Battery configuration for hybrid or electric vehicle

Abstract

The invention provides a battery configuration for a hybrid vehicle or an electric vehicle. A battery system includes an array of cells and an insulating plate. The cell array is arranged into a first cell core set and a second cell core set. The first set of battery cores and the second set of battery cores define a space therebetween. The insulating plate has a central region disposed within the space. The insulating plate has a first lateral region and a second lateral region disposed outside the space and extending beyond opposite first and second lateral ends of the array of cells, respectively. The central region has a first dimension extending in a first direction between the first set of cells and the second set of cells. The first lateral region and the second lateral region respectively have a second dimension and a third dimension extending in a second direction. The second direction is substantially parallel to the first direction. The second size and the third size are larger than the first size.

Description

Technical Field

[0001] The present disclosure relates to hybrid / electric vehicles and batteries for hybrid / electric vehicles. Background Art

[0002] Hybrid / electric vehicles may be propelled by an electric motor that draws power from a battery. Summary of the invention

[0003] A battery system includes a housing, an array of cells, and a plurality of insulating plates. The housing defines an internal cavity. The array of cells is disposed within the internal cavity and is arranged into a plurality of cell subsets. Adjacent cell subsets are spaced relative to each other. Cells in each cell subset are adjacent to adjacent cells in the same cell subset. A plurality of insulating plates are disposed within the housing. Each insulating plate has a central portion disposed between two cell subsets in the cell subsets. Each insulating plate extends beyond opposite first and second sides of the cell array. Each insulating plate has a first outer end and a second outer end, the first outer end and the second outer end being positioned between the opposite first and second sides of the cell array and the housing, respectively. The central portion of each insulating plate has a first dimension extending between the corresponding two cell subsets. The first outer end and the second outer end of each insulating plate have a second dimension and a third dimension, respectively, parallel to the first dimension. The second dimension and the third dimension are larger than the first dimension.

[0004] A battery system includes an array of cells and an insulating plate. The array of cells is arranged into a first subset of cells and a second subset of cells. The first subset of cells and the second subset of cells define a space therebetween. The insulating plate has a central region disposed within the space. The insulating plate has a first lateral region and a second lateral region, the first lateral region and the second lateral region being disposed outside the space and extending beyond opposite first and second lateral sides of the array of cells, respectively. The central region has a first dimension extending between the first subset of cells and the second subset of cells along a first direction. The first lateral region and the second lateral region have a second dimension and a third dimension extending in a second direction, respectively. The second direction is substantially parallel to the first direction. The second dimension and the third dimension are greater than the first dimension.

[0005] A battery system includes a first group of cells, a second group of cells, and an I-shaped insulator. The I-shaped insulator has a web disposed between the first group of cells and the second group of cells. The I-shaped insulator has a first flange and a second flange and extends beyond the opposite lateral ends of the first group of cells and the second group of cells, respectively. The web has a first width extending between the first group of cells and the second group of cells. The first flange and the second flange have a second width and a third width, respectively. The second width and the third width are greater than the first width, so that the first flange and the second flange each overhang the first group of cells and the second group of cells. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a schematic diagram of a representative powertrain system of an electric vehicle;

[0007] Figure 2 is a top view of the battery with the top cover or panel of the battery housing removed; and

[0008] Figure 3 is a side view of a battery with the side cover or panel of the battery housing removed. DETAILED DESCRIPTION

[0009] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show the details of a particular component. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for teaching those skilled in the art to adopt the embodiments in different ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any one of the drawings may be combined with the features shown in one or more other drawings to produce embodiments that are not explicitly shown or described. The combination of features shown provides representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0010] refer to Figure 1 , showing a schematic diagram of an electric vehicle 10 according to an embodiment of the present disclosure. Figure 1Representative relationships between components are shown. The physical layout and orientation of the components within the vehicle may vary. The electric vehicle 10 includes a powertrain 12. The powertrain 12 includes an electric machine, such as an electric motor / generator (M / G) 14, that drives a transmission (or gearbox) 16. More specifically, the M / G 14 may be rotatably connected to an input shaft 18 of the transmission 16. The transmission 16 may be placed in PRNDSL (parking, reverse, neutral, driving, sports, low gear) via a transmission gear selector (not shown). The transmission 16 may have a fixed gear transmission relationship that provides a single gear ratio between the input shaft 18 and the output shaft 20 of the transmission 16. A torque converter (not shown) or a starting clutch (not shown) may be provided between the M / G 14 and the transmission 16. Alternatively, the transmission 16 may be a multi-speed ratio automatic transmission. An associated traction battery 22 is configured to deliver power to or receive power from the M / G 14.

[0011] The M / G 14 is a drive source for the electric vehicle 10, which is configured to propel the electric vehicle 10. The M / G 14 can be implemented by any of a variety of types of electric machines. For example, the M / G 14 can be a permanent magnet synchronous motor. The power electronics 24 regulates the direct current (DC) power provided by the battery 22 according to the requirements of the M / G 14, as will be described below. For example, the power electronics 24 can provide three-phase alternating current (AC) to the M / G 14.

[0012] If the transmission 16 is a multi-ratio automatic transmission, the transmission 16 may include a gear set (not shown) that is selectively placed in different gear ratios by selectively engaging friction elements such as clutches and brakes (not shown) to establish a desired plurality of discrete or stepped gear ratios. The friction elements may be controlled by a shift schedule that connects and disconnects certain elements of the gear set to control the gear ratio between the transmission output shaft 20 and the transmission input shaft 18. The transmission 16 is automatically shifted from one gear ratio to another by an associated controller, such as a powertrain control unit (PCU), based on various vehicle and environmental conditions. Power and torque from the M / G 14 may be delivered to and received by the transmission 16. The transmission 16 then provides the powertrain output power and torque to the output shaft 20.

[0013] It should be understood that the hydraulically controlled transmission 16, which may be coupled to a torque converter (not shown), is merely one example of a gearbox or transmission device; any multi-ratio gearbox that accepts one or more input torques from a power source (e.g., M / G 14) and then provides torque to an output shaft (e.g., output shaft 20) at different gear ratios is acceptable for use with embodiments of the present disclosure. For example, the transmission 16 may be implemented by an automated mechanical (or manual) transmission (AMT) that includes one or more servomotors to translate / rotate a shift fork along a shift rail to select a desired gear ratio. As is generally understood by those of ordinary skill in the art, an AMT may be used, for example, in applications with higher torque requirements.

[0014] like Figure 1 As shown in the representative embodiment of FIG. 1 , the output shaft 20 is connected to a differential 26. The differential 26 drives a pair of drive wheels 28 via respective axles 30 connected to the differential 26. The differential 26 transmits approximately equal torque to each wheel 28, while allowing slight speed differences, such as when the vehicle is turning. Different types of differentials or similar devices can be used to distribute torque from the drivetrain to one or more wheels. In some applications, the torque distribution can vary depending on, for example, a specific operating mode or operating condition.

[0015] The powertrain system 12 also includes an associated controller 32, such as a powertrain control unit (PCU). Although shown as one controller, the controller 32 may be part of a larger control system and may be controlled by various other controllers throughout the vehicle 10, such as a vehicle system controller (VSC). Therefore, it should be understood that the powertrain control unit 32 and one or more other controllers may be collectively referred to as a "controller" that controls various actuators in response to signals from various sensors to control functions such as operating the M / G 14 to provide wheel torque or charging the battery 22, selecting or scheduling transmission shifts, etc. The controller 32 may include a microprocessor or central processing unit (CPU) that communicates with various types of computer-readable storage devices or media. The computer-readable storage devices or media may include, for example, volatile and non-volatile storage devices in read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the CPU is powered off. The computer readable storage device or medium may be implemented using any of a number of known memory devices such as a PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combination memory device capable of storing data, some of which represents executable instructions used by the controller to control the engine or vehicle.

[0016] The controller 32 communicates with various vehicle sensors and actuators via an input / output (I / O) interface (including input channels and output channels), which may be implemented as a single integrated interface that provides various raw data or signal conditioning, processing and / or conversion, short circuit protection, etc. Alternatively, one or more dedicated hardware or firmware chips may be used to condition and process specific signals before supplying them to the CPU. Figure 1 As generally shown in the representative embodiment of FIG. 1 , the controller 32 may transmit signals to the M / G 14, the battery 22, the transmission 16, the power electronics 24, and other components of the powertrain 12 that may be included but not shown. Figure 114 and the transmission 16). Although not explicitly shown, one of ordinary skill in the art will recognize the various functions or components within each of the subsystems identified above that may be controlled by the controller 32. Representative examples of parameters, systems, and / or components that may be directly or indirectly actuated using control logic and / or algorithms executed by the controller 32 include front end accessory drive (FEAD) components such as an alternator, an air conditioning compressor, battery charging or discharging, regenerative braking, M / G 14 operation, clutch pressure of the transmission gearbox 16, or any other clutch as part of the powertrain 12, etc. For example, sensors transmitting input through the I / O interface can be used to indicate wheel speed (WS1, WS2), vehicle speed (VSS), coolant temperature (ECT), accelerator pedal position (PPS), ignition switch position (IGN), ambient air temperature (e.g., ambient air temperature sensor 33), transmission gear, gear ratio or mode, transmission oil temperature (TOT), transmission input and output speeds, shift pattern (MDE), battery temperature, voltage, current or state of charge (SOC).

[0017] The control logic or functions performed by the controller 32 can be represented by a flowchart or similar diagram in one or more of the accompanying drawings. These drawings provide representative control strategies and / or logic that can be implemented using one or more processing strategies (such as event-driven, interrupt-driven, multi-tasking, multi-threading, etc.). Thus, the various steps or functions shown can be performed in the order shown, in parallel, or omitted in some cases. Although not always explicitly shown, it will be recognized by those of ordinary skill in the art that one or more of the steps or functions shown can be repeatedly performed according to the specific processing strategy used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for ease of illustration and description. The control logic can be implemented primarily in software executed by a microprocessor-based vehicle and / or powertrain controller (such as controller 32). Of course, depending on the specific application, the control logic can be implemented in software, hardware, or a combination of software and hardware in one or more controllers. When implemented in software, the control logic can be provided in one or more computer-readable storage devices or media, which store data representing codes or instructions executed by a computer to control a vehicle or a vehicle subsystem. The computer-readable storage device or medium may include one or more of several known physical devices that use electrical, magnetic, and / or optical storage to hold executable instructions and associated calibration information, operating variables, and the like.

[0018] The driver of the vehicle uses an accelerator pedal 34 to provide the desired torque, power or drive command for propulsion of the vehicle to the powertrain 12 (or more specifically, the M / G 14). Typically, depressing and releasing the accelerator pedal 34 generates an accelerator pedal position signal, which can be interpreted by the controller 32 as a need for increased power or reduced power, respectively. The driver of the vehicle also uses a brake pedal 36 to provide a required braking torque to decelerate the vehicle. Typically, depressing and releasing the brake pedal 36 generates a brake pedal position signal, which can be interpreted by the controller 32 as a need to reduce the vehicle speed. Based on inputs from the accelerator pedal 34 and the brake pedal 36, the controller 32 commands torque and / or power to the M / G 14 and the friction brake 38. The controller 32 also controls the timing of shifting in the transmission 16.

[0019] The M / G 14 can function as a motor and provide driving force for the powertrain 12. To drive the vehicle with the M / G 14, the traction battery 22 transmits stored electrical energy to the power electronics 24, which may include, for example, inverter and rectifier circuits, via the wiring 40. The inverter circuit of the power electronics 24 can convert the DC voltage from the battery 22 into an AC voltage to be used by the M / G 14. The rectifier circuit of the power electronics 24 can convert the AC voltage from the M / G 14 into a DC voltage to be stored by the battery 22. The controller 32 commands the power electronics 24 to convert the voltage from the battery 22 into an AC voltage provided to the M / G 14 to provide positive or negative torque to the input shaft 18.

[0020] The M / G 14 may also function as a generator and convert kinetic energy from the powertrain 12 into electrical energy for storage in the battery 22. More specifically, the M / G 14 may function as a generator during regenerative braking events, in which torque and rotational (or kinetic) energy from the rotating wheels 28 are transferred back through the transmission 16 and converted into electrical energy for storage in the battery 22.

[0021] It should be understood that the vehicle configurations described herein are exemplary only and are not intended to be limiting. Other electric vehicle or hybrid electric vehicle configurations should be interpreted as disclosed herein. Other electric or hybrid vehicle configurations may include, but are not limited to, series hybrid vehicles, parallel hybrid vehicles, series-parallel hybrid vehicles, plug-in hybrid electric vehicles (PHEVs), fuel cell hybrid vehicles, battery-operated electric vehicles (BEVs), or any other vehicle configuration known to those of ordinary skill in the art.

[0022] In a hybrid configuration including an internal combustion engine such as a gasoline, diesel or natural gas powered engine or a fuel cell, the controller 32 may be configured to control various parameters of such an internal combustion engine. Representative examples of internal combustion engine parameters, systems and / or components that may be directly or indirectly actuated using control logic and / or algorithms executed by the controller 32 include fuel injection timing, rate and duration, throttle position, spark plug firing timing (for spark ignition engines), intake / exhaust valve timing and duration, etc. Sensors that transmit inputs from such an internal combustion engine to the controller 32 via an I / O interface may be used to indicate turbocharger boost pressure, crankshaft position (PIP), engine speed (RPM), intake manifold pressure (MAP), throttle position (TP), exhaust oxygen (EGO) or other exhaust constituents amount or presence, intake air flow (MAF), etc.

[0023] It should be understood that Figure 1 The schematic diagrams shown in are representative only and are not intended to be limiting. Other configurations are contemplated without departing from the scope of the present disclosure. For example, the vehicle powertrain 12 may be configured to deliver power and torque to one or both of the front wheels, rather than the rear wheels 28 shown.

[0024] As lithium-ion batteries move toward higher energy density with high nickel chemistries, preventing thermal runaway events becomes more important. When a battery cell is experiencing a thermal runaway event, the thermal runaway may propagate to adjacent cells. It is important to slow down the rate of heat propagation.

[0025] Once a battery cell experiences a thermal runaway event, the cell may vent from three sealed sides, potentially causing heat and gas to propagate in three different directions. It is important to block the heat and gas between the cells of the battery to slow down or stop such a thermal runaway event. Directing and releasing heat and gas in a single direction during a thermal runaway event helps slow the propagation rate. An I-shaped thermal insulator made of mica (a group of silicate minerals, AB2–3(X,Si)4O10(O,F,OH)2) or any heat-resistant material (e.g., aerogel, etc.) is disposed between the cells or a group of cells of the battery 22 and one or more outlets are formed along one side (e.g., lateral side, top or bottom) of the frame, housing or shell of the battery 22 to direct and release heat and gas toward the side of the frame, housing or shell of the battery 22. Mica may also include any of a group of hydrated potassium, aluminum silicate minerals. Mica may also be a phyllosilicate exhibiting a two-dimensional sheet or layered structure.

[0026] refer to Figure 2 and Figure 3, shows a configuration of a battery system 42 (e.g., battery 22). The battery system 42 includes battery cells 44. The battery cells 44 are arranged in an array. The battery cells 44 are also arranged into groups or subsets 46 of the battery cells 44. The total number of battery cells 44, the total number of subsets 46 of battery cells 44, and the number of battery cells 44 in each subset 46 are for illustration purposes only. The battery system 42 can include any number of battery cells 44 and any number of subsets 46 of battery cells 44. In addition, each subset 46 of battery cells 44 can include any number of battery cells 44.

[0027] The battery system 42 includes a frame, housing, or casing 48. The casing 48 defines an interior cavity 50. The array of cells 44 is disposed within the interior cavity 50. The casing 48 may have a plurality of panels, covers, or walls 52. For example, the casing 48 may include two opposing side walls 54, two opposing end walls 56, a top wall 58, and a bottom wall 60. The array of cells 44 may be arranged in a direction extending between the opposing end walls 56. For illustration purposes, the top wall 58 may be disposed in a direction extending between the opposing end walls 56. Figure 2 The top wall 58 is removed. Figure 3 One of the side walls 54 is removed.

[0028] Adjacent subsets 46 of the cells 44 are spaced relative to each other such that gaps or spaces 62 are defined between adjacent subsets 46 of the cells 44. The cells 44 within each subset 46 of the cells 44 may abut or contact adjacent cells 44 within the same subset 46 of the cells 44. An insulating plate or insulator 64 may be disposed within the internal cavity 50 of the housing 48. More specifically, each insulator 64 (or a portion of each insulator 64) may be disposed within one of the spaces 62 defined between adjacent subsets 46 of the cells 44. Additional insulators (not shown) may be disposed between the ends of the array of cells 44 and the end wall 56. The insulator 64 may be composed of a material having thermal insulation properties, such as a mica material or an aerogel material.

[0029] The insulators 64 have a central portion or region 66. The central region 66 of each insulator 64 is disposed within one of the spaces 62 and between a first subset and a second subset of the subsets 46 of the cells 44, wherein the first subset and the second subset of the subsets 46 of the cells 44 are adjacent to each other. Each of the insulators 64 has a first outer side, outer end or lateral region 68 and a second outer side, outer end or lateral region 69 disposed outside of the corresponding space 62 but within the interior cavity 50 of the housing 48. When viewed from the top (e.g., when viewed from the top), the insulators 64 are disposed between the first and second subsets of the subsets 46 of the cells 44, and the first and second subsets of the subsets 46 of the cells 44 are adjacent to each other. Figure 2 The insulator 64 may be I-shaped such that the central region 66 corresponds to the web and the lateral regions 68, 69 correspond to first and second flanges extending laterally outward from ends of the web.

[0030] The first lateral region 68 and the second lateral region 69 of the insulator 64 extend beyond the opposing first lateral ends or sides 70 and the second lateral ends or sides 72, respectively, of the array of battery cells 44. The opposing first lateral ends or sides 70 and the second lateral ends or sides 72 may also correspond to the opposing first lateral ends or sides of the subset 46 of battery cells 44, or more generally to the opposing first lateral ends or sides of each battery cell 44. The first lateral region 68 and the second lateral region 69 of the insulator 64 are disposed or positioned between the opposing first lateral sides 70 and the second lateral sides 72 of the array of battery cells 44 and the housing 48, respectively. More specifically, the first lateral region 68 and the second lateral region 69 of the insulator 64 may be disposed or positioned between the opposing first lateral sides 70 and the second lateral sides 72 of the array of battery cells 44 and the first and second ones of the opposing side walls 54 of the housing 48, respectively.

[0031] The central region 66 of each insulator 64 has a first dimension 74 extending along a first direction 76 between the corresponding subset 46 of cells 44 between which each central region 66 is disposed. The first dimension 74 may correspond to the width of the central region 66 or web of each insulator 64. The first lateral region 68 and the second lateral region 69 of each insulator 64 have a second dimension 78 and a third dimension 80, respectively, extending in a second direction 82. The second dimension 78 and the third dimension 80 may correspond to the width of the first lateral region or flange and the second lateral region or flange of the lateral regions 68, 69, or flange of each insulator 64. The second direction 82 may be substantially parallel to the first direction 76. The second dimension 78 and the third dimension 80 may be substantially parallel to the first dimension 74. Substantially parallel may refer to any incremental angle between completely parallel and 15° different from completely parallel.

[0032] The second dimension 78 and the third dimension 80 of each insulator 64 are greater than the corresponding first dimension 74 of each insulator 64 such that the first lateral region 68 and the second lateral region 69 (e.g., the first flange and the second flange of each insulator 64) of each insulator 64 each overhang the two subsets 46 of cells 44 between which the corresponding central region 66 is disposed. More specifically, the first lateral region 68 and the second lateral region 69 of each insulator 64 overhang the two subsets 46 of cells 44 between which the corresponding central region 66 is disposed, respectively, along the opposite first and second lateral ends or sides 70, 72 of the array of cells 44 and along the second dimension 78 and the third dimension 80, respectively.

[0033] The first lateral region 68 and the second lateral region 69 of the insulator 64 abut the first lateral wall and the second lateral wall of the housing 48, respectively, within the interior cavity 50. The first lateral wall and the second lateral wall of the housing may refer to the first and second side walls of the side walls 54 of the housing 48. The first lateral region 68 and the second lateral region 69 of the insulator 64 also abut the opposite lateral sides of each of the two subsets 46 of cells 44 between which the corresponding central region 66 is disposed, respectively, and along the second dimension 78 and the third dimension 80, respectively. The opposite first and second lateral sides of each of the two subsets 46 of cells 44 between which the corresponding central region 66 is disposed may refer to the opposite first and second lateral sides 70 and 72.

[0034] Each of the insulators 64 has a top side, top end or top region 84 and a bottom side, bottom end or bottom region 86. The top side, top end or top region 84 and the bottom side, bottom end or bottom region 86 may be referred to as an upper side, upper end or upper region and a lower side, lower end or lower region, respectively. The top region 84 and the bottom region 86 of the insulator 64 abut the top wall 58 and the bottom wall 60 of the case 48, respectively, within the interior cavity 50. The top wall 58 of the case 48 defines venting apertures 88 between adjacent subsets 46 of the battery cells 44, thereby allowing heat energy and gases to escape during a thermal event, as indicated by arrows 90.

[0035] The insulator 64 establishes a boundary that separates adjacent subsets 46 of the cells 44 from one another by establishing contact (e.g., by abutting) with the top wall 58 of the housing, the bottom wall 60 of the housing 48, the side walls 54 of the housing 48, and opposing lateral sides of the subsets 46 of the cells 44 (e.g., opposing first lateral ends or sides 70 and second lateral ends or sides 72 of the array of cells 44). The insulator 64 also separates a space 92 surrounding the subsets 46 of the cells 44 from adjacent subsets 46 of the cells 44 and the space 92 surrounding the adjacent subsets 46 of the cells 44. The space 92 surrounding the subsets 46 of the cells 44 may be defined between the subsets 46 of the cells 44 and the housing 48. The separation between the adjacent subsets 46 of the cells 44 and the space 92 surrounding the subsets 46 of the cells 44 helps direct heat energy and gases through the vent openings 88 during a thermal event.

[0036] It should be understood that the first, second, third, fourth, etc. designations for any component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. In addition, it should be understood that any component, state, or condition described herein without a numerical designation may be given a first, second, third, fourth, etc. designation in the claims if one or more specific components, states, or conditions are claimed.

[0037] The words used in the specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present disclosure. As previously mentioned, the features of the various embodiments may be combined to form additional embodiments that may not be explicitly described or shown. Although various embodiments may have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, it should be recognized by those of ordinary skill in the art that one or more features or characteristics may be compromised to achieve the desired overall system properties, depending on the specific application and implementation. To this end, embodiments that are described as being less desirable than other embodiments or prior art implementations with respect to one or more characteristics are within the scope of the present disclosure and may be desirable for a particular application.

[0038] According to the present invention, a battery system is provided, the battery system comprising: a shell, the shell defining an internal cavity; a cell array, the cell array (i) being arranged in the internal cavity and (ii) being arranged into a plurality of cell subsets, wherein (a) adjacent cell subsets are spaced relative to each other, and (b) cells within each cell subset are adjacent to adjacent cells within the same cell subset; and a plurality of insulating plates, the plurality of insulating plates being arranged in the shell, wherein each insulating plate (i) has a central portion arranged between two cell subsets in the cell subsets, (ii) extending beyond opposite first and second sides of the cell array, and (iii) having a first outer end and a second outer end, the first outer end and the second outer end being respectively positioned between the opposite first and second sides of the cell array and the shell, wherein (a) the central portion of each insulating plate has a first dimension extending between the corresponding two cell subsets, (b) the first outer end and the second outer end of each insulating plate have a second dimension and a third dimension respectively parallel to the first dimension, and (c) the second dimension and the third dimension are larger than the first dimension.

[0039] According to an embodiment, the first outer end and the second outer end of each insulating plate overhangs over a side of each of the corresponding two subsets of battery cells along the second dimension and the third dimension, respectively.

[0040] According to an embodiment, the first outer end and the second outer end of each insulating plate abut against a first side wall and a second side wall of the housing, respectively, within the inner cavity.

[0041] According to an embodiment, the first outer end and the second outer end of each insulating plate abut opposite sides of each of the corresponding two subsets of battery cells along the second dimension and the third dimension, respectively.

[0042] According to an embodiment, a top end and a bottom end of each insulating plate abut against a top wall and a bottom wall of the housing, respectively, within the inner cavity.

[0043] According to an embodiment, the top wall of the housing defines venting apertures between adjacent subsets of battery cells.

[0044] According to an embodiment, each insulating plate consists of a mica material.

[0045] According to an embodiment, each insulating plate consists of an aerogel material.

[0046] According to the present invention, a battery system is provided, which comprises: a battery cell array, which is arranged into a first subset of battery cells and a second subset of battery cells, wherein the first subset of battery cells and the second subset of battery cells define a space therebetween; and an insulating plate, which (i) has a central area arranged in the space, and (ii) has a first lateral area and a second lateral area, which are arranged outside the space and extend respectively beyond the opposite first lateral side and second lateral side of the battery cell array, wherein (a) the central area has a first dimension extending between the first subset of battery cells and the second subset of battery cells along a first direction, (b) the first lateral area and the second lateral area respectively have a second dimension and a third dimension extending in a second direction, (c) the second direction is substantially parallel to the first direction, and (d) the second dimension and the third dimension are larger than the first dimension.

[0047] According to an embodiment, the first and second lateral regions of the insulating plate overhang sides of each of the first and second subsets of battery cells along the second and third dimensions, respectively.

[0048] According to an embodiment, the invention is also characterized by a housing defining an interior cavity, and wherein the array of battery cells and the insulating plate are disposed within the interior cavity.

[0049] According to an embodiment, the first and second lateral regions of the insulating plate adjoin a first and a second lateral wall, respectively, of the housing within the inner cavity.

[0050] According to an embodiment, the first and second lateral regions of the insulating plate adjoin opposite lateral sides of each of the first and second subsets of battery cells along the second and third dimensions, respectively.

[0051] According to an embodiment, the top end and the bottom end of each insulating plate abut against the top wall and the bottom wall of the housing, respectively, within the inner cavity.

[0052] According to an embodiment, a top wall of the housing defines a vent aperture between the first subset of battery cells and the second subset of battery cells.

[0053] According to the present invention, a battery system is provided, which comprises: a first group of battery cells and a second group of battery cells; and an I-shaped insulator, wherein the I-shaped insulator (i) has a web arranged between the first group of battery cells and the second group of battery cells, and (ii) has a first flange and a second flange and extends beyond the relative lateral ends of the first group of battery cells and the second group of battery cells, respectively, wherein (a) the web has a first width extending between the first group of battery cells and the second group of battery cells, (b) the first flange and the second flange have a second width and a third width, respectively, and (c) the second width and the third width are greater than the first width, so that the first flange and the second flange are respectively suspended above the first group of battery cells and the second group of battery cells.

[0054] According to an embodiment, the invention is also characterized by a housing defining an interior cavity, and wherein the first group of cells and the second group of cells and the I-shaped insulator are disposed within the interior cavity.

[0055] According to an embodiment, the first flange and the second flange of the I-shaped insulator abut against a first lateral wall and a second lateral wall of the housing, respectively, within the inner cavity.

[0056] According to an embodiment, the top end and the bottom end of the I-shaped insulator abut against the top wall and the bottom wall of the housing, respectively, within the inner cavity.

[0057] According to an embodiment, a top wall of the housing defines a venting aperture between the first group of battery cells and the second group of battery cells.

Claims

1. A battery system, comprising: a housing defining an interior cavity; A cell array (i) disposed within the interior cavity and (ii) arranged into a plurality of cell subsets, wherein (a) adjacent cell subsets are spaced relative to each other, and (b) cells within each cell subset are adjacent to adjacent cells within the same cell subset; as well as A plurality of insulating plates are disposed within the shell, wherein each insulating plate (i) has a central portion disposed between two of the battery cell subsets, (ii) extends beyond the first and second opposite sides of the battery cell array, and (iii) has a first outer end and a second outer end, the first outer end and the second outer end being respectively positioned between the first and second opposite sides of the battery cell array and the shell, wherein (a) the central portion of each insulating plate has a first dimension extending between the corresponding two battery cell subsets, (b) the first and second outer ends of each insulating plate have a second and third dimension parallel to the first dimension, and (c) the second and third dimensions are larger than the first dimension.

2. The battery system of claim 1, wherein the first outer end and the second outer end of each insulating plate overhang a side of each of the corresponding two battery cell subsets along the second dimension and the third dimension, respectively.

3. A battery system as described in claim 1, wherein the first outer end and the second outer end of each insulating plate are adjacent to the first side wall and the second side wall of the shell in the internal cavity, respectively, and wherein the first outer end and the second outer end of each insulating plate are adjacent to the opposite sides of each of the corresponding two battery cell subsets along the second dimension and the third dimension, respectively. 4 . The battery system of claim 1 , wherein a top end and a bottom end of each insulating plate abut against a top wall and a bottom wall of the housing, respectively, within the interior cavity.

5. The battery system of claim 1, wherein a top wall of the housing defines vent openings between adjacent subsets of battery cells.

6. The battery system as claimed in claim 1, wherein each insulating plate is composed of a mica material or an aerogel material.

7. A battery system, comprising: an array of cells arranged into a first subset of cells and a second subset of cells, wherein the first subset of cells and the second subset of cells define a space therebetween; as well as An insulating plate, the insulating plate (i) having a central area arranged in the space, (ii) having a first lateral area and a second lateral area, the first lateral area and the second lateral area are arranged outside the space and extend respectively beyond the opposite first lateral side and second lateral side of the battery cell array, wherein (a) the central area has a first dimension extending between the first battery cell subset and the second battery cell subset along a first direction, (b) the first lateral area and the second lateral area have a second dimension and a third dimension extending in a second direction, (c) the second direction is substantially parallel to the first direction, and (d) the second dimension and the third dimension are larger than the first dimension.

8. The battery system of claim 7, wherein the first lateral region and the second lateral region of the insulating plate overhang sides of each of the first and second subsets of cells along the second and third dimensions, respectively.

9. The battery system of claim 7, further comprising a housing defining an internal cavity, and wherein the battery cell array and the insulating plate are disposed within the internal cavity.

10. A battery system as described in claim 9, wherein the first lateral region and the second lateral region of the insulating plate are adjacent to the first lateral wall and the second lateral wall of the shell in the internal cavity, respectively, and wherein the first lateral region and the second lateral region of the insulating plate are adjacent to the opposite lateral sides of each of the first cell subset and the second cell subset along the second dimension and the third dimension, respectively.

11. The battery system of claim 9, wherein a top wall of the housing defines a vent aperture between the first subset of battery cells and the second subset of battery cells.

12. A battery system, comprising: a first group of battery cells and a second group of battery cells; as well as An I-shaped insulator, wherein the I-shaped insulator (i) has a web disposed between the first group of battery cells and the second group of battery cells, and (ii) has a first flange and a second flange and extends beyond the relative lateral ends of the first group of battery cells and the second group of battery cells, respectively, wherein (a) the web has a first width extending between the first group of battery cells and the second group of battery cells, (b) the first flange and the second flange have a second width and a third width, respectively, and (c) the second width and the third width are greater than the first width, so that the first flange and the second flange are respectively suspended above the first group of battery cells and the second group of battery cells.

13. The battery system of claim 12, further comprising a housing defining an internal cavity, and wherein the first group of battery cells and the second group of battery cells and the I-shaped insulator are disposed within the internal cavity.

14. The battery system of claim 13, wherein the first flange and the second flange of the I-shaped insulator abut a first lateral wall and a second lateral wall of the housing, respectively, within the interior cavity.

15. The battery system of claim 13, wherein a top wall of the housing defines a vent opening between the first group of cells and the second group of cells.

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