality of frame members 50, an interconnect carrier 80, an interconnect board 90, the elastomeric layer 100, and a potting compound 110.

#Referring to FIGS. 5-8, the plurality of battery cells 20 are each configured to generate an operational voltage. In one exemplary embodiment, each of the battery cells 20 are pouch-type lithium-ion battery cells. Of course, other types of battery cells known to those skilled in the art could be utilized. Also, in an exemplary embodiment, the plurality of battery cells 20 are electrically coupled in series to one another. In an alternative embodiment, the plurality of battery cells 20 could be electrically coupled in parallel to one another. Each of the plurality of battery cells 20 includes a battery portion 130 with electrical terminals 132, 134 extending from the battery portion 130. In one exemplary embodiment, the battery portion 130 is a pouch that contains active elements of the battery cell.

#Referring to FIGS. 1 and 6, the plurality of frame members 50 are provided to couple the plurality of battery cells 20 together in a single assembly. In particular, the plurality of frame members 50 are coupled together and hold the battery cells 20 therebetween. In one exemplary embodiment, the plurality of frame members 50 are constructed of plastic.