Battery cell, battery pack, and method of manufacturing the same

Abstract

A battery cell includes an inner plastic layer, an outer plastic layer, and a middle metal layer. The inner plastic layer and the outer plastic layer extend along at least three sides of the battery cell. The middle metal layer is disposed between the inner plastic layer and the outer plastic layer. The middle metal layer extends along at least three sides of the battery cell and protrudes from at least a fourth side of the battery cell to form at least one heat dissipation tab. The at least one heat dissipation tab is configured to transfer heat to at least one cooling plate through thermal conduction. The fourth side of the battery cell interconnects two of the at least three sides.

Description

Technical Field

[0001] The information provided in this section serves to provide a general overview of the background of this disclosure. To the extent described in this section, the work of the currently named inventors, and aspects of the description that may not conform to the prior art at the time of submission, are neither explicitly nor implicitly acknowledged as prior art to this disclosure.

[0002] This disclosure relates to battery cells, battery packs, and methods for manufacturing the same, which combine features of accelerated heat dissipation, improved uniformity of heat distribution, and reduced size. Background Technology

[0003] Battery packs in electric vehicles typically consist of groups of cells and one or more cooling plates positioned adjacent to the cell groups. A cell group usually comprises multiple sets of battery cells and thermally resistive barriers positioned between the cell groups. These thermal barriers inhibit heat transfer between cell groups. The cooling plates absorb heat from the battery cells to maintain the battery pack within a target temperature range. In some cases, each cooling plate is a metal plate that defines one or more channels through which coolant flows. Summary of the Invention

[0004] The battery cell according to this disclosure includes an inner plastic layer, an outer plastic layer, and an intermediate metal layer. The inner and outer plastic layers extend along at least three sides of the battery cell. The intermediate metal layer is disposed between the inner and outer plastic layers. The intermediate metal layer extends along at least three sides of the battery cell and protrudes from at least a fourth side of the battery cell to form at least one heat dissipation fin. The at least one heat dissipation fin is configured to transfer heat to at least one cooling plate via thermal conduction. The fourth side of the battery cell connects two of the at least three sides to each other.

[0005] On one hand, the inner plastic layer extends along at least three sides of the battery cell and a fourth side of the battery cell.

[0006] On one hand, the inner plastic layer extends along at least three sides of the battery cell but not along a fourth side of the battery cell.

[0007] In one aspect, the outer plastic layer extends along at least three sides of the battery cell and at least partially along a fourth side of the battery cell.

[0008] On one hand, the outer plastic layer also protrudes from the fourth side of the battery cell and surrounds a portion of the intermediate metal layer that forms at least one heat dissipation fin.

[0009] In one aspect, the outer plastic layer extends along at least three sides of the battery cell and not along a fourth side of the battery cell.

[0010] In one aspect, the inner plastic layer and the outer plastic layer extend along at least three sides of the battery cell but not along the fourth side of the battery cell, and the intermediate metal layer extends along at least three sides and the fourth side of the battery cell.

[0011] In one aspect, an intermediate metal layer protrudes from a fourth side of the battery cell and one of at least three sides of the battery cell to form a pair of heat dissipation fins configured to transfer heat to a pair of cooling plates via thermal conduction.

[0012] In one aspect, the inner plastic layer is a polypropylene layer, the outer plastic layer is a layer made of nylon, polyethylene terephthalate (PET), or a combination of nylon and PET, and the middle metal layer is a layer made of aluminum, nickel, titanium, or stainless steel.

[0013] A method of manufacturing a battery cell according to this disclosure includes forming a metal layer, forming a first plastic layer on one side of the metal layer, and forming a second plastic layer on the other side of the metal layer. The metal layer and the first and second plastic layers form a three-layer structure. At least one of the first and second plastic layers is formed as a discontinuous segment along the length of the metal layer, such that a portion of the metal layer is exposed. The method further includes cutting the three-layer structure such that the exposed portion of the metal layer forms opposite ends of the three-layer structure, and heating a portion of at least one of the first and second plastic layers to form a seal sealing the interior of the battery cell.

[0014] In one aspect, the method further includes folding the three-layer structure such that the first plastic layer forms the inner layer of the battery cell and the ends of the three-layer structure are adjacent to each other, and heating the portion of the first plastic layer adjacent to the ends to form a seal.

[0015] In one aspect, the second plastic layer forms discontinuous segments along the length of the metal layer.

[0016] In one respect, both the first and second plastic layers form discontinuous segments along the length of the metal layer.

[0017] In one respect, the exposed portion of the metal layer does not extend across the entire width of the metal layer.

[0018] In one aspect, the first plastic layer is a polypropylene layer, the second plastic layer is a layer made of nylon, polyethylene terephthalate (PET), or a combination of nylon and PET, and the metal layer is a layer made of aluminum, nickel, titanium, or stainless steel.

[0019] The battery pack according to this disclosure includes a first set of battery cells, a second set of battery cells, and a heat-resistant barrier disposed between the first set of battery cells and the second set of battery cells. The heat-resistant barrier includes a polyurethane layer having a first surface and a second surface opposite to the first surface. The first surface of the polyurethane layer directly faces the first set of battery cells, and the second surface of the polyurethane layer directly faces the second set of battery cells.

[0020] In one respect, the heat barrier does not contain any aluminum layer.

[0021] In one respect, the heat barrier does not contain any gel layer.

[0022] In one aspect, the battery pack also includes a cooling plate. One end of each battery cell in the first and second battery groups is in contact with the cooling plate. A heat-resistant barrier is spaced apart from the cooling plate.

[0023] In one aspect, each of the first and second battery cell groups includes an inner plastic layer extending along at least three sides of the battery cell, an outer plastic layer extending along at least three sides of the battery cell, and an intermediate metal layer disposed between the inner and outer plastic layers. The intermediate metal layer extends along at least three sides of the battery cell and protrudes from at least a fourth side of the battery cell to form at least one heat dissipation fin, the heat dissipation fin being configured to transfer heat to at least one cooling plate via thermal conduction. The fourth side of the battery cell connects two of the at least three sides to each other.

[0024] Other areas of application of this disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0025] This disclosure will be more fully understood from the detailed description and accompanying drawings, in which:

[0026] Figure 1 This is a perspective view of an example battery cell according to this disclosure;

[0027] Figure 2 This is a cross-sectional view of an example battery pack according to the present disclosure, the battery pack including Figure 1 Battery cells and heat-resistant barriers;

[0028] Figure 3 yes Figure 1 A plan view of one of the battery cells before the battery cell is folded and sealed;

[0029] Figure 4 yes Figure 3 A plan view of the battery cell after folding and sealing;

[0030] Figure 5 yes Figure 2 A perspective view of the battery cells and heat-resistant barrier;

[0031] Figure 6 yes Figure 2 End view of the battery cell and heat barrier;

[0032] Figure 7 It is used to form Figure 1 A cross-sectional view of an example of a three-layer structure of the housing of a battery cell in a first embodiment;

[0033] Figure 8 yes Figure 1 A cross-sectional view of the casing of a first embodiment of a battery cell;

[0034] Figure 9 It is used to form Figure 1 A cross-sectional view of an example of a three-layer structure of the housing of a second embodiment of a battery cell;

[0035] Figure 10 yes Figure 1 A cross-sectional view of a second embodiment of the battery cell;

[0036] Figure 11 It is used to form Figure 1 A cross-sectional view of an example of a three-layer structure of a third embodiment of a battery cell;

[0037] Figure 12 yes Figure 1 A cross-sectional view of a third embodiment of the battery cell;

[0038] Figure 13 yes Figure 9 A perspective view of the three-layer structure;

[0039] Figure 14 yes Figure 11 A perspective view of the first embodiment of the three-layer structure;

[0040] Figure 15 yes Figure 11 A perspective view of the second embodiment of the three-layer structure;

[0041] Figure 16 It is a plan view of an example battery cell according to the present disclosure, including a pair of heat dissipation fins protruding from opposite sides of the battery cell;

[0042] Figure 17 yes Figure 1 A perspective view of two battery cells, one of which has a heat dissipation fin protruding in one direction, and the other of which has a heat dissipation fin protruding in the opposite direction.

[0043] Figure 18This is a cross-sectional view of another example of a battery pack according to this disclosure; and

[0044] Figure 19 Based on this disclosure and Figure 18 A perspective view of another example of a battery pack similar to the one shown.

[0045] In the accompanying drawings, reference numerals may be reused to identify similar and / or identical elements. Detailed Implementation

[0046] A battery pack typically comprises multiple groups of battery cells, heat-resistant barriers disposed between the groups of cells, and one or more cooling plates. Each battery cell includes a body having a first end, a second end, and four peripheral surfaces or sides extending from the first end to the second end. Each battery cell also includes a pair of terminals attached to its first and second ends. In some cases, each battery cell includes an outer nylon layer, an inner polypropylene layer, and an intermediate aluminum layer. Each of the outer nylon layer, the inner polypropylene layer, and the intermediate aluminum layer extends around all four sides of the battery cell and completely surrounds its interior.

[0047] Each battery cell is assembled within the battery pack such that one side of it is adjacent to and / or in contact with a cooling plate. In some cases, thermal paste may be applied between the side of the battery pack and the cooling plate. In any case, heat flowing from inside each battery cell to the cooling plate must pass through all layers of the individual battery cell (i.e., the inner polypropylene layer, the outer nylon layer, and the intermediate aluminum layer). Therefore, the heat dissipation rate from the battery cell to the cooling plate may not be as high as expected, thus potentially increasing the size and cost of the cooling system to meet the cooling requirements of the battery pack.

[0048] The battery cell according to this disclosure includes one or more heat dissipation fins, which address these issues by increasing the heat dissipation rate from the inside of the battery cell to the cooling plate. In one example, the intermediate aluminum layer of the battery cell protrudes from one side of the battery cell to form the heat dissipation fins, while the inner polypropylene layer and the outer nylon layer do not extend along that side of the battery cell. In turn, heat flowing from the inside of each battery cell to the cooling plate only needs to pass through the outer nylon layer. Furthermore, the heat distribution fins are positioned closer to the cooling plate than the rest of the intermediate aluminum layer. Therefore, the heat dissipation rate from the battery cell to the cooling plate can be higher than typical, thus reducing the size and cost of the cooling system to meet the cooling requirements of the battery pack.

[0049] Furthermore, it improves the uniformity of heat distribution within the battery cell, thus reducing cell degradation and increasing cycle life. Additionally, heat buildup within one battery cell (e.g., hot spot formation) is less of a concern. Therefore, one or more layers of the heat barrier can be removed, or the heat barrier can be completely removed. This, in turn, reduces the overall size of the battery pack.

[0050] Now for reference Figure 1 and 2 The battery pack 10 includes battery cells 12, a heat barrier 14, and a cooling plate 16. The heat barrier 14 is disposed between battery cells 12 in a first group 18 and battery cells 12 in a second group 20. Each of the first group 18 and the second group 20 includes a pair of battery cells 12. The battery cells 12 store energy (not shown) that can be used to power one or more electric motors of an electric vehicle. The heat barrier 14 inhibits heat transfer between the battery cells 12 in the first group 18 and the second group 20. The cooling plate 16 absorbs heat from the battery cells 12.

[0051] Each battery cell 12 includes a body 22, a pair of terminals 24, and a pair of heat dissipation fins 26. The body 22 of each battery cell 12 has a first end 28, a second end 30 opposite to the first end 28, and first and second side surfaces 32 and 34 extending between the first end 28 and the second end 30. The first side surfaces 32 of each battery cell 12 are opposite to each other, and the second side surfaces 34 of each battery cell 12 are opposite to each other. Each first side surface 32 connects the second side surfaces 34 to each other, and each second side surface 34 connects the first side surfaces 32 to each other.

[0052] Each terminal 24 protrudes from one of the first and second ends 28 and 30. The terminals 24 are made of metal (e.g., copper, aluminum). In one example, when the battery cell 12 is assembled in the battery pack 10, all terminals 24 protruding from the first end 28 of the battery cell 12 are made of copper, and all terminals 24 protruding from the second end 30 of the battery cell 12 are made of aluminum.

[0053] Each heat dissipation fin 26 protrudes from one of the first side surfaces 32 of the body 22. The heat dissipation fins 26 are primarily or entirely made of metal (e.g., aluminum). When assembling the battery pack 10, the heat dissipation fins 26 can directly contact the cooling plate 16 to increase the heat dissipation rate from the battery cell 12 to the cooling plate 16. Alternatively, the heat dissipation fins 26 can be spaced apart from the cooling plate 16 by a gap 36, and thermal paste 98 (…) Figure 18 A heat sink 26 can be applied to the gap 36 between the heat sink 26 and the cooling plate 16 to further increase the heat dissipation rate from the battery cell 12 to the cooling plate 16. In either case, the heat sink 26 transfers heat to the cooling plate 16 via thermal conduction.

[0054] Now for reference Figure 3 This shows one of the battery cells 12 before it is folded and sealed and before the terminal 24 is attached to the body 22 of the battery cell 12. When the battery cell 12 is in such a state... Figure 3When the battery cell 12 is in its unfolded state, the inner surface 38 is exposed. Furthermore, one heat dissipation fin 26 extends from the first edge 40 of the body 22, while the other heat dissipation fin 26 extends from the second edge 42 of the body 22. To form the battery cell 12, the main body... Figure 4 As shown, the main body 22 of the battery cell 12 is folded around the longitudinal axis 44 of the battery cell 12, as indicated by arrow 46, until the heat dissipation fins 26 overlap each other.

[0055] Then the first and second edges 40 and 42 of the main body 22 are joined together to seal the interior 47 of the battery cell 12. Figure 8 , 10 (12, 18). Battery cell 12 can also be sealed along the first and second ends 28 and 30 of body 22 so that the interior 47 of battery cell 12 is completely sealed. Terminals 24 can be attached to or near the first and second ends 28 and 30 before or when the first and second ends 28 and 30 are sealed. Once battery cell 12 is sealed, a portion of the heat dissipation fins 26 can be bent in a direction perpendicular to the second side surface 34 of body 22, such as... Figure 2 As shown, these parts are parallel to the cooling plate 16.

[0056] Now for reference Figure 5 and 6 A heat-resistant barrier 14 is shown between two battery cells 12 and may include heat-dissipating fins 26. The heat-resistant barrier 14 includes a polyurethane layer 48. A metal (aluminum) layer 50 and a gel layer 52 are shown in dashed lines to indicate that the heat-resistant barrier 14 does not include either the metal layer 50 or the gel layer 52. The gel layer 52 comprises a microporous solid in which the dispersed phase is a gas. Examples of gel layers 52 include microporous silica, microporous glass, and zeolite.

[0057] The increased heat dissipation rate provided by the heat dissipation fins 26 reduces the need to insulate the first group 18 and the second group 20 battery cells 12 from each other, thus allowing the metal layer 50 and gel layer 52 to be omitted. Since the heat barrier 14 does not include the metal layer 50 or gel layer 52, the thickness 54 of the heat barrier 14 can be smaller than that of a heat barrier including the metal layer 50 and / or gel layer 52 (e.g., 60% to 70%). This, in turn, can reduce the overall size of the battery pack 10. In various embodiments, the heat barrier 14 can be omitted entirely, which can further reduce the size of the battery pack 10.

[0058] Now for reference Figure 7An example of a three-layer structure 56 that can be used to form each battery cell 12 is shown. The three-layer structure 56 has a first end 58 and a second end 60 opposite to the first end 60. The three-layer structure 56 includes an inner plastic layer 62, an outer plastic layer 64, and an intermediate metal layer 66. The inner plastic layer 62 may be a polypropylene layer, the outer plastic layer 64 may be a layer made of nylon, polyethylene terephthalate (PET), or a combination of nylon and PET, and the intermediate metal layer 66 may be a layer made of aluminum, nickel, titanium, or stainless steel. The inner plastic layer 62 and the outer plastic layer 64 may be formed on the first and second surfaces 68 and 70 of the intermediate metal layer 66, respectively (e.g., by spraying, coating, casting).

[0059] For further reference Figure 8 The three-layer structure 56 also includes a seal 72 for sealing the interior 47 of the battery cell 12. The seal 72 can be produced by, for example, melting a portion of the inner plastic layer 62 using a hot press. Although Figure 8 Only the seal 72 is shown positioned at a first location 74 adjacent to the first end 58 of the three-layer structure 56, but the seal 72 may also be positioned at a second location 76 adjacent to the second end 60 of the three-layer structure 56. The first and second locations 74 and 76 are positions along the length of the three-layer structure 56.

[0060] To form the battery cell 12, a three-layer structure 56 can be folded so that the first and second positions 74 and 76 are as follows: Figure 8 The positions 74 and 76 are shown adjacent to each other. A seal 72 can then be formed to engage the first and second positions 74 and 76 with each other, thereby sealing the interior 47 of the battery cell 12. The heat dissipation fin 26 is formed by the portion of the three-layer structure 56 extending beyond the seal 72 (i.e., disposed between the first end 58 and the first position 74 and between the second end 60 and the second position 76). In contrast, if the first end 58 and the second end 60 of the three-layer structure 56 were engaged together to form the seal 72, the battery cell 12 would not include the heat dissipation fin 26.

[0061] When battery cell 12 is as follows Figure 8 When the three-layer structure 56 shown is formed, the inner plastic layer 62 extends along the two first side surfaces 32 and the two second side surfaces 34. Furthermore, the outer plastic layer 64 and the intermediate metal layer 66 extend along one of the first side surfaces 32 and the two second side surfaces 34, and at least partially along the other side surface 32. Additionally, a portion of the intermediate metal layer 66 protrudes from the other side surface 32 to form a heat dissipation fin 26, and a portion of the outer plastic layer 64 protrudes from the other side surface 32 and surrounds the protruding portion of the intermediate metal layer 66. The portion of the inner plastic layer 62 protruding beyond the seal 72 is melted to form the seal 72 and / or removed.

[0062] Now for reference Figure 9 and10 This illustrates another example of a three-layer structure 78 that can be used to form each battery cell 12. The three-layer structure 78 is similar to the three-layer structure 56. However, in the three-layer structure 56, both the inner plastic layer 52 and the outer plastic layer 64 extend along the entire length of the three-layer structure 78 from its first end 58 to its second end 60. In contrast, in the three-layer structure 78, only the inner plastic layer 62 extends along the entire length of the three-layer structure 78, while the outer plastic layer 64 extends between the first position 74 and the second position 76, but does not extend beyond the first position 74 and the second position 76. As a result, a portion 80 of the second surface 70 of the intermediate metal layer 66 is exposed.

[0063] The three-layer structure 78 can be folded and sealed to form each battery cell 12 in the same way as the three-layer structure 56 is folded and sealed to form each battery cell 12. When the battery cell 12 is composed of, as shown in the figure Figure 10 When the three-layer structure 78 shown is formed, the inner plastic layer 62 extends along the two first side surfaces 32 and the two second side surfaces 34. Furthermore, the outer plastic layer 64 and the intermediate metal layer 66 extend along one of the first side surfaces 32 and the two second side surfaces 34, respectively, with the intermediate metal layer 66 extending at least partially along the other side surface 32. The outer plastic layer 64 does not extend along the other side surface 32.

[0064] Furthermore, a portion of the intermediate metal layer 66 protrudes from the other side surface 32 to form a heat dissipation fin 26. Since the outer plastic layer 64 does not extend beyond the first and second positions 74 and 76, the outer plastic layer 64 does not include the portion protruding from the other side surface 32 and surrounding the intermediate metal layer 66. As a result, the protruding portion of the intermediate metal layer 66 is exposed, which can further improve the heat dissipation rate from the battery cell 12 to the cooling plate 16.

[0065] Now for reference Figure 11 and 12 This illustrates another example of a three-layer structure 82 that can be used to form each battery cell 12. The three-layer structure 82 is similar to the three-layer structure 78. However, in the three-layer structure 82, both the inner plastic layer 52 and the outer plastic layer 64 extend between the first position 74 and the second position 76, but do not extend beyond the first position 74 and the second position 76. As a result, a portion 80 of the second surface 70 of the intermediate metal layer 66 is exposed, and a portion 84 of the first surface 68 is also exposed.

[0066] The three-layer structure 82 can be folded and sealed to form each battery cell 12 in the same way that the three-layer structure 56 is folded and sealed to form each battery cell 12. When the battery cell 12 is composed of... Figure 12When the three-layer structure 82 shown is formed, the inner plastic layer 62, the outer plastic layer 64, and the intermediate metal layer 66 extend along one of the first side surfaces 32 and both of the second side surfaces 34. Furthermore, the intermediate metal layer 66 extends at least partially along another side surface 32. The inner plastic layer 62 and the outer plastic layer 64 do not extend along the other side surface 32.

[0067] Furthermore, a portion of the intermediate metal layer 66 protrudes from the other side surface 32 to form a heat dissipation fin 26. Since the outer plastic layer 64 does not extend beyond the first and second positions 74 and 76, the protruding portion of the intermediate metal layer 66 is exposed. Furthermore, since the inner plastic layer 62 does not extend along the other side surface 32, heat within the interior 47 of the battery cell 12 can be transferred at a greater rate through the portion of the intermediate metal layer 66 extending along the other side surface 32. This can further increase the heat dissipation rate from the battery cell 12 to the cooling plate 16.

[0068] Now for reference Figure 13 The method for forming the three-layer structure 78 will now be described. To form the three-layer structure 56, each of the inner plastic layer 62 and the outer plastic layer 64 is formed as a single continuous segment along the length of the intermediate metal layer 66. In contrast, to form the three-layer structure 78, only the inner plastic layer 62 is formed as a single continuous segment along the length of the intermediate metal layer 66. The outer plastic layer 64 is formed as a discontinuous segment along the length of the intermediate metal layer 66, such that a portion 80 of the second surface 70 is exposed. To form... Figure 9 The three-layer structure 78 shown can be cut along plane 86. Figure 13 The three-layer structure 78 shown is such that the exposed portion 80 of the intermediate metal layer 66 forms the first and second ends 58 and 60 of the three-layer structure 78.

[0069] Now for reference Figure 14 The method for forming the three-layer structure 82 will now be described. To form the three-layer structure 56, the inner plastic layer 62 and the outer plastic layer 64 are formed as discontinuous segments along the length of the intermediate metal layer 66, such that portions 80, 84 of the first and second surfaces 68 and 70 are exposed. To form... Figure 11 The three-layer structure shown is part 82. Figure 14 The three-layer structure 78 shown can be cut along the plane 86 such that the exposed portions 80 and 84 of the intermediate metal layer 66 form the first and second ends 58 and 60 of the three-layer structure 82.

[0070] Now for reference Figure 15Another method for forming the three-layer structure 82 will now be described. To form the three-layer structure 82 according to this method, the inner plastic layer 62 is formed as discontinuous and continuous segments along the length of the intermediate metal layer 66, such that only a portion 88 of the first surface 68 is exposed. The exposed portion 88 does not extend through the entire width of the intermediate metal layer 66. In the example shown, the inner plastic layer 62 includes three discontinuous segments along the length of the three-layer structure 82 and a pair of continuous segments along the length of the three-layer structure 82. The continuous segments are disposed on opposite sides of the width of the three-layer structure 82 and include connecting portions 90 that connect the discontinuous segments to each other. The connecting portions 90 of the inner plastic layer 62 are disposed on opposite sides of the exposed portions 88 of the intermediate metal layer 66.

[0071] Furthermore, in order to form the three-layer structure 82 according to this method, the outer plastic layer 64 is formed as a discontinuous segment along the length of the intermediate metal layer 66, such that a portion 80 of the second surface 70 is exposed. Figure 11 The three-layer structure shown is part 82. Figure 15 The three-layer structure 78 shown can be cut along plane 86 such that the exposed portions 80, 88 of the middle metal layer 66 form the first and second ends 58 and 60 of the three-layer structure 82. When the three-layer structure 78 is cut along plane 86, the connecting portion 90 of the inner plastic layer 62 can also form the first and second ends 58 and 60 of the three-layer structure 82.

[0072] Now for reference Figure 16 Battery cell 92 is similar to battery cell 12. However, battery cell 12 includes only one pair of heat dissipation fins 26, which protrude from only one of the first side surfaces 32 of the body 22. In contrast, battery cell 92 includes one pair of heat dissipation fins 26 protruding from one of the first side surfaces 32, and another pair of heat dissipation fins 26 protruding from the other first side surface 32. Battery cell 92 can be stacked... Figure 3 The two unfolded battery cells 12 shown are aligned with each other at their outer peripheries, and then joined together along all four edges of their body 22 to seal the interior 47 of the battery cell 92.

[0073] Battery cell 12 can be used in vertically aligned cell groups, for example Figure 2 The battery pack 10 includes vertically aligned groups of battery cells 12, which also include a cooling plate 16 disposed only on one side of the cell group. In contrast, battery cells 92 can be used in horizontally aligned groups of cells, which are part of a battery pack, and which also include a pair of cooling plates 16 disposed on opposite sides of the cell group. For example, battery cells 92 can be used in... Figure 18 In the battery pack 94 shown, the battery cells 92 are horizontally aligned in a group, or in the battery pack 96, a pair of horizontally aligned groups of battery cells 92 are included, such as... Figure 19 As shown.

[0074] In various embodiments, the battery cell 12 may be included in Figure 18 Alternatively, it can be replaced by battery cell 92 in battery pack 94 or 96. For example, one of the battery cells 12 may be oriented such that its heat distribution tab 26 protrudes in one direction (e.g., toward one of the cooling plates 16 of battery pack 94 or 96), and the battery cells 12 stacked thereon may be oriented such that their heat distribution tabs 26 protrude in the opposite direction (e.g., toward the other cooling plate 16 of battery pack 94 or 96), as... Figure 17 As shown. The orientation of the heat distribution tabs 26 can continue to alternate in this manner to form cell groups of battery packs 92 or 94.

[0075] The foregoing description is illustrative in nature and is by no means intended to limit the invention, its application, or its uses. The broad teachings of this disclosure can be implemented in many forms. Therefore, while this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become apparent upon examination of the drawings, description, and appended claims. It should be understood that one or more steps in the method may be performed in different orders (or simultaneously) without altering the principles of this disclosure. Furthermore, while each embodiment is described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented in and / or combined with features of any other embodiment, even if such combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and substitutions of one or more embodiments for each other remain within the scope of this disclosure.

[0076] Spatial and functional relationships between components (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “joined,” “linked,” “adjacent,” “next to,” “on top,” “above,” “below,” and “set.” Unless explicitly described as “direct,” when describing the relationship between the first and second components in the above disclosure, the relationship can be a direct relationship in which no other intervening components exist between the first and second components, but it can also be an indirect relationship (spatial or functional) between the first and second components with one or more intervening components. As used herein, the phrase at least one of A, B, and C should be interpreted as indicating a logic (A or B or C) using the non-exclusive logic “OR”, and should not be interpreted as indicating “at least one of A, at least one of B, and at least one of C.”

Claims

1. A battery cell, comprising: An inner plastic layer extending along at least three sides of the battery cell; An outer plastic layer extending along at least three sides of the battery cell; and An intermediate metal layer is disposed between an inner plastic layer and an outer plastic layer, the intermediate metal layer extending along at least three sides of the battery cell and protruding from at least a fourth side of the battery cell to form at least one heat dissipation fin, the at least one heat dissipation fin being configured to transfer heat to at least one cooling plate by thermal conduction, the fourth side of the battery cell connecting two of the at least three sides to each other. The inner and outer plastic layers form discontinuous segments along the length of the intermediate metal layer, thus exposing portions of the intermediate metal layer. The inner plastic layer, the outer plastic layer, and the intermediate metal layer form a three-layer structure. This three-layer structure is folded such that the inner plastic layer forms the inner layer of the battery cell, and the ends of the three layers are adjacent to each other. In this embodiment, at least one heat dissipation fin is bent in a direction perpendicular to the side surface of the battery cell, such that at least one heat dissipation fin is parallel to at least one cooling plate.

2. The battery cell of claim 1, wherein the inner plastic layer extends along at least three sides and a fourth side of the battery cell.

3. The battery cell of claim 1, wherein the inner plastic layer extends along at least three sides of the battery cell and not along a fourth side of the battery cell.

4. The battery cell of claim 1, wherein the outer plastic layer extends along at least three sides of the battery cell and at least partially along a fourth side of the battery cell.

5. The battery cell of claim 1, wherein the outer plastic layer further protrudes from a fourth side of the battery cell and surrounds a portion of the intermediate metal layer forming at least one heat dissipation fin.

6. The battery cell of claim 1, wherein the outer plastic layer extends along at least three sides of the battery cell and not along a fourth side of the battery cell.

7. The battery cell according to claim 1, wherein: The inner and outer plastic layers extend along at least three sides of the battery cell but not along a fourth side of the battery cell; and The intermediate metal layer extends along at least three sides and a fourth side of the battery cell.

8. The battery cell of claim 1, wherein the intermediate metal layer protrudes from a fourth side of the battery cell and one of at least three sides of the battery cell to form a pair of heat dissipation fins, the pair of heat dissipation fins being configured to transfer heat to a pair of cooling plates by thermal conduction.

9. The battery cell according to claim 1, wherein: The inner plastic layer is a polypropylene layer; The outer plastic layer is a layer made of nylon, polyethylene terephthalate (PET), or a combination of nylon and polyethylene terephthalate (PET); and The intermediate metal layer is made of aluminum, nickel, titanium, or stainless steel.

10. A method for manufacturing a battery cell, comprising: Form a metal layer; A first plastic layer is formed on one side of the metal layer; A second plastic layer is formed on the other side of the metal layer, forming a three-layer structure with the first and second plastic layers. At least one of the first and second plastic layers forms a discontinuous segment along the length of the metal layer, such that a portion of the metal layer is exposed and the metal layer forms at least one heat dissipation fin. The three-layer structure is cut so that the exposed portions of the metal layers form opposite ends of the three-layer structure; and Heating at least a portion of the first and second plastic layers to form a seal inside the sealed battery cell. The three-layer structure is folded so that the first plastic layer forms the inner layer of the battery cell, and the ends of the three-layer structure are adjacent to each other. and The at least one heat dissipation fin is bent in a direction perpendicular to the side surface of the battery cell.

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