Prismatic battery cell separator and module using same

1 . A battery module, comprising:

a first side rail;

a second side rail;

one or more battery cell banks positioned between the first side rail and the second side rail; and

one or more battery cell separators positioned within the one or more battery cell banks and configured to separate one or more battery cells positioned adjacent one another, the one or more battery cell separators comprising:

one or more cell barriers positioned adjacent the one or more battery cell banks; and

a support structure positioned between the one or more cell barriers, the support structure disposed along a midpoint of the one or more battery cell separators, wherein the support structure comprises:

a male portion and a female portion, the male portion and female portion disposed on opposite sides of the support structure and spaced vertically from top and bottom portions of the support structure; and

a plurality of flanges extending from the support structure, each of the plurality of flanges extending in a direction substantially perpendicular to a longitudinal axis of the support structure and parallel to a plane defined by the one or more cell barriers;

wherein the one or more battery cell separators are configured to mitigate thermal energy propagation produced from the one or more battery cells.

2 . The battery module of claim 1 , wherein the one or more battery cell separators further comprises:

a plurality of sidewalls;

and

a bottom support extending along a portion of a length of the battery cell separator and extending outward from the one or more cell barriers.

3 . The battery module of claim 2 , wherein the one or more flanges, the bottom support, the one or more cell barriers, and the plurality of sidewalls cooperatively define an area for the one or more battery cells to be positioned therein.

4 . The battery module of claim 1 , wherein the support structure is configured to dampen impact forces onto the one or more battery cell separators.

5 . The battery module of claim 1 , wherein the one or more battery cell separators are manufactured out of a conductive material, and wherein the one or more battery cell separators direct the thermal energy towards a heat sink located proximate a bottom of the battery module.

6 . The battery module of claim 1 , wherein one of the one or more battery cell separators comprises two cell barriers.

7 . The battery module of claim 1 , wherein the one or more battery cell separators further comprises an interlocking mechanism coupled to an end of the one or more cell barriers, and wherein the interlocking mechanism is configured to receive a portion of the first side rail to couple the one or more battery cell separators to the battery module.

8 . The battery module of claim 1 , wherein the one or more battery cell separators further comprises a first battery cell separator and a second battery cell separator, and wherein the female portion is configured to receive a male portion of the first battery cell separator to couple the first battery cell separator to the second battery cell separator.

9 . A battery module, comprising:

a plurality of side rails;

one or more battery cell banks positioned between the plurality of side rails, the one or more battery cell banks comprising one or more battery cells positioned therein; and

one or more battery cell separators positioned within the one or more battery cell banks and configured to separate the one or more battery cells positioned adjacent one another, the one or more battery cell separators comprising:

a plurality of sidewalls;

one or more cell barriers positioned adjacent the one or more battery cell banks;

a bottom support extending along a portion of a length of the battery cell separator and extending outward from the one or more cell barriers;

a support structure positioned between the one or more cell barriers, the support structure disposed along a midpoint of the one or more battery cell, wherein the support structure comprises a male portion and a female portion, the male portion and female portion disposed on opposite sides of the support structure and spaced vertically from top and bottom portions of the support structure;

and one or more flanges extending from the support structure, each of the one or more flanges extending in a direction substantially perpendicular to a longitudinal axis of the support structure and parallel to a plane defined by the one or more cell barriers;

wherein the one or more flanges, the bottom support, the one or more cell barriers, and the plurality of sidewalls cooperatively define an area for a battery cell to be positioned therein.

10 . The battery module of claim 9 , wherein the one or more battery cell separators further comprises an interlocking mechanism coupled to an end of the one or more cell barriers, and wherein the interlocking mechanism is configured to receive a portion of the plurality of side rails to couple the one or more battery cell separators to the battery module.

11 . The battery module of claim 9 , wherein the one or more battery cell separators are configured to mitigate thermal energy propagation produced from the one or more battery cells.

12 . The battery module of claim 9 , wherein the one or more battery separators comprises a plurality of battery separators.

13 . The battery module of claim 12 , wherein each of the plurality of battery separators is structured to couple to an adjacent battery separator.

14 . The battery module of claim 13 , wherein each of the one or more flanges of each of the plurality of battery separators is structured to include the female portion, the female portion comprising at least one receptacle, the at least one receptacle structured to receive the male portion of the adjacent battery separator, the male portion comprising a pin.

15 . The battery module of claim 14 , wherein the at least one receptacle is structured to include a ridge such that the ridge creates a snap interaction with the pin.

16 . The battery module of claim 15 , wherein the at least one receptacle comprises two receptacles.

17 . The battery module of claim 16 , wherein a first of the two receptacles is positioned at a first distance from a top portion of each of the plurality of battery separators and a second of the two receptacles is positioned at a second distance from a bottom portion of each of the plurality of battery separators.

18 . The battery module of claim 14 , wherein the one or more flanges comprises four flanges.

19 . The battery module of claim 9 , wherein each of the plurality of sidewalls includes a plurality of slots, the plurality of slots structured to receive a portion of the plurality of side rails.

20 . The battery module of claim 14 , wherein the pin is structured as a ribbed boss extending horizontally from the support structure.