Energy storage cell

Abstract

The present invention relates to a system for incorporating one or more separate energy cells. A separate energy cell includes a top surface having a center terminal and an external terminal. The top surface may include a pressure discharge element configured for discharging in an opposite direction of the bottom surface. The first and second terminals may be substantially planar electrical contacts.

Description

[0001] Incorporation by reference into any priority application

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 366,454, filed on June 15, 2022, the entire disclosure of which is incorporated herein by reference for all purposes. background Technical Field

[0004] The present disclosure relates generally to energy storage devices, and in particular to improved energy storage device housings. Background Art

[0005] In general, a number of devices or components may be powered at least in part by a power source or energy storage device. In the context of a vehicle, an electric vehicle may be powered in whole or in part by a power source. An example of a power source for an electric vehicle may be a "battery," which may represent a single battery cell ("cell") or multiple cells used in a module and / or pack. In some approaches, a cluster of cells may be considered a separate module and a cluster of modules may be considered a pack. Power sources for electric vehicles may be installed and maintained in a pack configuration. Similar approaches / terms may be applied to grid storage applications for collecting, storing, and distributing energy.

[0006] Electric vehicles typically require a large amount of power, for example, a thousand times more powerful than a typical consumer product (e.g., a mobile device). In order to achieve these power requirements, the energy storage pack (e.g., battery pack) of an electric vehicle typically includes a large, dense arrangement of individual cells placed individually or configured into multiple modules. The composition and performance of the energy storage pack will depend on the characteristics of the individual cells, the total number of individual cells incorporated into the energy storage pack, and the configuration / orientation of the cells and auxiliary components into the modules or energy storage pack. The energy storage pack can represent one of the most expensive and bulky assemblies in the context of most electric vehicle transportation and grid storage applications.

[0007] Due to the large amount of power stored in an energy storage device, the energy storage device may have the ability to cause damage to the surrounding environment (e.g., vehicle components and other energy storage devices) and / or injure individuals in the event that a cell is defective or damaged. Therefore, energy storage device safety features can help reduce the damage and injuries that may be caused by these cells. Summary of the invention

[0008] In order to summarize the present invention and the advantages achieved over the prior art, certain objects and advantages of the present invention are described herein. In any particular embodiment of the present invention, not all of these objects or advantages may be achieved. Thus, for example, those skilled in the art will recognize that the present invention may be embodied or performed in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as taught or suggested herein.

[0009] In one aspect, an energy cell is disclosed. The energy cell comprises: a circular top surface having a center terminal, an outer terminal, and a terminal insulator washer, wherein the circular top surface comprises a pressure discharge element, wherein the center terminal and the outer terminal are configured as electrical contacts, wherein the center terminal is surrounded by the outer terminal, wherein the pressure discharge element surrounds the center terminal and the outer terminal, wherein the center terminal and the outer terminal are separated by the terminal insulator washer, wherein the terminal insulator washer is an electrical insulator; and wherein the pressure discharge element is configured to be at least partially removed in response to a discharge force in an opposite direction along the bottom surface; a side surface, which is mechanically connected to the top surface; a circular bottom surface, which is mechanically connected to the side surface, the side surface having an annular interface, wherein the annular interface is configured to form a base of the cell; and energy storage material within the top surface, the side surface, and the bottom surface.

[0010] In some embodiments, the top surface and the side surface are contiguous. In some embodiments, the area of ​​the center terminal and the area of ​​the outer terminals are configured to be related. In some embodiments, the area of ​​the center terminal and the area of ​​the outer terminals are determined based on a threshold value of the statistical likelihood that a single cell array-level interconnect soldering or other assembly process will succeed.

[0011] In another aspect, an energy cell is disclosed. The energy cell includes: a top surface having a center terminal and an outer terminal, wherein the first terminal and the second terminal are configured as substantially planar electrical contacts, wherein the top surface includes a pressure discharge element configured to discharge in an opposite direction of the bottom surface; a side surface that is mechanically connected to the top surface; wherein the bottom surface is mechanically connected to the side surface; and energy storage material within the top surface, the side surface, and the bottom surface.

[0012] In some embodiments, the top surface is substantially circular. In some embodiments, the center terminal and the outer terminals substantially cover the top surface. In some embodiments, the pressure discharge element is defined to surround the first terminal and the second terminal. In some embodiments, in response to the discharge ground in the opposite direction of the bottom surface, a first portion of the top surface is removed. In some embodiments, in response to the discharge ground in the opposite direction of the bottom surface, at least one second portion of the top surface remains intact. In some embodiments, the center terminal and the outer terminals are separated by a terminal insulator washer, wherein the terminal insulator washer is an electrical insulator. In some embodiments, the center terminal is a cathode and the outer terminal is an anode. In some embodiments, the area of ​​the center terminal and the area of ​​the outer terminal are configured to be related.

[0013] In some embodiments, the area of ​​the center terminal and the area of ​​the external terminals are determined based on a threshold value of the statistical probability that the interconnect welding or other assembly process at the single cell array level will succeed. In some embodiments, the discharge element defines an area surrounding at least one of the external terminals or the center terminal for attaching at least one positive lead and at least one negative lead, the at least one positive lead and the at least one negative lead corresponding to the interconnect welding at the array level. In some embodiments, in response to the discharge ground in the opposite direction of the top surface, at least one negative lead and the positive lead are cut off. In some embodiments, the top surface and the side surface are adjacent. In some embodiments, the top surface is sufficiently ferrous to allow movement by manufacturing equipment via magnetic adhesion. In some embodiments, the bottom surface has an annular interface configured to form a substrate for a single cell.

[0014] In another aspect, a battery system is disclosed. The battery system includes: a plurality of cells, wherein each cell includes: a top surface having a center terminal and an outer terminal, wherein the first terminal and the second terminal are configured as electrical contacts, wherein the top surface includes a vent element configured to separate from a portion of the top surface in response to a pressure peak, the portion of the top surface being defined by an area defined by the vent element; a side surface mechanically connected to the top surface; a bottom surface mechanically connected to the side surface; and energy storage material within the top surface, the side surface, and the bottom surface, wherein the cells are interconnected by laser welding and aligned in a substantially planar configuration.

[0015] In another aspect, an energy storage device is disclosed. The energy storage device includes: a first terminal; a second terminal; a pressure relief element; a housing including a housing surface, wherein the housing surface includes the first terminal, the second terminal and the pressure relief element; and an energy storage material disposed within the housing.

[0016] In some embodiments, the pressure discharge element comprises a material selected from the group consisting of machined materials, degradable materials, formed materials, and combinations thereof. In some embodiments, the pressure discharge element comprises a material selected from the group consisting of stamped materials, perforated materials, welded materials, etched materials, chemically treated materials, engraved materials, and combinations thereof. In some embodiments, the pressure discharge element comprises a discharge surface thickness, the shell surface comprises the shell surface thickness, and the discharge surface thickness is thinner than the shell surface thickness. In some embodiments, the shell surface comprises an outer surface and an inner surface, wherein the position of the pressure discharge element is selected from the group consisting of the outer surface, the inner surface, and combinations thereof. In some embodiments, the energy storage device further comprises a terminal insulator washer positioned between the first terminal and the second terminal.

[0017] In some embodiments, the housing surface includes a top surface, a side surface, and a bottom surface. In some embodiments, the first terminal, the second terminal, and the pressure discharge element are positioned on the top surface. In some embodiments, the first terminal and the second terminal are positioned on the top surface, and the pressure discharge element is positioned on the bottom surface. In some embodiments, the first terminal and the second terminal are positioned on the top surface, and the pressure discharge element is positioned on the side surface. In some embodiments, the top surface is substantially circular. In some embodiments, the bottom surface includes a substantially annular surface.

[0018] In some embodiments, the first terminal is surrounded by the second terminal, and wherein the pressure discharge element surrounds the first terminal and the second terminal. In some embodiments, the first terminal and the second terminal are respectively substantially planar. In some embodiments, the housing is substantially cylindrical. In some embodiments, the first terminal and the second terminal together cover at least about 50% of the surface area of ​​the top surface. In some embodiments, the first terminal and the second terminal together cover at least about 75% of the surface area of ​​the top surface. In some embodiments, the first terminal and the second terminal are substantially flat. In some embodiments, the first terminal includes a first terminal shape selected from a group including a circular shape and an annular shape. In some embodiments, the second terminal includes an annular second terminal shape. In some embodiments, the width of the first terminal is about 5-15mm. In some embodiments, the width of the second terminal is about 5-15mm. In some embodiments, the aspect ratio of the first terminal size to the second terminal size is about 3:1 to about 1:3.

[0019] In some embodiments, the first terminal is a cathode terminal and the second terminal is an anode terminal. In some embodiments, the energy storage device further comprises a positive lead in contact with the anode terminal and a negative lead in contact with the cathode terminal. In some embodiments, the positive lead and the negative lead are welded to the anode terminal and the cathode terminal, respectively. In some embodiments, the positive lead and the negative lead are laser welded to the anode terminal and the cathode terminal, respectively. In some embodiments, a portion of the housing surface is substantially ferrous. In some embodiments, the pressure discharge element comprises a discharge pressure of at least about 20 bar. In some embodiments, the energy storage device further comprises a housing cover. In some embodiments, the energy storage device further comprises a housing port.

[0020] In another aspect, an energy storage device is disclosed. The energy storage device includes: a first terminal; a second terminal, wherein the second terminal surrounds the first terminal; an insulating gasket positioned between the first terminal and the second terminal; a housing including a housing surface; and an energy storage material disposed within the housing; wherein the housing surface includes a top surface, a side surface, and a bottom surface; wherein the top surface includes the first terminal and the second terminal; and wherein the first terminal and the second terminal are respectively substantially planar.

[0021] In some embodiments, the first terminal protrudes from the top surface. In some embodiments, the second terminal is substantially flush with the top surface. In some embodiments, the first terminal and the second terminal together cover at least about 50% of the surface area of ​​the top surface. In some embodiments, the width of the first terminal is about 5-15 mm. In some embodiments, the width of the second terminal is about 5-15 mm. In some embodiments, the aspect ratio of the first terminal size to the second terminal size is about 3:1 to about 1:3. In some embodiments, the energy storage device is a battery.

[0022] In another aspect, an energy storage device array is disclosed. The energy storage device array includes a plurality of energy storage devices, wherein the plurality of energy storage devices includes the energy storage device.

[0023] In another aspect, an electric vehicle is disclosed. The electric vehicle includes an energy storage device.

[0024] In another aspect, a process for manufacturing an energy storage device is disclosed. The process includes: forming a pressure venting element on a housing surface of a housing, wherein the housing surface includes a first terminal and a second terminal; disposing an energy storage material within the housing; and attaching the energy storage material to the first terminal and the second terminal.

[0025] In another aspect, a process for manufacturing an array of energy storage devices is disclosed. The process includes: placing an energy storage device into an array housing; contacting a first lead with a first terminal and contacting a second lead with a second terminal; and attaching the first lead to the first terminal and attaching the second lead to the second terminal. In some embodiments, the position of the battery is not adjusted after the energy storage device is placed into the array housing. In some embodiments, attaching the first lead to the first terminal and attaching the second lead to the second terminal includes laser welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] These and other features, aspects, and advantages of the present disclosure are described with reference to the accompanying drawings of certain configurations, which are intended to schematically illustrate certain configurations and not to limit the present disclosure.

[0027] Figure 1A An example of an energy storage cell in a sleeve is shown.

[0028] Figure 1B A perspective view of an example of an energy storage cell is shown.

[0029] Figure 1C A perspective view of an example of an energy storage cell is shown.

[0030] Figure 2A A top view of an example of an energy storage cell is shown.

[0031] Figure 2B An alternative top view of an example of an energy storage cell is shown.

[0032] Figure 3 A bottom view of an example of an energy cell is shown.

[0033] Figure 4 A side structural diagram showing the top and bottom surfaces of an example of an energy cell.

[0034] Figure 5 An exploded view of an example of an energy storage system is shown. DETAILED DESCRIPTION

[0035] Although certain embodiments and examples are described herein, it will be appreciated by those skilled in the art that the invention extends beyond the specifically disclosed embodiments and / or uses and obvious modifications and equivalents thereof. Therefore, the scope of the invention disclosed herein should not be limited by any specific embodiments described herein.

[0036] In general, one or more aspects of the present disclosure relate to energy storage cells. More specifically, the present disclosure relates to an energy storage cell designed for integration into large-scale vehicle and grid storage products. Illustratively, in order to support such integration, in some embodiments, a separate energy storage cell may correspond to a cylindrical storage cell of various volumes and aspect ratios. The cylindrical storage cell has specific characteristics or configurations that further support integration. More specifically, in one aspect, in some embodiments, a cylindrical storage cell includes a top surface that is specifically configured to present concentric and substantially coplanar positive and negative terminals so that the surface area for welding interconnects provides a statistically balanced result between the positive and negative terminals. In another aspect, in some embodiments, the center terminal interface (positive or negative) may be elevated relative to the surrounding geometry, including other terminals, terminal insulator washers or another element of a cell box that serves as an electrical insulator between the two terminals. In some embodiments, the top surface may include one or more components for calibrated discharge in thermal runaway. In some embodiments, such a component may illustratively correspond to a terminal discharge disk as described herein.

[0037] On the other hand, in some embodiments, the cylindrical storage cell includes a side surface that is sleeved to electrically isolate the individual cells from each other and from auxiliary components in the cell array. Additionally, in some embodiments, the side surface illustratively serves to interface with a cooling system added as part of the cell array, the cooling system acting as the primary conduit for extracting heat generated within the individual cells.

[0038] In yet another aspect, in some embodiments, the cylindrical storage cell design includes a bottom surface that selectively groups cell features or functions that may need to be incorporated into the top surface or side surface in the prior art. These additional features may include features similar to, complementary to, or alternative to the top surface, including geometries for sealing the open ends of drawn or extruded cell tanks. Additionally, in some embodiments, the bottom surface may be reinforced in such a way that the forces (commonly referred to as pressures, pressure peaks, ejection forces, etc.) to which the cell is subjected, such as forces caused by thermal runaway, are more inclined to ejection from the top surface rather than from the bottom surface.

[0039] In illustrative embodiments, specific combinations of the above aspects of the top surface, side surface, and bottom surface of the cylindrical storage cell facilitate optimization of the increase in the functions implemented by each corresponding surface. For example, the functions or components of the positive and negative terminals are presented on the top surface, and the illustrative cylindrical storage cell can increase the surface area of ​​the top surface corresponding to the positive and negative terminals, and thereby facilitate the welding of electrical interconnects via manufacturing processes, such as laser welding. This can improve economic and performance characteristics. In another example, the use of a sleeve material with additional temperature conduction properties enables the establishment of cost- and performance-optimized cooling channels in a cell array embodiment. It will be understood by those skilled in the relevant art that additional examples and benefits are also facilitated by such a configuration or combination. Additionally, it will be understood by those skilled in the relevant art that other storage cell embodiments within the scope of the present application may incorporate different combinations of aspects of the surfaces presented herein.

[0040] Various energy storage cell designs attempt to optimize cost, packaging volume, quality, performance, durability and manufacturing efficiency at a single cell level. However, this local optimization is usually not translated into a system-level metric optimization of an energy storage system, into which a storage cell is integrated, and the energy storage system, for example, has a cell array used in an electric vehicle or grid energy storage system. The cell form factor selection provides effective and efficient leverage on the performance, cost, packaging volume, durability and manufacturing efficiency of the battery pack. Three different form factors are most typically used in large-scale product applications: bag-shaped cells, prismatic cells and cylindrical cells. In some embodiments, the cylindrical form provides decisive benefits in terms of cost / manufacturing efficiency via a one-piece continuous motion assembly process and provides decisive benefits in terms of packaging / durability via the expansion force of the electrode stack material decomposed internally. The cylindrical form can also generally produce improvements in performance through a shorter thermal path length, and volume energy density is produced by the geometry of the package of the electrode stack. It will be understood by those skilled in the relevant art that, in order to embody the advantages of the cylindrical form described above at the level of the integrated battery pack, the material and mechanical features of the individual cells (including the exterior of the cells) may affect the ability to integrate multiple cells to achieve the functionality of the battery pack. Therefore, as described herein, specific features and functional configurations on various surfaces of individual cylindrical storage cells can provide additional product system-level optimizations of cost, packaging volume, quality, performance, durability, and manufacturing efficiency for the integrated cell array.

[0041] Although the present disclosure focuses on its use in energy storage systems, in some embodiments, the cylindrical energy storage cell design can be used to improve any energy storage device (battery, capacitor, etc.) of a cylindrical form factor, where automated manufacturing of large arrays of cost, volume, performance, and quality sensitive products is a priority result. It will be understood by those skilled in the relevant art that additional advantages or technical efficiencies may be associated with one or more aspects or combinations of multiple aspects of the present application without limitation.

[0042] Energy storage cell

[0043] Figure 1A A cut-away side view of an illustrative cylindrical energy storage cell 100 is shown. The storage cell 100 may have a top surface 102, a side surface 104, and a bottom surface 106. The side surface 104 may include a cell wall of the storage cell 100. The cell dimensions (e.g., height and diameter, etc.) may be optimized to form a repeating pattern of identical voltage clusters on energy grid networks in various energy storage systems, such as, but not limited to, vehicle battery platforms and various bus voltages. The materials used to construct the storage cell 100 may be chemically and thermally compatible with the materials in internal and external contact in a given energy storage application. Although in Figure 1A and 1B Although shown as a cylindrical embodiment in FIG. 1 , in other embodiments, the energy storage cell 100 may have a non-cylindrical shape, such as a prismatic or pouch form factor.

[0044] Figure 1B A perspective view of an illustrative cylindrical energy storage cell 100 is shown. The side surface 104 can be a part of a continuous structure forming a cell structure. The top surface 102 and the side surface 104 can be adjacent (e.g., adjacent in material, mechanically adjacent, or any other form of adjacent or continuous). Similarly, the bottom surface 106 and the side surface 104 can be adjacent. For example, the external structure of a cell is generally referred to as a "tank", and wherein the side surface can be referred to as a "tank wall". Illustratively, the side surface 104 of a cell can be adjacent to the top surface 102 or the bottom surface 106 to reduce the number or severity of mechanical and electrical weaknesses on the cell. For example, in an embodiment where the side surface 104 is adjacent to the top surface 102, the cell presents a locally uniform structure in terms of rigidity and strength. This cell structure can be better suited for processing mechanical loads, pressures or stresses applied or otherwise experienced at the top surface 102. This is also advantageous for the assembly of the cell or for the assembly of a product using the cell by eliminating mechanical weaknesses and associated assembly errors. In some embodiments, the top surface 102 or the bottom surface 106 may be a housing cover that is added to the energy storage cell 100 to form a housing enclosure for the energy storage material disposed therein.

[0045] Additionally, as described below, once the cell is deployed for use, the top surface 102 can be used to handle a portion of the mechanical loads, pressures, or stresses applied to the top surface 102. Illustratively, the top surface 102 can be configured for increased tensile strength and stiffness for product structural integration and increased compressive strength and stiffness for reacting to fixing forces during the electrical interconnection process. More specifically, the top surface 102 can be bonded directly to the sheet material so that an array of cells 100 creates a sandwich panel structure that provides sufficient strength and stiffness to support its own mass, or additionally support a product frame (e.g., a vehicle body). It should be noted that although in Figure 1B 1. Although shown as circular in FIG. 1, top surface 102 may be any other suitable shape (eg, polygonal).

[0046] As this article about Figure 1C As described, in some embodiments, the top surface 102 may include a discharge element 210 that releases at least a portion of the top surface 102 from the cell 100 in a manner that cuts off one or both of the cell array electrical interconnects 212, 214, and allows the discharge gas or other material to be released through an opening created by utilizing the ruptured portion of the top surface. In some embodiments, the discharge element 210 is illustratively defined as a circular seal, thereby defining an outer perimeter of the top surface that is at least partially or completely separated from any remaining portion of the top surface 102. The discharge element 210 can be made of a material having sufficient weakening to separate the portion of the top surface 102 from the cell 100. In other embodiments, the discharge element 210 can be formed using a manufacturing technique such as embossing to create a material weakening or a geometric weakening in the portion of the top surface 102 to facilitate separation as described herein. In other embodiments, the discharge element 210 can be configured as other advantageous shapes (e.g., elliptical, diamond, square, rectangular, spiral, etc.) or combinations thereof to produce non-uniform, asymmetric, or multi-element designs. Although in Figure 1B Although not shown, in some embodiments, the drainage element 210 can be positioned on other surfaces of the cell 100. For example, in some embodiments, the drainage element 210 can be positioned on the side surface 104, the bottom surface 106, and / or around the boundary between two surfaces (e.g., the top surface 102 and the side surface 104). Figure 1B Drain element 210 is depicted as being positioned on an exterior surface of a surface of cell 100 , but in some embodiments, drain element 210 may additionally or alternatively be positioned on an interior location surface of cell 100 .

[0047] In some embodiments, the sleeve may be applied to the outer surface of the storage cell 100. The sleeve may substantially surround at least the cylindrical side surface 104 of the cell 100. Illustratively, the cylindrical side surface 104 is made of a conductive material. In some embodiments, the sleeve does not substantially surround the cylindrical side surface 104 of the cell, but may be composed of one or more bands that partially expose the side surface 104 of the cell 100. These bands of the sleeve may be spaced equidistantly from each other along the height of the cylindrical side surface 104 of the cell or may be placed substantially close to the top surface 102 of the cell or the bottom surface 106 of the cell. When the sleeve includes one or more bands, the sleeve enables electrically insulated physical contact to be achieved between the cell and other components (including other cells) while maintaining the opportunity for direct mechanical bonding to the side surface 104 of the cell 100.

[0048] In some embodiments, the sleeve can be an electrically insulating material. The sleeve can produce an electrical barrier that electrically insulates each energy storage cell from other energy storage system components, such as a product frame, other storage cells, and a cooling system. The sleeve can facilitate the construction or configuration of a plurality of storage cells 100 corresponding to a series voltage string with a maximum volume packaging density of a battery cell 100. In this configuration, the sleeve mitigates the undesirable electrical connectivity between individual cells, thereby allowing the cell array to eliminate the spacing gap between storage cells. Therefore, the use of a sleeve can provide several benefits in an energy storage system, including but not limited to improving volumetric energy density, reducing internal void volume (which directly reduces the cost of structural filling modules and battery pack configurations), promoting balanced distribution of heat energy from induced or uninduced thermal runaway (which reduces the possibility of propagation to module or pack-level safety events), using the cell spacing as a buffer, buffer or mechanical gasket between cells, and allowing adjacent components to conduct electricity or heat for application-specific performance improvements.

[0049] Alternatively, sleeve can be used as buffer, buffer or mechanical pad, to physically strengthen the single cell separation, and itself does not serve as main electrical insulating medium.Use sleeve as buffer or buffer to strengthen the single cell spacing and can reduce the movement and pitch of the single cell.In certain embodiments, sleeve can be a label for the single cell and include information about the single cell, such as management information or important usage details.

[0050] In some embodiments, the sleeve is a single package of material. In some embodiments, the sleeve is a double package of one or two materials. If the key performance characteristics of one or both packages degrade over time, the double package is useful. The double package can also be used for improved maintainability by creating a sliding interface layer that simplifies removing a single cell from a single cell array and replacing a single cell within a single cell array.

[0051] In other embodiments, the storage cells 100 may be manufactured without a sleeve, leaving the conductive side surfaces exposed. In such embodiments, during use in an energy storage system, the storage cells 100 may then be arranged so that a distance is maintained between the storage cells 100 and other components of the energy storage system. If a distance between storage cells 100 is not desired in such embodiments, cells in adjacent same voltage clusters may be configured with reversed terminal polarity so that direct contact between the side surfaces 104 results in zero potential, making the contact unimportant for constructing a series voltage stack.

[0052] refer to Figure 1B , the side surface 104 can be designed to promote air, liquid or passive cooling along the side surface 104 where there is no other competing function. In some embodiments, the side surface 104 can be docked with an active cooling channel or cooling component (e.g., a radiator) provided as part of the manufacture of the single cell array. Therefore, compared with one or two other surfaces of the storage cell 100, the side surface 104 and the sleeve can be presented (alone or in combination) as having a better thermal conduction path. In some embodiments, the storage cell 100 can be cooled via the top surface 102 or the bottom surface 106. Any subgroup of these interfaces can be cooled at the same time, or they are all cooled together (e.g., immersion, phase change, etc.), or not cooled at all (passive / dependent on the heat capacity of the single cell). In some embodiments, the side surface 104 can be swept around the single cell in a cylindrical shape. In some embodiments, the side surface 104 can be bent near the top surface 102 or the bottom surface 106. The cooling side surface 104 can be used to cool the top surface 102 and the bottom surface 106 instead. This in turn can allow the design of the top surface 102 and the bottom surface 106 to be designed primarily for pressure discharge, electrical terminal single cell function and structural connection. Cooling the side surface 104 is also beneficial for maximizing the height of the single cell box that can be packaged in a fixed vehicle product height standard (envelope), and in fact for minimizing the cost / quality overhead of the single cell active material. This cooling arrangement also makes it possible to remove the thermal management interface from the typical abuse zone in the series load path of the structurally integrated energy storage system. This configuration can provide additional thermal benefits, such as by minimizing the heat leakage rate to the surrounding environment, so that the single cell provides thermal storage for heating the car body. In an embodiment where the side surface 104 is cooled, the sleeve may not have a high thermal resistance.

[0053] The side surfaces 104 can further be used to precisely position the storage cell 100 in the energy storage system by aligning the side surfaces 104 with a complementary rigid component in the energy storage system. In some embodiments, the complementary component can be a thermal component in the energy storage system.

[0054] In some embodiments, the side surface 104 has a thickness of 0.1-2mm. In some embodiments, the side surface 104 has a thickness of 0.05mm, 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm or 1.0mm. The side surface 104 has a thickness of about 1.1mm, 1.2mm, 1.3mm, 1.4mm, 1.5mm, 1.6mm, 1.7mm, 1.8mm, 1.9mm or 2mm or any value range therebetween. The side surface 104 has a thickness of 0.05mm. Thinner side surface 104 can be used to realize higher volume energy density. If the single cell size is longer or has longer electrode, wall (referring to side surface 104) can be thicker. Important factors in considering the side surface thickness include mechanical strength due to fatigue over time, resistance to possible side cracking due to large hoop stresses due to internal pressure, and thermal balance acting as a parallel resistor during cooling / heating of the cell.

[0055] The top surface 102 or bottom surface 106 can be relatively thicker than the side surface 104. One or more of the top surface 102 or bottom surface 106 can have a thickness of 0.1–2 mm. In some embodiments, the top surface 102 or bottom surface 106 can have a thickness of, about, at least or at least about 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or 1.0 mm. The top surface 102 or bottom surface 106 can have a thickness of about 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm or 2 mm or any value range therebetween. In some embodiments, the top surface 102 can also have a varying thickness, especially in order to define the discharge element 210, which can have a relatively thin surface (e.g., due to embossing) to facilitate the rupture at the discharge element 210.

[0056] Thicker top surface 102 or bottom surface 106 can provide additional substrate for electrical connection. Thicker top surface 102 or bottom surface 106 can be used for more firmly welding to side surface 104, which optionally has a larger interconnection process window. Thicker top surface 102 or bottom surface 106 can be used to realize more heat transfer from electrical joints during the normal operation of a single cell, thereby realizing high thermal performance capabilities. Thicker top surface 102 or bottom surface 106 is useful for manufacturing, so as to accommodate more magnetic flux from material handling or assembly equipment during single cell and final product assembly. This can realize the manufacture of larger single cell and higher factory operation speed. As described above, in some embodiments, the configuration of bottom surface 106 can be selected to promote the force (such as thermal runaway) experienced in single cell 100, to be released by the top surface 102, such as by the illustrated portion of the top surface 102 corresponding to the outer edge / periphery of the discharge element 210. Additionally, any portion of the top surface 102 outside the outer edge / perimeter defined by the discharge element 210 will not be released by any discharge forces or pressure spikes and can be used to mechanically retain internal contents or assist in controlled or directed expulsion of discharged material through the formed orifice.

[0057] Figure 1C The addition of two interconnects 212 and 214 is shown, which are connected to the positive and negative connections provided by the top surface 120, respectively. In some embodiments, the coupling of the interconnects 212, 214 to the top surface is specifically designed so that the rupture of the discharge element 210 will also cause at least one of the two electrical connections to the top surface 102 to be completely disconnected and provide a runaway discharge function. In one embodiment, the welding of the interconnects 212, 214 can be implemented according to the maximum allowable strength to facilitate severing the interconnects 212, 214. In other embodiments, the interconnects 212, 214 can be scored or preconfigured in such a way that the rupture of the discharge element 210 and the resulting discharge of the top surface 102 will cause the interconnects to break. For example, the interconnects 212, 214 can be made of a material, such as aluminum, that can have a relatively low melting temperature, which will allow the interconnects 212, 214 to be destroyed in a thermal runaway discharge scenario. In other embodiments, a combination of such embodiments or alternatives can be used to cause the release of the interconnects 212, 214. Illustratively, the interconnects 212 , 214 are configured such that both interconnects may be separated relatively simultaneously to eliminate the possibility of a short circuit scenario following a runaway.

[0058] Figure 2A The top surface 102 of the storage cell 100 is shown. The top surface 102 may include a conductive material configured as a concentric positive terminal and a negative terminal. Figure 2A204. The central terminal 202 and the outer terminal 204 can be marked with text, symbols, colors, geometric features, etc. to allow identification of each terminal or the boundary of each terminal. In some embodiments, the central terminal can be surrounded by a terminal insulator washer 206. The terminal insulator washer 206 can be used as an electrical insulator (or dielectric insulator) between the central terminal 202 and the outer terminal 204. The central terminal 202 and the outer terminal 204 can be connected with other components to deliver power to other systems, subsystems or components. The central terminal 202 and / or the outer terminal 204 can be configured externally to improve the applicability as an electrical contact. This external configuration can improve material compatibility and the area and thickness that can be used to form an electrical joint with the central terminal 202 and / or the outer terminal 204.

[0059] In some embodiments, the center terminal 202 is a positive terminal and the outer terminal 204 is a negative terminal. In other embodiments, the center terminal 202 is a negative terminal and the outer terminal 204 is a positive terminal. In some embodiments, the center terminal 202 can be a solid conductive component protruding from the top surface 102 (e.g., protruding from the terminal insulator washer 206 and / or the outer terminal 204), which minimizes interference with the interconnection components at the single cell array level. The center terminal 202 can also be used as a gap setting feature for adhesives, sealants, or heat dissipation elements. The sleeve 108 can overlap on the outer periphery of the top surface 102 to prevent accidental bridging of the positive and negative terminals between adjacent storage cells in the energy storage system, or force the minimum cross-surface "creep" of conductive components at different potentials, such as cooling systems or product frames.

[0060] In some embodiments, the top surface 102 may include a single cell pressure discharge element 210. The single cell pressure discharge element 210 may be designed to allow the storage cell 100 that experiences thermal runaway to mechanically destroy or disconnect the storage cell 100 itself from other cells in the cell array or from the electrical connection of the energy storage system. Similarly, the single cell pressure discharge element 210 may separate one or both of the central terminal 202 and the external terminal 204 from any combination of the following: the rest of the top surface 102, the wall of the single cell 100, or the electrical connection to the interconnect 212, 214. The pressure discharge element 210 on the top surface 102 may improve the repeatability of the single cell failure scenario, particularly by further guiding high temperature gases, debris and flames away from adjacent cells, sensitive components and product users. By manipulating these hazards with greater certainty, the probability of propagating thermal runaway and damage may be reduced.

[0061] The single cell pressure discharge element 210 can be large enough to surround the center terminal 202 and the external terminal 204. The single cell pressure discharge element 210 can be close to the edge of the top surface 102. It will be understood by those skilled in the relevant art that the area and shape of the single cell pressure discharge element 210 can be adjusted to balance the manufacturing assembly results with the uncontrolled discharge performance characteristics. For example, in some embodiments, the discharge element 210 may not directly correspond to the outer edge of the top surface 102. Instead, the discharge element 210 can be inserted from the edge of the top surface so that some parts of the top surface 102 remain as part of the single cell, wherein the separation or partial separation is related to the discharge force or pressure peak. Additionally, the position and shape of the discharge element 210 can be further incorporated or taken into account the available surface area provided by the external terminal 204, which can be included in or outside the area defined by the discharge element 210, so as to facilitate welding the lead to the external terminal 204. When contained in the area defined by the discharge element 210, the separation of the top surface 102 (or a portion thereof) will increase the possibility that the two electrical leads are completely removed as described above.

[0062] The center terminal 202 and the external terminal 204 of the top surface 102 can be customized to the maximum flat and unobstructed feasible welding area, including the substrate thickness and material (converted into the interconnection assembly gap robustness) suitable for giving a wide interconnection energy process window, with the minimum risk of damaging the airtightness of the storage cell 100. Sufficient positive and negative terminal areas can be provided to be used for the foil pressing down holding, welding area and four-probe Kelvin interconnection verification test to be carried out synchronously on the opposite side of each terminal welding. Because all positive and negative cell terminals of the storage cell 100 are placed substantially coplanar and in a common orientation, the electrical interconnects required for power delivery and voltage sensing can also extend along a single plane (e.g., integrated into foil). The laser welding interconnects along the common plane of the top surface 102 can produce conductive connections, which are used to supply voltage and current with low heat loss, and to connect voltage sensing and control electronics with reduced manufacturing and operation costs. As described above, the relevant strength of the welding of the interconnects can be based on the maximum allowable welding strength for allowing the connection to be cut off.

[0063] In some embodiments, the top surface 102 can be made of iron or magnetic material. In some embodiments, the center terminal 202 or the outer terminal 204 is made of iron or magnetic material. In some embodiments, the portion of the top surface 102 that is not the center terminal 202 or the outer terminal 204 includes iron or magnetic material. Sufficient iron or magnetic material can be located on the top surface 102 so that the assembly tool can be used to pick up the single cell and the entire battery assembly by magnetic attraction to the top surface 102.

[0064] In some embodiments, side surface 104 can be made of the same ferrous or magnetic material as top surface 102. Alternatively, side surface 104 can be made of a different material. Side surface 104 can be made of a non-magnetic or non-ferrous material. Side surface 104 can be made of a lighter material, such as aluminum.

[0065] In an illustrative embodiment, the size of the circular area presented by the center terminal 202 and the outer terminal 204 can be determined based on a threshold of the statistical probability that a single cell array-level interconnection process (e.g., laser welding) will succeed. For example, in one embodiment, the threshold success probability can be set to 99.9999% (4 sigma) or a maximum failure rate of 0.0001 or lower. Further, the size of the circular area presented by the center terminal 202 and the outer terminal 204 can be configured to be subordinate. In one embodiment, the diameter of the center terminal 202 can be proportionally set to half (1 / 2) of the diameter of the outer terminal 204. In another embodiment, the flat conductive diameter of the center terminal 202 can be set to be approximately equal to the flat conductive radial width of the outer terminal 204. In some embodiments, the flatness or roughness (e.g., RMS) of the terminal (e.g., center terminal 202 or external terminal 204) can be, be about, be at most, or be at most about 2 μm, 5 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, or 500 μm, or any value range therebetween. In these embodiments, the flatness of the terminal can be convenient for attachment (e.g., laser welding) to an external interface (e.g., positive or negative lead) in production. It will be appreciated by those skilled in the art that other failure rates, thresholds, dependencies, or proportionality can be achieved for different storage cells, manufacturing environments, thermal system configurations, or desired cell arrays. Additionally, in the case where additional functionality is implemented on the top surface 102, such as the port 208 for receiving internal materials or for forming a physical connection, the size of the center terminal 202 or the outer terminal 204 can be adjusted accordingly, such as in Figure 2B , in order to statistically rebalance the interconnect soldering or other assembly process results. In embodiments where a relatively small portion of the external terminal 204 surface is required for electrical interconnection, the remaining area can be used as an interface for a single cell terminal temperature instrument.

[0066] In some embodiments, the terminal insulator washer 206 has a small radial width (e.g., 0.1 mm). The terminal insulator washer 206 can be thin enough to meet the electrical creep requirements in a 4.2V potential. Alternatively, the terminal insulator washer can be configured to meet the electrical creep requirements in 3.0V, 3.2V, 3.4V, 3.6V, 3.8V, 4.0V, 4.4V, 4.6V, 4.8V, or 5.0V. The thin terminal insulator can be used to maximize the electrical interface area on the top surface 102.

[0067] As in Figure 2A As shown in , the center terminal 202 has a center width 302, the outer terminal 204 has an outer radial width 306, and the washer 206 has a washer radial width 304. Figure 2A , center width 302 is related to the diameter of the circle formed by the center terminal 202 terminating at the gasket 206, and as observed from the top of the single pool terminating at the pressure discharge element 210 or the external terminal 204, the outer radial width 306 and the gasket radial width 304 are respectively the exposed ring width parts of the external terminal 204 and the gasket 206. In other embodiments, radial width or center width can be associated with the side length or diagonal length of a polygon (e.g., square) or a polygonal ring. In some embodiments, the length of center width 302 can be, be about, be at least or be at least about 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, 18mm, 19mm, 20mm, 25mm, 30mm, 50mm or 100mm, or any value range therebetween. In some embodiments, the length of the gasket radial width 304 can be, be approximately, be at most, or be at most approximately 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm, or any range of values ​​therebetween. In some embodiments, the length of outer radial width 306 can be, be about, be at least, or be at least about 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm, or 100 mm, or any range of values ​​therebetween. Figure 2AIt is not easy to observe in the figure, but in some embodiments, the ratio or aspect ratio between the center width 302 and the outer radial width 306 can be, be approximately, be at least, be at least approximately, be at most, or be at most approximately 5:1, 4:1, 3:1, 2:1, 1.5:1, 1:1, 1:1.5, 1:2, 1:3, 1:4 or 1:5, or any range of values ​​therebetween.

[0068] As in Figure 2B As shown in , the port 208 has a port width 308, the center terminal 202 has a center radial width 302, the outer terminal 204 has an outer radial width 306, and the gasket 206 has a gasket radial width 304. As shown in Figure 2B As shown in , port width 308 is associated with the diameter of the circle of port 208 terminating at center terminal 202, and center radial width 302, outer radial width 306 and gasket radial width 304 are respectively the exposed ring width parts of center terminal 202, outer terminal 204 and gasket 206, as observed from the top of a single pool terminating at gasket 206, pressure discharge element 210 or outer terminal 204, respectively. In other embodiments, radial width can be associated with the side length or diagonal length of a polygon (e.g., square) or polygonal ring. In some embodiments, the length of center radial width 302 can be, be about, be at least or be at least about 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, 18mm, 19mm, 20mm, 25mm, 30mm, 50mm or 100mm, or any value range therebetween. In some embodiments, the length of the gasket radial width 304 can be, be approximately, be at most, or be at most approximately 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm, or any range of values ​​therebetween. In some embodiments, the length of outer radial width 306 can be, be about, be at least, or be at least about 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm, or 100 mm, or any range of values ​​therebetween. Figure 2BIt is not easy to observe in the figure, but in some embodiments, the ratio or aspect ratio between the central radial width 302 and the outer radial width 306 can be, be approximately, be at least, be at least approximately, be at most, or be at most approximately 5:1, 4:1, 3:1, 2:1, 1.5:1, 1:1, 1:1.5, 1:2, 1:3, 1:4 or 1:5, or any range of values ​​therebetween.

[0069] Figure 3 The bottom surface 106 of the storage cell 100 is shown. The bottom surface 106 can integrate all storage cell features that do not need to be accessed or docked for the cell array or battery pack integration. For example, the bottom surface 106 can contain all functions other than accommodating the terminals, such as but not limited to the geometry for sealing the open side of the cell tank and / or the geometry for calibrated discharge in thermal runaway. The integration of all non-planar, non-terminal features into the bottom surface 106 can allow the top surface 102 to reach the maximum electrical interface area, which in turn can optimize the interconnect welding or other assembly process results.

[0070] Figure 4 A cut-away side structural view of the top surface 102 and bottom surface 106 of a cell is shown enclosing a cell interior 410. The bottom surface may have a port 408 for receiving interior material or for making a physical connection.

[0071] In some embodiments, the bottom surface 106 has one or more recessed portions 404 and a line contact base 406. The line contact base 406 is configured to allow the cell to rest stably on the bottom surface 106. The line contact base 406 can be a ring on the bottom surface 106 or a ring substantially relative to the contact surface to provide stability to the cell 100. Alternatively, the line contact base 406 can be three or more contact points or areas on the bottom surface 106 that are configured to give the cell stability when the cell rests on the bottom surface 106. One or more recessed portions 404 can be used to shield an airtight sealing closure on the bottom surface 106 or between the bottom surface 106 and the side surface 104, etc. One or more recessed portions 404 can be used for other purposes related to the structural integrity of the cell and the bottom surface 106.

[0072] In some embodiments, bottom surface 106 is not adjacent to side surface 104 so that bottom surface 106 can be installed and sealed following components (e.g., conductors and active materials) inside the cell. For example, in some embodiments, a housing cover forming bottom surface 106 can be installed and attached to side surface 104. In some embodiments, bottom surface 106 can include a port for receiving materials for the battery cell.

[0073] Having a top surface 102 that is not abutted in at least one manner (e.g., mechanical abutment, material abutment, or any other form of abutment or continuity) also helps fine-tune the pressure venting characteristics in a manner that is largely independent of the constraints and tradeoffs presented by the side surfaces 104 and the bottom surface 106. Subsequent optimization of additional or alternative pressure venting elements 210 on the top surface 102 can further improve the repeatability of single cell failure scenarios, particularly by further directing hot gases, debris, and flames away from adjacent single cells, sensitive components, and product users. By more deterministically manipulating these hazards, the probability of propagating thermal runaway and damage can be reduced.

[0074] The perimeter of the bottom surface 106 may be recessed to accommodate some overlap in the sleeve so that quality defects or thickness variations in the sleeve or profile variations on the edge of the box being rolled or welded do not affect the single cell alignment accuracy in the energy storage system. The configuration of the bottom surface 106 may simultaneously protect the sleeve from mechanical wear during manufacturing operations and abuse of handling and transportation, and promote a larger contact area between the bottom surface 106 and adjacent components, such as strength-limited adhesives.

[0075] Continue to refer Figure 4 , the center terminal 202 may include a solid piece of conductive material. The center terminal 202 may be separated from the outer terminal 204 by a terminal insulator washer (e.g., a compressed seal) 206. As described herein, the bottom surface 106 may have a recessed portion 404 on which the sleeve may overlap. The center terminal 202 and the outer terminal 204 may include any material suitable for laser welding and internal single cell structure welding (e.g., aluminum).

[0076] In some embodiments, the conductive side surface 104 may be continuous with the external terminal 204 and may include an extruded or drawn aluminum grade to improve thermal conductivity, thermal diffusivity, solder interconnect yield, and gravimetric energy density relative to conventionally employed foil materials.

[0077] The disclosed energy storage cell design can be used with any internal structure suitable for energy storage devices. An example of a suitable internal design may include a first substrate, an internal separator, a second substrate, and an external separator. The first substrate may be conductive. The internal separator may be electrically insulating and disposed above the first substrate (e.g., stacked on top of the first substrate). The conductive second substrate may be further disposed on the internal separator (e.g., stacked on top of the internal separator). An electrically insulating external separator may be disposed above the second substrate (e.g., stacked on top of the second substrate). When the first substrate, the internal separator, the second substrate, and the external separator are stacked in a continuous manner, the first substrate, the internal separator, the second substrate, and the external separator may be wound around the central axis, with the first substrate being closest to the central axis in position. In some embodiments, there is no external separator. Then, the wound assembly may be contained in the cylindrical energy storage cell design disclosed herein together with the ion transfer medium.

[0078] In some embodiments, the technology described herein relates to an energy storage device. In some embodiments, the energy storage device includes a first terminal, a second terminal, an energy storage material disposed within a housing, and a housing, wherein the housing has a housing surface including the first terminal and the second terminal. In some embodiments, the first terminal and / or the second terminal are substantially planar. In some embodiments, the housing of the energy storage device is substantially cylindrical.

[0079] In some embodiments, the energy storage device further comprises a pressure discharge element. In some embodiments, the pressure element comprises a material selected from a machined material, a degradable material, a formed material, and / or a combination thereof. In some embodiments, the pressure discharge element comprises a material selected from a stamping material, a perforated material, a welding material, an etching material, a chemically treated material, an engraved material, and / or a combination thereof. In some embodiments, the pressure discharge element has a discharge surface thickness, and the shell surface has a shell surface thickness, and the discharge surface thickness is thinner than the shell surface thickness. In some embodiments, the shell surface comprises an outer surface and an inner surface, wherein the position of the pressure discharge element is selected from a group comprising an outer surface, an inner surface, and / or a combination thereof. In some embodiments, the pressure discharge element may correspond to a portion of the shell surface (e.g., a top surface) that is thinner than other portions of the surface. For example, in some embodiments, the pressure discharge element may be structurally formed as one or more grooves and / or indentation areas of the surface. In some embodiments, the discharge element may be positioned on an inner surface (e.g., inside the shell), an outer surface (e.g., outside the shell), a top surface, a side surface, a bottom surface, or any combination thereof. In some embodiments, the pressure exhaust element includes a discharge pressure (i.e., an internal housing pressure that causes damage to the pressure exhaust element (e.g., partial, substantial, or complete rupture) of, about, at most, or at most about 15 bar, 20 bar, 21 bar, 22 bar, 23 bar, 24 bar, 25 bar, 26 bar, 27 bar, 28 bar, 29 bar, 30 bar, 31 bar, 32 bar, 35 bar, 40 bar, 45 bar, 50 bar, 55 bar, 60 bar, 65 bar, 70 bar, or 80 bar, or any range of values ​​therebetween.

[0080] In some embodiments, the first terminal and / or the second terminal have a terminal shape selected from a filled shape (e.g., a circle) and a non-filled shape (e.g., a frame or annular shape). In some embodiments, the second terminal surrounds the first terminal. In some embodiments, the pressure discharge element surrounds the first terminal and / or the second terminal. In some embodiments, the housing surface includes a top surface, a side surface, and a bottom surface, wherein the top surface includes the first terminal and the second terminal. In some embodiments, the first terminal and / or the second terminal are substantially planar. In some embodiments, the first terminal and / or the second terminal protrude from the top surface. In some embodiments, the first terminal and / or the second terminal are substantially flush with the top surface. In some embodiments, the first terminal and / or the second terminal covers, approximately covers, at least covers, or at least approximately covers 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 92%, 95%, 98%, 99% or 100% of the surface area of ​​the housing surface (e.g., the top surface), or any value range therebetween. In some embodiments, the first terminal has a width dimension (e.g., center width or radial width) of, about, at least, or at least about 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm, or 100 mm, or any range of values ​​therebetween. In some embodiments, the second terminal has a width dimension (e.g., center width or radial width) of, about, at least, or at least about 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm, or 100 mm, or any range of values ​​therebetween. In some embodiments, the aspect ratio between the first terminal size and the second terminal size is, is about, is at least, is at least about, is at most, or is at most about 5:1, 4:1, 3:1, 2:1, 1.5:1, 1:1, 1:1.5, 1:2, 1:3, 1:4, or 1:5, or any range of values ​​therebetween. For example, if the center width or radial width of the first terminal is 10 mm and the center width or radial width of the second terminal is 15 mm, the aspect ratio of the first terminal size to the second terminal size is 1:1.5. In some embodiments, the first and / or second terminals are substantially flat. In some embodiments, the first terminal and the second terminal are coplanar.In some embodiments, the flatness or roughness (e.g., RMS) of a terminal (e.g., a first terminal and / or a second terminal) may be, be approximately, be at most, or be at most approximately 2 μm, 5 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, or 500 μm, or any range of values ​​therebetween.

[0081] In some embodiments, the first terminal, the second terminal, and the pressure relief element are positioned on the top surface. In other embodiments, the first terminal and the second terminal are positioned on the top surface, and the pressure relief element is positioned on the bottom surface. In still other embodiments, the first terminal and the second terminal are positioned on the top surface, and the pressure relief element is positioned on the side surface. In some embodiments, the top surface is substantially circular. In some embodiments, the bottom surface includes a substantially annular surface.

[0082] In some embodiments, the energy storage device further comprises a terminal insulator washer. In some embodiments, the terminal insulator washer is positioned between the first terminal and the second terminal. In some embodiments, the terminal insulator washer is positioned between the first terminal and the second terminal so that the first terminal and the second terminal are not physically and directly in contact with each other. In some embodiments, the insulating washer covers a portion of the surface of the first terminal and / or the second terminal. In some embodiments, the length of the radial width of the washer can be, is about, is at most, or is at most about 0.05mm, 0.06mm, 0.07mm, 0.08mm, 0.09mm, 0.1mm, 0.11mm, 0.12mm, 0.13mm, 0.14mm, 0.15mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1mm, 1.5mm or 2mm, or any range of values ​​therebetween.

[0083] In some embodiments, the first terminal or the second terminal is a cathode terminal. In some embodiments, the first terminal or the second terminal is an anode terminal. In some embodiments, the energy storage device further comprises a positive lead in contact with the anode terminal and / or a negative lead in contact with the cathode terminal. In some embodiments, the positive lead and the negative lead are attached (e.g., welded) to the anode terminal and the cathode terminal, respectively. In some embodiments, welding can be selected from laser welding, ultrasonic bonding welding, resistance welding, and TIG welding. In some embodiments, welding is laser welding.

[0084] In some embodiments, the energy storage device further comprises a housing cover. In some embodiments, the housing cover forms a bottom surface of the housing. In some embodiments, the energy storage device further comprises a housing port. In some embodiments, the housing port is positioned on the top surface and / or the bottom surface. In some embodiments, the housing port is surrounded by a first terminal, a second terminal, an insulating gasket, and / or a pressure relief element. In some embodiments, a portion of the housing surface is substantially ferrous. In some embodiments, the energy storage device is a battery.

[0085] Product System

[0086] Figure 5 An example of an energy storage system 500 is shown, in which a storage cell 100 can be used in a cell array 530. In one embodiment, the storage cell 100 can be arranged as a module in a common orientation. In other embodiments, the cell array can be arranged as a module in an alternating or staggered orientation. In some embodiments, the storage cell 100 can have a sleeve 108 and can be arranged directly adjacent to each other. In other embodiments, the storage cell 100 may not have a sleeve 108 and can therefore be arranged at a distance between each cell. In some embodiments, the storage cell 100 can be electrically interconnected by a lower voltage brick foil 540, wherein the foil 540 is laser welded to produce an electrical connection with the cell 100, the sensing electronics, and the positive / negative array terminals. In other embodiments, the foil 540 can be completely omitted. In other embodiments, the storage cell 100 is interconnected via another method. The side surface 104 of the storage cell 100 can be cooled using a thermal assembly 538. The cell array can be contained in a frame structure 502 and sealed with a lid 520.

[0087] The interconnects between the storage cells 100 may also be configured to ensure product durability under normal stress, but may be configured to be cut off from the terminals on the storage cells 100 under undesirable mechanical and thermal loads, such as thermal runaway. The interconnects may be adjusted to different widths or thicknesses to be cut off from the terminals on the storage cells 100. Other stress-concentrating geometries may be added to the interconnects to allow for cutting, such as weld patterns, shapes, footprints, power, and penetration. Additionally, the interconnect material may be configured from a material with a lower melting temperature.

[0088] In some embodiments, the technology described herein relates to an array of energy storage devices. In some embodiments, the array of energy storage devices includes a plurality of energy storage devices, wherein each of the energy storage devices may be any of the energy storage devices described above. In some embodiments, the technology described herein relates to an electric vehicle including an energy storage device, such as any of the energy storage devices described above.

[0089] Energy storage device manufacturing process

[0090] In some embodiments, the technology described herein relates to a process for manufacturing an energy storage device, such as a cell 100. In some embodiments, the process for manufacturing an energy storage device may include disposing an energy storage material in a housing; and attaching the energy storage material in the housing. In some embodiments, the process also includes forming a pressure discharge element on a housing surface of the housing. In some embodiments, the housing surface includes a first terminal and a second terminal. In some embodiments, after the energy storage material is disposed in the housing, a cover is attached to the housing.

[0091] Energy storage device array manufacturing process

[0092] In some embodiments, the technology described herein relates to a process for manufacturing an array of energy storage devices, such as a single cell array 530. For example, the process for manufacturing an array of energy storage devices may include placing at least one or more energy storage devices into an array housing; contacting a first lead to a first terminal of the energy storage device and contacting a second lead to a second terminal of the energy storage device; and attaching the first lead to the first terminal of the energy storage device and the second lead to the second terminal of the energy storage device. In some embodiments, the attachment includes welding (e.g., laser welding). In some embodiments, the position of the battery is not adjusted after the energy storage device is placed into the array housing. By utilizing terminals as described herein, such as those shown in Figures 1 to Figure 5 As shown in one of the drawings, the ability to attach leads to energy storage devices within an array without adjustment can be achieved.

[0093] Although certain embodiments have been described, these embodiments are presented only by way of example, and the foregoing disclosure is not intended to limit the present disclosure to the precise form disclosed or to the specific field of use. In fact, the novel methods and systems described herein can be embodied in various other forms. In addition, various omissions, substitutions, and changes can be made to the systems and methods described herein without departing from the spirit of the present disclosure. Therefore, it is conceivable that, according to the present disclosure, various alternative embodiments and / or modifications (whether explicitly described or implied herein) of the present disclosure are possible. After the embodiments of the present disclosure have been described in this way, those of ordinary skill in the art will recognize that changes can be made in form and detail without departing from the scope of the present disclosure. The attached claims and their equivalents are intended to cover these forms or modifications that fall within the scope and spirit of the present disclosure. Therefore, the present disclosure is limited only by the claims.

[0094] In the foregoing description, the present disclosure has been described with reference to specific embodiments. However, as will be understood by those skilled in the art, without departing from the spirit and scope of the present disclosure, the various embodiments disclosed herein may be modified or implemented differently in various other ways. Therefore, this description should be considered illustrative and is to teach those skilled in the art to make and use the various embodiments of the disclosed single pool assembly. It should be understood that the disclosed forms shown and described herein should be considered as representative embodiments. Equivalent elements, materials, processes or steps may replace those represented and described herein. In addition, some features of the present disclosure may be utilized independently of the use of other features, all of which are obvious to those skilled in the art after benefiting from the description of the present disclosure. Expressions such as "including", "containing", "incorporating", "comprising", "having", "being" used to describe and claim the present disclosure are intended to be interpreted in a non-exclusive manner, i.e., allowing for the presence of items, components or elements that are not explicitly described. References to the singular are also interpreted as involving plural numbers.

[0095] In addition, various embodiments disclosed herein should be understood with illustrative and explanatory meanings and should not be interpreted as limitations to the present disclosure in any way. All combined references (such as attachment, fixing, coupling, connection, etc.) are only used to help readers understand the present disclosure, and may not produce restrictions, especially the position, orientation or use of the system and / or method disclosed herein. Therefore, combined reference (if any) will be interpreted broadly. In addition, this combined reference does not necessarily represent that two elements are directly connected to each other.

[0096] In addition, although the operations can be depicted in the drawings or described in a specific order in the specification, these operations do not need to be performed in the specific order shown or in a continuous order, or do not need to perform all operations to achieve the desired result. Other operations not depicted or described can be incorporated into the examples of methods and processes. Additionally, all numerical terms, such as but not limited to "first", "second", "third", "primary", "secondary", "primary" or any other common and / or numerical terms should also be considered as identifiers only, to help readers understand the various elements, embodiments, variations and / or modifications of the present disclosure, and no limitation, especially any limitation relative to or exceeding another element, embodiment, variation and / or modification, may be generated.

[0097] It will also be understood that one or more of the elements depicted in the drawings / figures may also be implemented in a more separate or integrated manner, or even removed or rendered inoperable in some cases, as is useful depending on the particular application. Additionally, any signal shading in the drawings / figures should be considered merely exemplary and not limiting unless specifically stated otherwise.

[0098] For purposes of the present disclosure, certain aspects, advantages, and novel features are described herein. Not all of these advantages may be achieved according to any particular embodiment. Thus, for example, those skilled in the art will recognize that the present disclosure may be embodied or performed in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as taught or suggested herein.

[0099] Unless otherwise specifically stated or understood within the context of use, conditional terms such as "can," "can," "might," or "may" are generally intended to convey that certain embodiments include and other embodiments do not include certain features, elements, and / or steps. Thus, such conditional terms generally do not imply that features, elements, and / or steps are in any way required for one or more embodiments, or that one or more embodiments necessarily include logic (with or without user input or prompting) for determining whether such features, elements, and / or steps are included or are to be performed in any particular embodiment.

[0100] Unless expressly stated otherwise, connective terms such as the phrase "at least one of X, Y, and Z" are understood in context as generally used to convey that an item, term, etc. can be X, Y, or Z. Thus, such connective terms are generally not intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0101] Words of degree as used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein, represent a value, amount or characteristic that approaches the stated value, amount or characteristic and still performs the desired function or achieves the desired result.

[0102] The scope of the present disclosure is not intended to be limited by the specific disclosure of the embodiments in this section or elsewhere in this specification, and may be defined by the claims presented in this section or elsewhere in this specification or presented in the future. The terms of the claims should be interpreted broadly based on the terms employed in the claims, and not limited to the examples described in this specification or during the prosecution of the application, which examples should be interpreted as non-exclusive.

[0103] Although certain embodiments have been described, these embodiments are presented by way of example only and are not intended to limit the scope of the present disclosure. In fact, the novel methods and systems described herein may be embodied in various other forms. In addition, various omissions, substitutions, and changes may be made to the systems and methods described herein without departing from the spirit of the present disclosure. The attached claims and their equivalents are intended to cover these forms or modifications that fall within the scope and spirit of the present disclosure. Therefore, the scope of the present invention is defined only by the attached claims.

Claims

1. An energy storage device, comprising: First terminal; Second terminal; Pressure relief elements; a housing, the housing comprising a housing surface, wherein the housing surface comprises the first terminal, the second terminal, and the pressure discharge element; as well as An energy storage material is disposed within the housing.

2. The energy storage device according to claim 1, wherein: The pressure relief element comprises a material selected from the group consisting of a machined material, a degraded material, a formed material, and combinations thereof.

3. The energy storage device according to claim 1 or 2, wherein: The pressure relief element includes a material selected from the group consisting of a stamped material, a perforated material, a welded material, an etched material, a chemically treated material, an engraved material, and combinations thereof.

4. The energy storage device according to any one of claims 1 to 3, wherein: The pressure discharge element includes a discharge surface thickness, the housing surface includes a housing surface thickness, and the discharge surface thickness is thinner than the housing surface thickness.

5. The energy storage device according to any one of claims 1 to 4, wherein: The housing surface includes an outer surface and an inner surface, wherein the position of the pressure relief element is selected from the group consisting of the outer surface, the inner surface, and combinations thereof.

6. The energy storage device of any one of claims 1 to 5, further comprising a terminal insulator washer positioned between the first terminal and the second terminal.

7. The energy storage device according to any one of claims 1 to 6, wherein: The housing surface includes a top surface, side surfaces, and a bottom surface.

8. The energy storage device according to claim 7, wherein: The first terminal, the second terminal, and the pressure discharge element are positioned on the top surface.

9. The energy storage device according to claim 7, wherein: The first terminal and the second terminal are positioned on the top surface, and the pressure discharge element is positioned on the bottom surface.

10. The energy storage device according to claim 7, wherein: The first terminal and the second terminal are positioned on the top surface, and the pressure discharge element is positioned on the side surface.

11. An energy storage device according to any one of claims 7 to 10, wherein: The top surface is substantially circular.

12. An energy storage device according to any one of claims 7 to 11, wherein: The bottom surface includes a substantially annular surface.

13. An energy storage device according to any one of claims 1 to 8, 11 and 12, wherein: The first terminal is surrounded by the second terminal, and wherein the pressure relief element surrounds the first terminal and the second terminal.

14. The energy storage device according to any one of claims 1 to 13, wherein: The first terminal and the second terminal are each substantially planar.

15. The energy storage device according to any one of claims 1 to 14, wherein: The housing is substantially cylindrical.

16. An energy storage device according to any one of claims 1 to 15, wherein: The first terminal and the second terminal together cover at least about 50% of the surface area of ​​the top surface.

17. An energy storage device according to any one of claims 1 to 15, wherein: The first terminal and the second terminal together cover at least about 75% of the surface area of ​​the top surface.

18. An energy storage device according to any one of claims 1 to 15, wherein: The first terminal and the second terminal are substantially planar.

19. An energy storage device according to any one of claims 1 to 18, wherein: The first terminal includes a first terminal shape selected from the group consisting of a circular shape and a ring shape.

20. An energy storage device according to any one of claims 1 to 19, wherein: The second terminal includes a ring-shaped second terminal shape.

21. An energy storage device according to any one of claims 1 to 20, wherein: The width of the first terminal is about 5-15 mm.

22. An energy storage device according to any one of claims 1 to 21, wherein: The width of the second terminal is about 5-15 mm.

23. An energy storage device according to any one of claims 1 to 22, wherein: An aspect ratio of the first terminal size to the second terminal size is about 3:1 to about 1:

3.

24. An energy storage device according to any one of claims 1 to 23, wherein: The first terminal is a cathode terminal and the second terminal is an anode terminal.

25. The energy storage device of claim 24, further comprising a positive lead in contact with the anode terminal and a negative lead in contact with the cathode terminal.

26. The energy storage device of claim 25, wherein: The positive lead and the negative lead are welded to the anode terminal and the cathode terminal, respectively.

27. The energy storage device of claim 26, wherein: The positive lead and the negative lead are laser welded to the anode terminal and the cathode terminal, respectively.

28. An energy storage device according to any one of claims 1 to 27, wherein: A portion of the shell surface is substantially ferrous.

29. An energy storage device according to any one of claims 1 to 28, wherein: The pressure discharge element includes a discharge pressure of at least about 20 bar.

30. The energy storage device of any one of claims 1 to 29, further comprising a housing cover.

31. The energy storage device of any one of claims 1 to 30, further comprising a housing port.

32. An energy storage device comprising: First terminal; a second terminal, wherein the second terminal surrounds the first terminal; an insulating washer positioned between the first terminal and the second terminal; a housing, the housing comprising a housing surface; and an energy storage material disposed within the housing; Wherein, the shell surface includes a top surface, a side surface and a bottom surface; wherein the top surface includes the first terminal and the second terminal; and The first terminal and the second terminal are respectively substantially planar.

33. The energy storage device of claim 32, wherein: The first terminal protrudes from the top surface.

34. An energy storage device according to claim 32 or 33, wherein: The second terminal is substantially flush with the top surface.

35. An energy storage device according to any one of claims 32 to 34, wherein: The first terminal and the second terminal together cover at least about 50% of the surface area of ​​the top surface.

36. An energy storage device according to any one of claims 32 to 35, wherein: The width of the first terminal is about 5-15 mm.

37. An energy storage device according to any one of claims 32 to 36, wherein: The width of the second terminal is about 5-15 mm.

38. An energy storage device according to any one of claims 32 to 37, wherein: An aspect ratio of the first terminal size to the second terminal size is about 3:1 to about 1:

3.

39. An energy storage device according to any one of claims 1 to 38, wherein: The energy storage device is a battery.

40. An energy storage device array, comprising a plurality of energy storage devices, wherein: The plurality of energy storage devices comprises an energy storage device according to any one of claims 1-39.

41. An electric vehicle comprising an energy storage device according to any one of claims 1 to 39.

42. A process for manufacturing an energy storage device, comprising: forming a pressure relief element on a housing surface of the housing, wherein the housing surface includes a first terminal and a second terminal; disposing an energy storage material within the housing; and The energy storage material is attached to the first terminal and the second terminal.

43. A process for manufacturing an array of energy storage devices, comprising: Arranging the energy storage device according to any one of claims 1 to 39 into the array housing; contacting a first lead wire with the first terminal and contacting a second lead wire with the second terminal; as well as The first lead is attached to the first terminal and the second lead is attached to the second terminal.

44. The process of claim 43, wherein: After the energy storage device is positioned in the array housing, the position of the battery is not adjusted.

45. A process according to claim 43 or 44, wherein: Attaching the first lead to the first terminal and attaching the second lead to the second terminal includes laser welding.

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