Hexagonal battery cell with wound jelly roll

Abstract

A hexagonal battery cell is disclosed. The battery cell may include a wound jelly roll within a hexagonal housing. The jelly roll may include a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer, and the anode layer are wound together relative to a central axis. The hexagonal shell can surround the periphery of the jelly roll.

Description

Technical Field

[0001] introduction

[0002] The present disclosure relates to battery cells configured for storing and supplying electrical power, such as, but not necessarily limited to, hexagonal battery cells configured for maximizing volumetric efficiency and cell density of a vehicle battery pack. Background Art

[0003] Vehicles may include battery cells to facilitate the storage and supply of electricity for a wide variety of electrical-dependent operations. Although other types of devices may similarly employ battery cells, vehicles with high power requirements (such as vehicles that employ electric motors to propel the vehicle) may include multiple battery cells, which are often contained in one or more battery packs. A battery pack may generally be understood to correspond to a structure configured to accommodate and electrically interconnect multiple battery cells. For vehicles and other devices that employ such battery packs, it may be advantageous to maximize the number of battery cells that can be stored therein in order to maximize volumetric efficiency and cell density. The ability to tightly pack battery cells into close proximity to each other and thereby maximize volumetric efficiency and cell density may be beneficial in minimizing packaging, minimizing battery pack footprint, enabling the use of more battery cells in the same battery pack (e.g., to support higher power applications), permitting the use of different shapes or form factors, improving design flexibility, increasing cost savings, and the like. Summary of the invention

[0004] One non-limiting aspect of the present disclosure relates to a polygonal battery cell, such as but not necessarily limited to a hexagonal battery cell. The hexagonal battery cell may include a hexagonal housing surrounding the perimeter of a jelly roll. The hexagonal housing may include a plurality of flat faces arranged in a hexagonal shape so that the flat faces of a plurality of battery cells may be packaged in a side-by-side facing relationship to maximize the volumetric efficiency and cell density of the battery pack.

[0005] One non-limiting aspect of the present disclosure relates to a battery cell. The battery cell may include a jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer, and the anode layer are wound together relative to a central axis. The battery cell may further include a hexagonal shell surrounding the periphery of the jelly roll, optionally wherein the hexagonal shell includes six faces and six vertices, wherein each vertex occurs at a pair of adjacent faces of the faces.

[0006] The cathode layer may include a non-uniform variable thickness, wherein a plurality of first cathode segments having a first thickness are interposed between a plurality of second cathode segments having a second thickness, the second thickness being greater than the first thickness.

[0007] The second cathode segments may be spaced apart from one another along the length of the cathode layer such that each second cathode segment, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0008] The anode layer may include a non-uniform variable thickness, wherein a plurality of first anode segments having a first thickness are interposed between a plurality of second anode segments having a second thickness, the second thickness being greater than the first thickness.

[0009] The second anode segments may be spaced apart from one another along the length of the anode layer such that each second anode segment, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0010] The battery cell may include a plurality of cathode current collector tabs spaced apart from one another along a length of the cathode layer such that each cathode current collector tab, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0011] The battery cell may include a plurality of anode current collector tabs spaced apart from one another along a length of the anode layer such that each anode current collector tab, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0012] The membrane layer may comprise a uniform continuous thickness.

[0013] The hexagonal shell may include a regular hexagonal configuration in which the faces have equal lengths and the vertices have equal angles.

[0014] The hexagonal shell may include an irregular hexagonal configuration in which at least one of the following occurs: one or more of the faces have unequal lengths; and one or more of the vertices have unequal angles.

[0015] The jelly roll and the central axis may be circular.

[0016] The jelly roll and the central axis may be hexagonal.

[0017] One non-limiting aspect of the present disclosure relates to a battery cell. The battery cell may include a jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer, and the anode layer are wound together relative to a central axis. The battery cell may further include a polygonal shell surrounding the periphery of the jelly roll, optionally wherein the polygonal shell includes a plurality of straight shell faces and a plurality of shell vertices, wherein each shell vertex occurs at a pair of adjacent faces of the straight shell face.

[0018] The cathode layer may include a plurality of first cathode segments having a first thickness interposed between a plurality of second cathode segments having a second thickness greater than the first thickness, optionally wherein the second cathode segments are spaced apart from one another along the length of the cathode layer such that each second cathode segment is aligned with one of a plurality of radii when wound, the plurality of radii extending from a central axis to each of the vertices.

[0019] The anode layer may include a plurality of first anode segments having a first thickness interposed between a plurality of second anode segments having a second thickness greater than the first thickness, optionally wherein the second anode segments are spaced apart from one another along the length of the anode layer such that each second anode segment is aligned with one of the radii when wound.

[0020] The battery cell may include a plurality of cathode current collector tabs spaced apart from one another along the length of the cathode layer such that each cathode current collector tab, when wound, is aligned with one of the radii extending from the central axis to each of the vertices.

[0021] The battery cell may include a plurality of anode current collector tabs spaced apart from one another along the length of the anode layer such that each anode current collector tab is aligned with one of the radii when wound.

[0022] The polygonal shell may comprise a regular polygonal configuration in which the straight shell faces have equal lengths and the shell vertices have equal angles.

[0023] The polygonal shell may include an irregular polygonal configuration in which at least one of the following occurs: one or more of the straight shell faces have unequal lengths; and one or more of the shell vertices have unequal angles.

[0024] The jelly roll may include a plurality of straight roll faces and a plurality of roll vertices arranged concentrically with a corresponding one of the shell face and the shell vertex.

[0025] The straight roll face and the roll vertex may abut the corresponding one of the shell face and the shell vertex.

[0026] A non-limiting aspect of the present disclosure relates to a battery cell system. The system may include a plurality of battery cells, optionally wherein each battery cell includes: a polygonal housing including a plurality of straight housing faces and a plurality of housing vertices, wherein one of a plurality of radii extends from a central axis to each of the vertices; and a polygonal jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer, and the anode layer are wound together relative to the central axis. The polygonal jelly roll may include a plurality of straight roll faces and a plurality of roll vertices arranged concentrically relative to a matching one of the housing faces and the housing vertices. The system may further include a group housing containing the battery cells in a side-by-side manner such that one of the straight housing faces of each battery cell abuts no more than one straight housing face of each adjacent battery cell in the battery cell.

[0027] The present invention may also include the following aspects.

[0028] 1. A battery cell, comprising:

[0029] a jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer, and the anode layer are rolled together about a central axis; and

[0030] A hexagonal shell surrounds the perimeter of the jelly roll, the hexagonal shell comprising six faces and six vertices, wherein each vertex occurs at a pair of adjacent ones of the faces.

[0031] 2. The battery cell according to claim 1, wherein:

[0032] The cathode layer has a non-uniform variable thickness, wherein a plurality of first cathode segments having a first thickness are interposed between a plurality of second cathode segments having a second thickness, the second thickness being greater than the first thickness.

[0033] 3. The battery cell according to claim 2, wherein:

[0034] The second cathode segments are spaced apart from one another along the length of the cathode layer such that each second cathode segment, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0035] 4. The battery cell according to claim 1, wherein:

[0036] The anode layer has a non-uniform varying thickness, wherein a plurality of first anode segments having a first thickness are interposed between a plurality of second anode segments having a second thickness, the second thickness being greater than the first thickness.

[0037] 5. The battery cell according to claim 4, wherein:

[0038] The second anode segments are spaced apart from one another along the length of the anode layer such that each second anode segment, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0039] 6. The battery cell according to claim 1, further comprising:

[0040] A plurality of cathode current collector tabs are spaced apart from one another along the length of the cathode layer such that each cathode current collector tab, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0041] 7. The battery cell according to claim 1, further comprising:

[0042] A plurality of anode current collector tabs are spaced apart from one another along the length of the anode layer such that each anode current collector tab, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

[0043] 8. The battery cell according to claim 1, wherein:

[0044] The diaphragm layer has a uniform continuous thickness.

[0045] 9. The battery cell according to claim 1, wherein:

[0046] The hexagonal shell has a regular hexagonal configuration, wherein the faces have equal lengths and the vertices have equal angles.

[0047] 10. The battery cell according to claim 1, wherein:

[0048] The hexagonal shell has an irregular hexagonal configuration, wherein at least one of the following occurs:

[0049] One or more of the faces are of unequal lengths; and

[0050] One or more of the vertices have unequal angles.

[0051] 11. The battery cell according to claim 1, wherein:

[0052] The jelly roll is circular; and

[0053] The central axis is circular.

[0054] 12. The battery cell according to claim 1, wherein:

[0055] The jelly roll is hexagonal; and

[0056] The central axis is hexagonal.

[0057] 13. A battery cell comprising:

[0058] a jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer, and the anode layer are rolled together about a central axis; and

[0059] A polygonal shell surrounds the perimeter of the jelly roll, the polygonal shell comprising a plurality of straight shell faces and a plurality of shell vertices, wherein each shell vertex occurs at a pair of adjacent ones of the straight shell faces.

[0060] 14. The battery cell according to claim 13, wherein:

[0061] the cathode layer comprising a plurality of first cathode segments having a first thickness interposed between a plurality of second cathode segments having a second thickness, the second thickness being greater than the first thickness, wherein the second cathode segments are spaced apart from one another along a length of the cathode layer such that each second cathode segment is aligned with one of a plurality of radii when wound, the plurality of radii extending from the central axis to each of the vertices; or

[0062] The anode layer comprises a plurality of first anode segments having a first thickness interposed between a plurality of second anode segments having a second thickness greater than the first thickness, wherein the second anode segments are spaced apart from one another along the length of the anode layer such that each second anode segment is aligned with one of the radii when wound.

[0063] 15. The battery cell according to claim 14, further comprising:

[0064] a plurality of cathode current collector tabs spaced apart from one another along the length of the cathode layer such that each cathode current collector tab, when wound, is aligned with one of the radii extending from the central axis to each of the vertices; or

[0065] A plurality of anode current collector tabs are spaced apart from one another along the length of the anode layer such that each anode current collector tab is aligned with one of the radii when wound.

[0066] 16. The battery cell according to claim 13, wherein:

[0067] The polygonal shell comprises a regular polygonal configuration wherein the straight shell faces have equal lengths and the shell vertices have equal angles.

[0068] 17. The battery cell according to claim 13, wherein:

[0069] The polygonal shell comprises an irregular polygonal configuration, wherein at least one of the following occurs:

[0070] One or more of the straight housing faces are of unequal lengths; and

[0071] One or more of the shell vertices have unequal angles.

[0072] 18. The battery cell according to claim 13, wherein:

[0073] The jelly roll includes a plurality of straight roll faces and a plurality of roll vertices that are concentrically arranged with a corresponding one of the outer shell face and the outer shell vertex.

[0074] 19. The battery cell according to claim 18, wherein:

[0075] The straight roll surface and the roll vertex are adjacent to the corresponding one of the shell surface and the shell vertex.

[0076] 20. A battery cell system comprising:

[0077] A plurality of battery cells, each battery cell comprising:

[0078] a polygonal shell comprising a plurality of straight shell faces and a plurality of shell vertices, wherein one of a plurality of radii extends from a central axis to each of the vertices; and

[0079] A polygonal jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer and the anode layer are rolled together relative to the central axis, the polygonal jelly roll comprising the plurality of straight roll faces and the plurality of roll vertices arranged concentrically relative to a matching one of the shell faces and the shell vertices; and

[0080] A pack housing contains the battery cells in a side-by-side manner such that one of the straight housing faces of each battery cell abuts no more than one of the straight housing faces of each adjacent one of the battery cells.

[0081] These features and advantages of the present teaching, together with other features and advantages, are apparent from the following detailed description of the mode for implementing the present teaching in conjunction with the accompanying drawings. It should be understood that even though the following figures and embodiments may be described separately, their single features may also be combined into additional embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0082] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0083] Figure 1 A vehicle having a battery pack according to one non-limiting aspect of the present disclosure is illustrated.

[0084] Figure 2 A battery cell according to one non-limiting aspect of the present disclosure is illustrated.

[0085] Figure 3 A schematic diagram of a battery pack according to one non-limiting aspect of the present disclosure is illustrated.

[0086] Figure 4 A cross-sectional view of a battery cell according to one non-limiting aspect of the present disclosure is illustrated.

[0087] Figure 5 Illustrated is a partial top view of a tabless jelly roll according to one non-limiting aspect of the present disclosure.

[0088] Figure 6 Illustrated is a cross-sectional view of a tabless jelly roll according to one non-limiting aspect of the present disclosure.

[0089] Figure 7 A cross-sectional view of a battery cell including a tabless jellyroll according to one non-limiting aspect of the present disclosure is illustrated.

[0090] Figure 8 A partial top view of a tabbed jelly roll according to one non-limiting aspect of the present disclosure is illustrated.

[0091] Fig. 9 Illustrated is a cross-sectional view of a tabbed jelly roll according to one non-limiting aspect of the present disclosure.

[0092] Fig.10 A cross-sectional view of a battery cell including a tabbed jellyroll according to one non-limiting aspect of the present disclosure is illustrated. DETAILED DESCRIPTION

[0093] As required, detailed embodiments of the present disclosure are disclosed herein; however, it will be understood that the disclosed embodiments are merely examples of the present disclosure, which may be embodied in various and alternative forms. The figures are not necessarily drawn to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein are not to be construed as limiting, but merely as a representative basis for teaching those skilled in the art to adopt the present disclosure in various ways.

[0094] Figure 1A vehicle 10 having a battery pack 12 is illustrated according to one non-limiting aspect of the present disclosure. The vehicle 10 may be configured with a propulsion system, powertrain, or other drivetrain having an electric motor or other electric drive device operable to propel or otherwise drive the vehicle 10. Alternatively, the vehicle 10 may be a hybrid type vehicle 10 having an internal combustion engine (ICE) operating in conjunction with the electric motor. The ICE and the electric motor or other device configured to convert electrical power into mechanical power may cooperate to provide rotational force / torque to one or more of a plurality of wheels. The powertrain may include a gearbox, a drive shaft, a differential, an axle, and / or other components that facilitate the delivery of rotational force from the ICE and / or motor to the wheels. The vehicle 10 may include a controller to generate control signals associated with directing and otherwise implementing desired control of the powertrain, motor, ICE, and / or other features of the vehicle 10. For non-limiting purposes, the vehicle 10 is presented as representing a variety of vehicles and / or other devices that may rely on the battery pack 12 to supply and store electrical power. The battery pack 12 may, for example, be included as part of a rechargeable energy storage system (RESS) operable to supply and store power for a motor and / or other onboard and / or off-board systems of the vehicle 10 .

[0095] The vehicle 10 may be generally referred to as an electric vehicle and includes a wide range of capabilities that support the conversion of electricity into mechanical power. The vehicle 10 is contemplated to include different configurations to generate, store, and supply electricity to an electric motor and / or other onboard devices or systems of the vehicle 10, optionally in place of or in conjunction with the battery pack 12. As described in more detail below, the battery pack 12 may include a plurality of polygonal battery cells 14 packaged together in a side-by-side facing relationship. The battery cells 14 may be housed within a structure of the battery pack 12, which, for non-limiting purposes, is illustrated as including a pack housing 16 having a plurality of walls configured to surround the battery cells 14. The battery pack 12 may include circuitry (not shown) to electrically interconnect the battery cells 14 and / or selectable multiple groups of battery cells 14 for the purpose of exchanging power with other onboard and non-onboard components of the vehicle 10. For non-limiting purposes, the battery cells 14 presented herein are primarily described with respect to being included within a battery pack 12 , as the present disclosure fully contemplates battery cells 14 being useful and advantageous in a wide variety of applications, including applications that may not package multiple battery cells 14 within the same structure.

[0096] Figure 2A battery cell 14 is illustrated according to one non-limiting aspect of the present disclosure. The battery cell 14 may include a polygonal battery housing 18 having a plurality of faces 20, 22, 24, 26, 28, 30 disposed between a top end cap 34 and a bottom end cap 36, and a power generation feature 40 disposed at its periphery, which, as will be appreciated by those skilled in the art, may be referred to as a jelly roll 40. The top end cap 34 and the bottom end cap 36 may include terminals, connectors, and / or other features 42 adapted to establish electrical conductivity with the jelly roll 40. For non-limiting purposes, the polygonal battery housing 18 is illustrated as being hexagonal in shape, having six faces 20, 22, 24, 26, 28, 30 and six vertices 44, 46, 48, 50, 52, 54, which faces and vertices may each include a blended radius (e.g., 0.5-5 mm) to present a smoother surface and avoid sharp corners. Although the polygonal housing 18 is shown in the form of a hexagon, the present disclosure fully contemplates housings 18 having other polygonal shapes and configurations, including being shaped as a triangle (3 faces), a quadrilateral (4 faces), a pentagon (5 faces), a heptagon (7 faces), an octagon (8 faces), a nonagon (9 faces), a decagon (10 faces), etc. For non-limiting purposes, the battery housing 18 is also described as including a polygonal shape, as the present disclosure fully contemplates battery housings 18 including other non-polygonal shapes. A polygonal shape (or more specifically, being shaped to include one or more straight or flat faces 20, 22, 24, 26, 28, 30, such as the illustrated hexagonal shaping with multiple flat faces 20, 22, 24, 26, 28, 30) can be beneficial in enabling the battery cells 14 to be packed closely together to minimize gaps between adjacent battery cells 14. The ability to closely pack battery cells 14 to other battery cells 14 may be beneficial in many implementations, and particularly with respect to achieving a side-by-side facing relationship that is utilized to maximize volumetric efficiency and cell density of the battery pack 12 .

[0097] Figure 3A schematic diagram of a battery pack 12 according to one non-limiting aspect of the present disclosure is illustrated. For illustrative purposes, the battery pack 12 is shown relative to a pack housing 16 having an angled box-shaped configuration, wherein one of the walls 60 is formed at an angle to provide an inclined profile. This is presented for non-limiting purposes, as the present disclosure fully contemplates pack housings 16 having other shapes and configurations, optionally wherein the battery pack 12 includes a plurality of separate pack housings 16 that are separately interconnected with each other. The illustrated shaping of the pack housing 16 is presented to highlight the common configuration of the battery pack 12 when included on an electric vehicle 10 (due to the fact that electric vehicles often have external dimensions or other constraints), whereby flat or straight faces of different sizes may be required. Even if the pack housing 16 has other configurations (including arched or curved walls or features), the advantageous ability of the battery cell 14 configuration described herein to facilitate packing the battery cells 14 closely in a side-by-side relationship in close proximity to each other can also be apparent from the lack of unused or wasted space between the battery cells 14 and / or walls. The ability to pack the battery cells 14 tightly within the battery pack 12 (such as by placing the planar face of one battery cell 14 against the planar face of another battery cell 14 or a wall of the pack case) may be useful in maximizing cell density.

[0098] Figure 4 A schematic cross-sectional view of a battery cell 14 according to one non-limiting aspect of the present disclosure is illustrated. A jelly roll 40 may be disposed within a battery housing 18, optionally extending from the top to the bottom between a top end cap 34 and a bottom end cap 36. The jelly roll 40 may include a plurality of layers 62, 64, 66, 68, which may include a first separator layer 62, a cathode layer 64, a second separator layer 66, and an anode layer 68. The layers 62, 64, 66, 68 may be wound together relative to a central axis 70 of a mandrel 72, and once disposed within the battery housing 18, an electrolyte (not shown) may be included therewith. Although the jelly roll 40 may be non-polygonal, it is presented as having a polygonal shape that matches the battery housing 18. The jelly roll 40 may include a plurality of straight roll faces and a plurality of roll vertices arranged concentrically with a corresponding one of the housing faces 20, 22, 24, 26, 28, 30 and the housing vertices 44, 46, 48, 50, 52, 54. As will be appreciated by those skilled in the art, the jelly roll 40 may include a wide variety of configurations, layers, materials, etc. to facilitate storing and supplying power. Thus, for non-limiting purposes, the illustrated layers are presented as merely illustrative of common components that are typically included as at least a portion of the jelly roll 40. The battery cell 14 may be configured in this manner to correspond to what those skilled in the art may refer to as a prismatic battery cell 14 or a battery cell 14 with a prismatic can. This is also done for non-limiting purposes, as the present disclosure fully contemplates battery cells 14 having other configurations.

[0099] In some embodiments, the battery cell 14 may be constructed as a type of lithium-ion battery, which may optionally have: a negative current collector layer comprising copper; an anode electrode layer 68 comprising a material selected from the group consisting of graphite, lithium titanate, silicon / carbon, or tin / cobalt alloy, or a combination thereof; a separator layer 62, 66 comprising a microporous polyolefin polymer selected from the group consisting of microporous polyethylene (PE), microporous polypropylene (PP) or microporous polyethylene terephthalate (PET) and combinations thereof; and a cathode electrode layer 64 comprising a compound selected from the group consisting of lithium metal oxide, LiCoO2 (LCO), LiMn2O4 (LMO), LiFePO4 (LFP), nickel manganese cobalt oxide (NMC), or nickel cobalt aluminum oxide (NCA) and combinations thereof; and a positive current collector layer 42 comprising aluminum.

[0100] The jelly roll 40 may be configured to include a volumetrically contiguous fit with the battery housing 18. The volumetrically contiguous fit may be characterized by the jelly roll 40 being contiguous with, in contact with, or in close proximity to each of the faces 20, 22, 24, 26, 28, 30 and the vertices 44, 46, 48, 50, 52, 54, such that the jelly roll 40 may be considered to effectively fill the entire cross-sectional area of ​​the battery housing 18. In the event that additional components (not shown) may be included as part of the jelly roll 40 and / or the battery cell 14, the jelly roll 40 may similarly be configured to minimize the amount of unused or unoccupied space within the battery housing 18. The jelly roll 40 is shown wound relative to a mandrel, which may include a hexagonal shape to facilitate orienting, pushing, or otherwise positioning the layers into or relative to the vertices 44, 46, 48, 50, 52, 54. However, the hexagonal mandrel may be shaped differently (such as by having a rounded or flatter cross-section), and / or the jelly roll 40 may be wound and / or placed within the battery housing 18 without the use of the mandrel 72 .

[0101] The battery housing 18 can be configured to include a plurality of radii 74, 76, 78, 80, 82, 84, wherein each of these radii 74, 76, 78, 80, 82, 84 extends from the central axis to a corresponding one of the vertices 44, 46, 48, 50, 52, 54. The battery housing is shown as including a regular polygonal (hexagonal) configuration, provided that each of the faces 20, 22, 24, 26, 28, 30 has an equal length, each of the vertices 44, 46, 48, 50, 52, 54 has an equal angle, and each of the radii 74, 76, 78, 80, 82, 84 has an equal length and relative spacing. The battery housing 18 may alternatively be configured with an irregular polygonal (hexagonal) configuration, such as by having one or more of the faces 20, 22, 24, 26, 28, 30 have unequal lengths, and / or one or more of the vertices 44, 46, 48, 50, 52, 54 have unequal angles. The battery pack 12 may alternatively be configured with battery cells 14 having different structures, such as by including some battery cells 14 having a regular polygonal configuration and including other battery cells 14 having an irregular polygonal configuration. Return to Figure 3 , the battery cells 14 are each shown as having a regular hexagonal configuration, which, at least with respect to manufacturing, may be beneficial in minimizing manufacturing complexity when mounting, packaging, or otherwise arranging the battery cells 14 within the battery pack 12 without having to specifically orient each battery cell 14 to account for some battery cells 14 having different shapes, sizes, etc.

[0102] Figure 5 A partial top view of a tabless jelly roll 90 according to one non-limiting aspect of the present disclosure is illustrated. The tabless jelly roll 90 can be configured for use within the battery cell 14 described above, and as described in more detail below, can be particularly useful for maximizing the volume footprint of a polygonal battery housing (such as the polygonal battery housing 18 described above). The tabless configuration can be characterized as follows: the tabless jelly roll 90 omits current collector tabs, electrodes, or other included items for assisting in providing electrical connection to the end caps 34, 36 or other interfaces of the battery cell 14. Figure 6 A cross-sectional view of an unfolded tabless jelly roll 90 is illustrated in accordance with one non-limiting aspect of the present disclosure. Tabless jelly roll 90 is shown as being constructed similarly to jelly roll 40 described above in terms of including a plurality of layers 94, 96, 98, 100, namely a first separator layer 94, a cathode layer 96, a second separator layer 98, and an anode layer 100. Figure 7 Illustrated is a cross-sectional view of a battery cell 14 including a tabless wound jelly roll 90 in accordance with one non-limiting aspect of the present disclosure.

[0103] The tabless jelly roll 90 may include a first separator layer 94, a second separator layer 96, and a cathode layer 98 having uniform thicknesses, and an anode layer 100 having a non-uniform variable thickness. The non-uniform variable thickness anode layer 100 may correspond to a plurality of first anode segments 102 interposed between a plurality of second anode segments 104, wherein the first anode segments 102 have a first thickness, and the second anode segments 104 have a second thickness greater than the first thickness. Figure 7 , when the tabless jelly roll 90 is rolled and disposed within the battery housing 18, the second anode segments 102 may each individually align with a corresponding one of the radii 74, 76, 78, 80, 82, 84. The second anode segments 102 may be arranged in such a manner that the second anode segments 102 align with the radii 74, 76, 78, 80, 82, 84 and the vertices 44, 46, 48, 50, 52, 54 upon insertion into the battery housing, and / or the tabless jelly roll 90 may be rolled, compressed, or otherwise configured so as to expand once inserted into the battery housing 18 so that the second anode segments thereafter align with the radii 74, 76, 78, 80, 82, 84 and the vertices 44, 46, 48, 50, 52, 54. The tabless jelly roll 90 can utilize the second or extended anode segment 104 in this manner to minimize the unused space between the outer perimeter of the jelly roll 40 and the inner perimeter of the battery housing 18. Alternatively and / or additionally, the cathode layer 96 can similarly include interposed first and second cathode segments (not shown) that similarly have different first and second thicknesses to achieve the purpose of aligning the second or extended cathode segment with the apex 44, 46, 48, 50, 52, 54 in a similar manner. At least compared to a circular jelly roll (not shown), the tabless jelly roll 90 can protrude further into the apex 44, 46, 48, 50, 52, 54 to minimize unused space and maximize volume occupancy.

[0104] Figure 8 A partial top view of a tabbed jelly roll 110 according to one non-limiting aspect of the present disclosure is illustrated. The tabbed jelly roll 110 can be configured for use within the battery cell 14 described above, and as described in more detail below, can be particularly useful for maximizing the volume footprint of a polygonal battery housing (such as the polygonal battery housing 18 described above). The tabbed configuration can be characterized as follows: The tabbed jelly roll 110 includes current collector tabs, electrodes, or other included items 112, 114 for facilitating electrical connection with the end caps 34, 36 or other interfaces of the battery cell 14. Fig. 9A cross-sectional view of a tabbed jelly roll 110 according to one non-limiting aspect of the present disclosure is illustrated. The tabbed jelly roll 110 is shown to be constructed similarly to the jelly roll 40 and the tabless jelly roll 90 described above in terms of including a plurality of layers 118, 120, 122, 124, namely a first separator layer 118, a cathode layer 120, a second separator layer 122, and an anode layer 124. Fig.10 A cross-sectional view of a battery cell 14 including a tabbed jelly roll 110 is illustrated in accordance with one non-limiting aspect of the present disclosure.

[0105] The tabbed jelly roll 110 may include cathode current collector tabs 114 attached to the cathode layer 120 and spaced apart along the length of the cathode layer, and anode current collector tabs 112 attached to the anode layer 124 and spaced apart along the length of the anode layer. Fig.10 As shown in , when the tabbed jelly roll 110 is wound and disposed within the battery housing 18, the cathode current collector tab 114 and the anode current collector tab 112 can each be individually aligned with a corresponding one of the radii 74, 76, 78, 80, 82, 84 and vertices 44, 46, 48, 50, 52, 54 of the battery housing 18. The cathode and anode current collector tabs 114, 112 may be arranged in such a manner that the cathode and anode current collector tabs 114, 112 are aligned with the radii 74, 76, 78, 80, 82, 84 and vertices 44, 46, 48, 50, 52, 54 when inserted, and / or the tabbed jelly roll 110 may be rolled, compressed, or otherwise configured to expand once inserted into the battery housing 18 so that the cathode and anode current collector tabs 114, 112 are thereafter aligned with the radii 74, 76, 78, 80, 82, 84 and vertices 44, 46, 48, 50, 52, 54. The tabbed jelly roll 110 may utilize the cathode and anode current collector tabs 114, 112 in such a manner as to minimize unused space between the outer perimeter of the tabbed jelly roll 110 and the inner perimeter of the battery housing 18. The tabbed jelly roll 110 may protrude further into the apex 44, 46, 48, 50, 52, 54 in order to minimize unused space and maximize volumetric occupation, at least as compared to a circular jelly roll (not shown).

[0106] As supported above, due to the greater advantages of maximizing the volumetric efficiency of polygonal battery cells and improving battery density, the present disclosure contemplates the use of replacing cylindrical battery cells and form factors in battery packs with polygonal battery cells described herein. Hexagonal cells can be used, for example, to minimize the gap between cells and the unutilized space between cells and the RESS boundary, thereby improving the volumetric efficiency of the battery pack. The hexagonal cells may include circular or hexagonally wound jelly rolls. The hexagonally wound jelly rolls may be produced during the jelly roll winding process, or formed by pressing circular jelly rolls. The battery cells contemplated herein may include the form factors of a hexagonal hard shell, optionally with small rounded corners or mixed corners within the vertices.

[0107] The terms "comprising", "including" and "having" are inclusive and thus specify the presence of the stated features, steps, operations, elements or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements or parts. Where possible, the order of steps, processes and operations may be changed, and additional or alternative steps may be adopted. As used in this specification, the term "or" includes any one and all combinations of the associated listed items. The term "any of" is understood to include any possible combination of the referenced items, including "any of" the referenced items. "One", "an", "the", "at least one" and "one or more" are used interchangeably to indicate that there is at least one of the items. Unless the context clearly indicates otherwise, there may be multiple such items. Unless otherwise clearly or clearly indicated by the context (including the appended claims), all parameter (e.g., quantity or condition) values ​​will be understood to be modified by the term "about" in all cases, regardless of whether "about" actually appears before the value. A component "configured to" perform a specified function is capable of performing the specified function without modification, rather than merely having the potential to perform the specified function after further modification. In other words, the hardware described, when expressly configured to perform a specified function, is selected, created, implemented, utilized, programmed, and / or designed specifically for the purpose of performing the specified function.

[0108] Although various embodiments have been described, the description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that there are still more embodiments and implementations possible within the scope of the embodiments. Unless specifically limited, any feature of any embodiment may be used in combination with any other feature or element in any other embodiment, or may replace any other feature or element in any other embodiment. Therefore, the embodiments will not be limited except for considering the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims. Although several modes for implementing many aspects of the present teachings have been described in detail, technicians familiar with the fields to which these teachings relate will recognize various alternative aspects for practicing the present teachings within the scope of the appended claims. It is expected that all matters contained in the above description or shown in the drawings should be interpreted as illustrating and illustrating the entire range of alternative embodiments that ordinary technicians will recognize, such as implied by the included content, structurally and / or functionally equivalent to the included content, or otherwise presented as obvious based on the included content, and are not recognized as being limited to those embodiments that are explicitly depicted and / or described.

Claims

1. A battery cell, comprising: a jelly roll having a separator layer sandwiched between a cathode layer and an anode layer, wherein the separator layer, the cathode layer and the anode layer are rolled together about a central axis; as well as A hexagonal shell surrounds the perimeter of the jelly roll, the hexagonal shell comprising six faces and six vertices, wherein each vertex occurs at a pair of adjacent ones of the faces.

2. The battery cell according to claim 1, wherein: The cathode layer has a non-uniform variable thickness, wherein a plurality of first cathode segments having a first thickness are interposed between a plurality of second cathode segments having a second thickness, the second thickness being greater than the first thickness.

3. The battery cell according to claim 2, wherein: The second cathode segments are spaced apart from one another along the length of the cathode layer such that each second cathode segment, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

4. The battery cell according to claim 1, wherein: The anode layer has a non-uniform varying thickness, wherein a plurality of first anode segments having a first thickness are interposed between a plurality of second anode segments having a second thickness, the second thickness being greater than the first thickness.

5. The battery cell according to claim 4, wherein: The second anode segments are spaced apart from one another along the length of the anode layer such that each second anode segment, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

6. The battery cell according to claim 1, further comprising: A plurality of cathode current collector tabs are spaced apart from one another along the length of the cathode layer such that each cathode current collector tab, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

7. The battery cell according to claim 1, further comprising: A plurality of anode current collector tabs are spaced apart from one another along the length of the anode layer such that each anode current collector tab, when wound, is aligned with one of a plurality of radii extending from the central axis to each of the apexes.

8. The battery cell according to claim 1, wherein: The diaphragm layer has a uniform continuous thickness.

9. The battery cell according to claim 1, wherein: The hexagonal shell has a regular hexagonal configuration, wherein the faces have equal lengths and the vertices have equal angles.

10. The battery cell according to claim 1, wherein: The hexagonal shell has an irregular hexagonal configuration, wherein at least one of the following occurs: One or more of the faces are of unequal lengths; and One or more of the vertices have unequal angles.

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