Patent ID: 12203998

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics of the disclosure may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided. One skilled in the relevant art will recognize, however, that the disclosure can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the disclosure.

A battery is a device that stores and discharges energy through the controlled conversion of chemical energy to electric energy. Energy is stored by preventing the flow of electrons between chemical reactants with different electric potential. Energy is released when electrons are allowed to flow between a positive terminal (cathode) and a negative terminal (anode). When the terminals are connected, the compounds undergo chemical reactions that are known as oxidation and reduction. The chemical reactions may cause a flow of electrolytes and drive current through a circuit.

Batteries may be classified by the type of electrochemical cells that contain the chemical reactants. Cell types include galvanic cells, electrolytic cells, fuel cells, flow cells, saltwater cells, molten salt cells, and voltaic piles. These cells may use a liquid electrolyte (wet cell) or a low-moisture paste (dry cell).

A battery may be either single-use (primary) or rechargeable (secondary). The chemical reactions of a primary battery may be irreversible, and the battery may stop producing current once it has exhausted the supply of chemical reactants. The chemical reactions of a secondary battery may be reversed by applying a voltage in the opposite direction thereby replenishing the supply of chemical reactants.

FIG.1illustrates an example of a cell105that supports preventing battery failure by preventing cell failure propagation in accordance with aspects of the present disclosure. Cell105may be an example of, or incorporate aspects of, cell225as described with reference toFIG.2.

In some examples, cell105may include can110, current interrupt device (CID)115, positive temperature coefficient (PTC) device120, and vent125.

Cell105may be an example of one of a plurality of lithium ion electrochemical components, wherein each of the plurality of the lithium ion electrochemical cells105is configured to generate electrical energy from chemical reactions, each of the plurality of the lithium ion electrochemical cells105comprising a respective first end and a respective second end, wherein each respective first end comprises a respective vent125, wherein each of the plurality of lithium ion electrochemical cells105is aligned along parallel axes with each other of the plurality of lithium ion electrochemical cells105with each the respective first end in a first direction, and each the respective second end in a second direction. In variations of the present disclosure, electrochemical cells105may comprise the respective first end and the respective second end, wherein each respective second end comprises the respective vent125. In further variations of the present disclosure, electrochemical cells105may comprise the respective first end and the respective second end, wherein each respective first end comprises the respective vent125and wherein each respective second end comprises another respective vent, such that each of the electrochemical cells has two vents, one at each of its first end and second end.

In some cases, the plurality of lithium ion electrochemical cells105comprises at least two lithium ion electrochemical cells105. In one embodiment, each cell105may be a standard Lithium-Ion18650battery cell105.

FIG.2illustrates an example of a module205that supports preventing battery failure by preventing cell failure propagation in accordance with aspects of the present disclosure. In some examples, module205may include diffuser plate210, first bus plate215, first composite plate220, cell225, cell support230, second composite plate235, second bus plate240, heat sink layer245, and third bus plate250.

Diffuser plate210may be an example of, or incorporate aspects of, diffuser plate305and405as described with reference toFIGS.3and4. Diffuser plate210may be juxtaposed with the bus plate215at the respective first end, wherein the diffuser plate210is aligned with a plane normal to the parallel axes, the diffuser plate210comprising a first side facing the respective first ends and a second side facing away from the respective first ends, the diffuser plate210comprising channels on the first side.

First bus plate215may be an example of a first bus electrically coupled to respective first electrodes of each of the plurality of lithium ion electrochemical cells225at the respective first end. In some cases, the first bus plate215comprises nickel, aluminum, copper or combinations thereof.

First composite plate220may be an example of a first glass epoxy composite material interposed between the first bus and each of the plurality of the lithium ion electrochemical cells225at the respective first end. In some cases, the first glass epoxy composite material comprises G10.

In a variation of the present disclosure, where each of the electrochemical cells has two vents, one at each of its first end and second end, a second diffuser plate may be an example of, or incorporate aspects of, diffuser plate210,305and405as described with reference toFIGS.2,3and4. The second diffuser plate may be juxtaposed with a second bus plate240, described below, at the respective second end, wherein the second diffuser plate is aligned with a plane normal to the parallel axes, the second diffuser plate comprising a first side facing the respective second ends and a second side facing away from the respective second ends, the second diffuser plate comprising channels on the first side.

Cell225may be an example of, or incorporate aspects of, cell105as described with reference toFIG.1.

Cell support230may be an example of a foam component comprising a plurality of tubes each of which holds one of the plurality of lithium ion electrochemical cells225in a spaced-apart relationship relative to others of the plurality of lithium ion electrochemical cells225. In some cases, the foam cell support230comprises polyurethane.

Second composite plate235may be an example of a second glass epoxy composite material interposed between the second bus and each of the plurality of the lithium ion electrochemical cells225at the respective second end. In some cases, the second glass epoxy composite material comprises G10.

Second bus plate240may be an example of a second bus electrically coupled to respective second electrodes of each of the plurality of lithium ion electrochemical cells225at the respective second end; be an example of a fuse coupled to one of the first bus plate215and the second bus plate240. In some cases, second bus plate240comprises nickel, aluminum, copper or combinations thereof.

Heat sink layer245may be an example of a component juxtaposed with one of the first bus and the second bus. In some cases, the heat sink layer comprises a phase change material.

Third bus plate250may be an example of a third bus electrically coupled to respective second electrodes of each of the plurality of lithium ion electrochemical cells225at the respective second end, wherein the heat sink layer245is interposed between the second bus plate240and the third bus plate250and be an example of a fuse interposed between the second bus plate240and the third bus plate250.

One or more cells225may be combined into a battery module205. Each battery module205may include a heat sink (e.g. made from an aluminum-nickel phase change material). The module205may also include a flame resistant cell support230structure. Diffuser plates210may direct hot vent gases past neighboring cells225in the event of a failure. Cell spacing and fusing may also be designed in a manner to prevent propagation of cell225failure. Cells225are clamped together with one or more non-conductive rods, and connected in series with copper connecting bars. In some cases, slide pads are bonded to the foam support structure, to assist in inserting the half-string into battery pressure vessel. In some cases, integrated cooling fans are connected to each module205.

In some examples, one or more battery modules205may be combined to form a battery management system. For example, Support brackets may be used to connect adjoining battery modules205. Sliding electrical connectors may also assist in joining adjacent battery modules205. Brackets may be used to bolt together frames between modules205to create a structurally solid module205pair. The frame may serve as a plenum between two battery modules205to allow the cooling fans to push air between them. Channels in the frame may guide the air into the diffuser plates210. The battery management system may perform the functions of passive cell225balancing, temperature sensing, health monitoring, and cell225cooling (both passive and active).

A diffuser plate210may be constructed from a metallic material such as aluminum. It may include channels that allow for venting gases, and overflow chambers to accommodate cell225swelling and molten debris collection. Flex tabs in the first bus plate215may allow for cell225swelling, venting, and low heat transfer between cells225. The second bus plate240may facilitate heat dissipation within a cell225group. A phase change heat sink layer245may be located between the second bus plate240and the third bus plate250. The third bus plate250may include a group fuse component.

FIG.3illustrates an example of a diffuser plate305arrangement that supports preventing cell failure propagation in accordance with aspects of the present disclosure. Diffuser plate305may be an example of, or incorporate aspects of, diffuser plate210and405as described with reference toFIGS.2and4. In some examples, diffuser plate305may include diverter310.

Diverter310may be an example of, or incorporate aspects of, diverter410as described with reference toFIG.4. In some examples, diverter310may include arc315and gap320.

Arc315may be an example of, or incorporate aspects of, arc415as described with reference toFIG.4. Gap320may be an example of, or incorporate aspects of, gap420as described with reference toFIG.4.

The diffuser plate305may include multiple diverters310. Each diverter310may be located directly above a cell, and may have one or more arcs315separated by gaps320. The gaps320may be arranged to divert vented gases in a direction that does not directly face any other cell.

FIG.4illustrates an example of an angled view of a diffuser plate arrangement that supports preventing battery failure by preventing cell failure propagation in accordance with aspects of the present disclosure. Diffuser plate405may be an example of, or incorporate aspects of, diffuser plate210and305as described with reference toFIGS.2and3. In some examples, diffuser plate405may include diverter410.

Diverter410may be an example of, or incorporate aspects of, diverter310as described with reference toFIG.3. In some examples, diverter410may include arc415and gap420.

Arc415may be an example of, or incorporate aspects of, arc315as described with reference toFIG.3. Gap420may be an example of, or incorporate aspects of, gap320as described with reference toFIG.3.

The diffuser plate405may include multiple diverters410. Each diverter410may be located directly above a cell, and may have one or more arcs415separated by gaps420. The gaps420may be arranged to divert vented gases in a direction that does not directly face any other cell. As shown inFIG.4, each arc comprises a curved cross-section oriented parallel to the diffuser plate alignment.

FIG.5illustrates an example of a process performed by a manufacturing system for preventing battery failure by preventing cell failure propagation in accordance with aspects of the present disclosure. In some examples, a manufacturing system may execute a set of codes to control functional elements of the manufacturing system to perform the described functions.

Additionally or alternatively, a manufacturing system may use special-purpose hardware. These operations may be performed according to the methods and processes described in accordance with aspects of the present disclosure. For example, the operations may be composed of various substeps, or may be performed in conjunction with other operations described herein.

At block505the manufacturing system may provide a plurality of lithium ion electrochemical cells, wherein each of the plurality of the lithium ion electrochemical cells is configured to generate electrical energy from chemical reactions, each of the plurality of the lithium ion electrochemical cells comprising a respective first end and a respective second end, wherein each respective first end comprises a respective vent. In a variation, each respective second end may comprise a respective vent, either in lieu of the respective vent of the first end of in addition to the respective vent of the first end.

At block510the manufacturing system may align each of the plurality of lithium ion electrochemical cells is aligned along parallel axes with each other of the plurality of lithium ion electrochemical cells with each the respective first end in a first direction, and each the respective second end in a second direction.

At block515the manufacturing system may couple a first bus electrically to respective first electrodes of each of the plurality of lithium ion electrochemical cells at the respective first end.

At block520the manufacturing system may couple a second bus electrically to respective second electrodes of each of the plurality of lithium ion electrochemical cells at the respective second end.

At block525the manufacturing system may juxtapose a diffuser plate with the first bus at the respective first end, comprising aligning the diffuser plate a plane normal to the parallel axes, the diffuser plate comprising a first side facing the respective first ends and a second side facing away from the respective first ends, the diffuser plate comprising channels on the first side.

While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.