PLASTIC CELL SWELLING RESTRAINT FEATURE

Disclosed is an advanced battery module comprising a feature for the restraint of cell swelling. In particular, disclosed is an advanced battery module for a vehicle, comprising a housing having a first wall, second wall, third wall, and fourth wall wherein the first wall is perpendicular to the second wall and fourth wall, and the third wall is parallel to the first wall, wherein the first wall comprises a first wall member, a second wall member parallel to the first wall member, and a plurality of first wall cross-members extending between the first wall member and second wall member; wherein the plurality of first wall cross-members are angled relative to the first wall, at least the first wall and the third wall comprising a plastic; and a plurality of cells.

FIELD

The present disclosure relates to the field of batteries. The present disclosure more specifically relates to the field of battery housings.

BACKGROUND

Lithium ion cells are generally housed in an injection molded plastic housing. The cells create internal pressure and expand due to typical electrical loading. The pressure creates great force that is difficult to constrain with only a single-wall plastic housing. Accordingly, many existing devices use a metal constraint to control the expansion or swelling and pressure on the single-wall plastic housing. Unfortunately, using metal adds weight, manufacturing complexity, and cost to the battery.

SUMMARY

Accordingly, a battery housing having a plastic cell swelling restraint feature is provided which solves one or more of the problems faced by existing devices. The disclosed battery housing may, in various embodiments, allow for restraint on cell swelling while minimizing increase in weight to the battery.

Disclosed is a housing for an advanced battery module, the housing comprising: a first wall comprising a first wall member; a second wall member parallel to the first wall member; and a plurality of cross-members extending between the first wall member and second wall member; wherein the plurality of cross-members are angled relative to the first wall member. Further disclosed is a housing comprising a second wall and a fourth wall, both the second wall and fourth wall being perpendicular to the first wall, and a third wall; wherein the third wall comprises: a third wall member; a fourth wall member parallel to the third wall member; and a plurality of cross-members extending between the third wall member and the fourth wall member; wherein the plurality of cross-members are angled relative to the third wall member. Further disclosed is a housing wherein the plurality of cross-members are neither perpendicular nor parallel to the first wall member. Further disclosed is a housing wherein the first wall comprises a plastic. Disclosed herein is an advanced battery having the housing described herein.

Disclosed is a n advanced battery module for a vehicle, comprising: a housing having a first wall, the first wall comprising: a first wall member; a second wall member parallel to the first wall member; and a plurality of cross-members extending between the first wall member and second wall member; wherein the plurality of cross-members are angled relative to the first wall member; and a plurality of cells. Further disclosed is an advanced battery module wherein the housing further comprises: a second wall, a third wall, and a fourth wall; wherein the third wall comprises: a third wall member; a fourth wall member parallel to the third wall member; and a plurality of third wall cross-members extending between the third wall member and the fourth wall member; wherein the plurality of third wall cross-members are neither parallel nor perpendicular to the third wall member. Further disclosed is an advanced battery module wherein the first wall and third wall are parallel to each other, the second wall is perpendicular to the first wall, and the fourth wall is parallel to the second wall. Further disclosed is an advanced battery module wherein the first wall comprises a plastic. Further disclosed is an advanced battery module wherein the plurality of cells are prismatic. Further disclosed is an advanced battery module wherein a long edge of each cell in the plurality of cells is oriented parallel to the first wall. Further disclosed is an advanced battery module wherein the plurality of cross-members comprises a first cross-member and a second cross-member oriented in a different angle to the first wall member than the second cross-member. Further disclosed is an advanced battery module wherein the first cross-member is essentially perpendicular to the second cross-member. Further disclosed is an advanced battery module wherein the plurality of cross-members are neither parallel nor perpendicular to the first wall member. Further disclosed is an advanced battery module wherein a long edge of the prismatic cell is neither parallel nor perpendicular to the first cross-member or the second cross-member.

Disclosed herein is an advanced battery module for a vehicle, comprising: a housing having a first wall, second wall, third wall, and fourth wall; wherein the first wall is perpendicular to the second wall and fourth wall, and the third wall is parallel to the first wall; wherein the first wall comprises: a first wall member; a second wall member parallel to the first wall member; and a plurality of first wall cross-members extending between the first wall member and second wall member; wherein the plurality of first wall cross-members are angled relative to the first wall member; and wherein the third wall comprises: a third wall member; a fourth wall member; and a plurality of third wall cross-members extending between the third wall member and fourth wall member; wherein the plurality of third wall cross-members are angled relative to the third wall member; at least the first wall and the third wall comprising a plastic; and a plurality of cells. Further disclosed is an advanced battery module wherein the plurality of first wall cross-members comprise a first cross-member and a second cross-member, the first cross-member intersecting the first wall at a different angle than the second cross-member. Further disclosed is an advanced battery module wherein the plurality of cells are prismatic. Further disclosed is an advanced battery module, wherein a long edge of at least one of the plurality of cells is parallel to the first wall. Further disclosed is an advanced battery module, wherein the plurality of first wall cross-members are neither parallel nor perpendicular to the first wall member and wherein the plurality of third wall cross-members are neither parallel nor perpendicular to the third wall member.

Further advantages may be understood from the detailed disclosure herein.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

Referring toFIG. 1, a vehicle100is shown. Within the vehicle100, a battery103is provided to support operational functionality of the vehicle. For example, battery103may be an advanced battery such as a lithium ion battery (while lithium ion is provided, other advanced battery chemistries may be considered as within the scope of this disclosure). This advanced battery103may be comprised of a plurality of cells as shown and described herein. These cells267may undergo swelling during operation of vehicle100as result of the use of the battery103. Therefore housing101,201, may incorporate certain cell swelling restraint features as shown and described further herein.

FIG. 2shows a housing101for a battery. As may be seen, a lid, bottom (not shown), first wall151, second wall155, third wall153, and fourth wall (not shown) may be understood to define an exterior of the battery. The housing101may be understood to be sized to fit within a vehicle103. The battery housing101may be understood to comprise a plastic.

Referring toFIG. 3, a battery housing103is shown with the cover removed, again having a first wall151, second wall155, third wall153, and fourth wall157. First wall151and third wall153may be understood to each further comprise a cell swelling restraint feature. In detail, the cell swelling restraint feature may comprise a double wall163which may be comprised of plastic. The double wall163may comprise a first wall member160and second wall member161. Angled cross-members165may be seen spanning between the first wall member160and second wall member161. In various embodiments, second wall155and fourth wall157may not comprise the cell swelling restraint feature. While two walls having the cell swelling restraint feature are shown, permutations thereon (one, three, or four cell swelling restraint features, etc.) should be contemplated as within the scope of this disclosure. Cross-members165may be seen intersecting with the first wall member160at an angle.

Turning toFIG. 4, another embodiment of a battery housing201is shown with the cover removed, now showing battery cells267within the battery housing201and the restraint feature. Battery cells267may be seen as prismatic, having two relatively longer sides extending in parallel to first wall251and third wall253. Battery housing201may be understood to be a plastic battery housing. Again, the housing may be understood as provided for holding a plurality of battery cells267or a battery pack assembly. The battery housing has a bottom or base (not shown), two end walls (251,253), two side walls (255,257), and may also include, in some examples of embodiments, one or more dividing walls which divide the battery cells. The battery housing201may also include a cover (not shown). As can be seen inFIG. 4, the end walls (first wall251and second wall253) comprise a double-wall structure while the side walls (second wall255and fourth wall257) and dividing walls may be seen as comprising a single solid wall. However, it is contemplated that more walls or fewer walls may have the double-wall structure. Likewise, it is contemplated that more walls or fewer walls may be a single solid wall.

In the illustrated example, each end wall (first wall251and/or third wall253) comprises a plastic double-wall structure263or assembly having angled cross members265between two adjacent, but spaced apart longitudinal wall members (first wall member260, second wall member261). This structure on the end walls251and253(including but not limited to first wall member260, second wall member261, and angled cross members265) may be understood to provide constraint against swelling for battery cells contained within the battery housing (cell-swelling restraint feature). The thickness of each wall (260,261) of the plastic double-wall structure, the number of angled cross members265, the angle of the cross member(s) (first angle269, second angle270), and thicknesses may be varied depending upon the desired structural and performance characteristics, which may be dictated by any number of different and suitable parameters, such as, but not limited to, desired wall strength, desired thickness, manufacturing preferences, and so forth. The thickness of each wall of the housing (251,253,255,257) may also vary. In various embodiments, the first angle269may differ as measured from the wall member260from the second angle270. In various embodiments, first angle269may be from the intersection of the second cross member271with a wall member263and second angle270may be measured based on the intersection between a first cross member271with the same wall member263. In some non-limiting embodiments, first cross member271and second cross member273may be substantially perpendicular to each other. While a particular configuration of cross members is shown and described, variations thereon may be understood as within the scope of this disclosure.

In one or more examples of embodiments, the housing may be formed by injection molding. However, alternative processes may also be suitable for the purposes provided.

Advantageously, the plastic restraint feature, namely the plastic double-wall structure with angled cross members described herein, may have advantages to manufacturability. For example, instead of manufacturing and assembling a separate metal piece, additional plastic structure can be integrated into the housing. Moreover, there are fewer parts in the battery pack. Eliminating a metal structure inside the housing may provide advantages to battery size and allow for reduction in overall weight of the battery.

It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.