Battery cell including internal stack structure expansion control mechanism

Abstract

A battery cell includes a cell can having a base, a plurality of sidewalls connected to the base, the base and the plurality of sidewalls defining a cell stack containment area. And a battery cell stack which is arranged in the battery cell stack accommodating area. A resilient expansion limiter is disposed at one of the plurality of sidewalls in the stack housing area. The elastic expansion limiter controls expansion of the cell stack structure.

Description

Technical Field

[0001] The present disclosure relates to the field of battery assemblies, and more particularly, to battery cells including an internal stack structure expansion control mechanism. Background Art

[0002] A battery assembly is formed by a plurality of battery cells. A battery cell includes an electrode stack structure disposed in a housing. Over time, charging and discharging of the battery cell will cause the stack structure to expand. When the stack structure expands, pressure is applied to the inner housing wall surface. In addition, the expansion reduces the open space in the housing that houses the electrolyte. The pressure on the housing and the increased pressure on the electrolyte due to the reduced volume in the housing may reduce battery performance. Accordingly, it is desirable to provide a system for controlling the expansion of a battery pack. Summary of the Invention

[0003] According to a non-limiting example, a battery cell includes a cell can having a base and a plurality of sidewalls connected to the base, the base and the plurality of sidewalls defining a cell stack receiving area. A battery cell stack is disposed in the battery stack receiving area. An elastic expansion limiter is disposed at one of the plurality of sidewalls in the battery stack receiving area. The elastic expansion limiter controls the expansion of the battery cell stack structure.

[0004] In addition to one or more of the features described herein, the plurality of sidewalls include a first sidewall, a second sidewall spaced apart from the first sidewall, a third sidewall, and a fourth sidewall spaced apart from the third sidewall, the third sidewall and the fourth sidewall extending between and connecting the first sidewall and the second sidewall, and the elastic expansion limiter is mounted to one of the first sidewall and the second sidewall.

[0005] In addition to one or more of the features described herein, the first sidewall includes a first area, and the third sidewall includes a second area, the first area being greater than the second area.

[0006] In addition to one or more of the features described herein, the elastic expansion limiter includes a first surface mounted to one of the first sidewall and the second sidewall and a second surface opposite the first surface.

[0007] In addition to one or more of the features described herein, the second surface is a substantially flat surface.

[0008] In addition to one or more of the features described herein, the second surface is a curved surface.

[0009] In addition to one or more of the features described herein, the elastic expansion limiter includes a plurality of spring elements disposed between the first surface and the second surface.

[0010] In addition to one or more features described herein, the resilient expansion limiter includes a first resilient expansion limiter mounted to a first surface and a second resilient expansion limiter mounted to a second surface.

[0011] In addition to one or more features described herein, an extrusion pad is disposed between the resilient expansion limiter and one of the plurality of side walls.

[0012] In addition to one or more features described herein, the resilient expansion limiter includes a honeycomb structure.

[0013] According to a non - limiting example, a vehicle includes a body having a passenger compartment, a plurality of wheels connected to the body, and a drive unit supported in the body. The drive unit is operatively connected to at least one of the plurality of wheels. A battery assembly is supported by the body and electrically connected to the drive unit. The battery assembly includes a plurality of battery cells. Each of the plurality of battery cells includes a cell canister having a base, a plurality of side walls connected to the base, the base and the plurality of side walls defining a battery stack receiving area. A battery cell stack is disposed in the battery stack receiving area. A resilient expansion limiter is disposed at one of the plurality of side walls in the battery stack receiving area. The resilient expansion limiter controls the expansion of the battery cell stack structure.

[0014] In addition to one or more features described herein, the plurality of side walls includes a first side wall, a second side wall spaced from the first side wall, a third side wall, and a fourth side wall spaced from the third side wall, the third side wall and the fourth side wall extending between and connecting the first side wall and the second side wall, and the resilient expansion limiter is mounted to one of the first side wall and the second side wall.

[0015] In addition to one or more features described herein, the first side wall includes a first area, and the third side wall includes a second area, the first area being greater than the second area.

[0016] In addition to one or more features described herein, the resilient expansion limiter includes a first surface mounted to one of the first side wall and the second side wall and a second surface opposite the first surface.

[0017] In addition to one or more features described herein, the second surface is a substantially flat surface.

[0018] In addition to one or more features described herein, the second surface is a curved surface.

[0019] In addition to one or more features described herein, the resilient expansion limiter includes a plurality of spring elements disposed between the first surface and the second surface.

[0020] In addition to one or more features described herein, the resilient expansion limiter includes a first resilient expansion limiter mounted to a first surface and a second resilient expansion limiter mounted to a second surface.

[0021] In addition to one or more features described herein, the extrusion pad is disposed between the resilient expansion limiter and one of the plurality of side walls.

[0022] In addition to one or more features described herein, the resilient expansion limiter includes a honeycomb structure.

[0023] The above and other features and advantages of the present disclosure, as well as other features and advantages, are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other features, advantages, and details appear only by way of example in the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1 is a left side view of a vehicle including a battery assembly according to a non - limiting example, the battery assembly having battery cells provided with an internal stack expansion control mechanism;

[0026] Figure 2 is an exploded view of a battery assembly according to a non - limiting example, the battery assembly having battery cells provided with an internal stack structure expansion control mechanism;

[0027] Figure 3 is a partial perspective view of a battery cell provided with an internal laminate expansion control mechanism according to a non - limiting example;

[0028] Figure 4 is according to a non - limiting example of Figure 3 an exploded perspective view of one of the battery cells;

[0029] Figure 5 is a cross - sectional top view of a battery cell taken along line 5 - 5 through Figure 4 ;

[0030] Figure 6 is a cross - sectional top view of a battery cell provided with an internal stack structure expansion control mechanism according to another non - limiting example;

[0031] Figure 7 is according to another non - limiting example of Figure 3 an exploded perspective view of one of the battery cells;

[0032] Figure 8 is a cross - sectional top view of a battery cell taken along line 8 - 8 through Figure 7 ;

[0033] Figure 9 is a cross-sectional top view of a battery cell according to another non-limiting example;

[0034] Figure 10 is a cross-sectional top view of a battery cell provided with an internal stack structure expansion control mechanism and a squeeze pad according to another non-limiting example;

[0035] Figure 11 is a cross-sectional top view of a battery cell provided with an internal stack structure expansion control mechanism and a squeeze pad according to yet another non-limiting example;

[0036] Figure 12 is a cross-sectional top view of a battery cell provided with an internal stack structure expansion control mechanism and a squeeze pad according to yet another non-limiting example; and

[0037] Figure 13 is a cross-sectional top view of a battery cell provided with an internal stack structure expansion control mechanism and a squeeze pad according to yet another non-limiting example. Detailed Description

[0038] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals denote the same or corresponding parts and features.

[0039] According to a non-limiting example, a vehicle is generally designated by 10 in Figure 1 Vehicle 10 includes a body 12 supported on a plurality of wheels 16. Body 12 partially defines a passenger compartment 20 having a seat 23 positioned behind a dashboard 26. A steering controller 30 is disposed between seat 23 and dashboard 26. Operating steering control 30 controls the orientation of a selected one of the plurality of wheels 16. Vehicle 10 includes an electric drive unit 34 that provides power to one or more of the plurality of wheels 16.

[0040] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed in body 12 and supplies power to electric drive unit 34. In other arrangements, a fuel cell (not shown) may be used to supply power to electric drive unit 34. At this time, it should be understood that the positions of electric drive unit 34 and battery assembly 38 may vary. As Figure 2 shown, battery assembly 38 includes a housing 50 having a base member 52, an outer cover 54, and a plurality of inner covers 56. Inner covers 56 shield a plurality of battery cells 60 arranged in a plurality of adjacent rows 62, as Figure 3 shown.

[0041] Now reference will be made to Figure 4, describing one of the plurality of battery cells 60, it should be understood that the remaining battery cells in the plurality of battery cells 60 may include similar structures. The battery cell 60 includes a cell can 70 having a base 72, a plurality of side walls 76, and a top wall 78. The top wall 78 supports a pair of electrodes 80 including a cathode 82 and an anode 84. The base 72, the plurality of side walls 76, and the top wall 78 define a battery stack receiving area 86.

[0042] The plurality of side walls 76 include a first side wall 88, a second side wall 90 disposed opposite the first side wall 88, a third side wall 92, and a fourth side wall 94 disposed opposite the third side wall 92. The third side wall 92 and the fourth side wall 94 extend between the first side wall 88 and the second side wall 90 and are connected to the first side wall 88 and the second side wall 90. In one non-limiting example, the first side wall 88 and the second side wall 90 include a first area, and the third side wall 92 and the fourth side wall 94 include a second area smaller than the first area. As Figure 5 shown, the battery stack 100 is disposed in the battery stack receiving area 86 between the first side wall 88 and the second side wall 90 and between the third side wall 92 and the fourth side wall 94.

[0043] Reference will now be made to Figure 5 , and continuing reference will be made to Figure 4 , to describe the cell can 70 according to a non-limiting example. The first side wall 88 includes a first inner surface 102, and the second side wall 90 includes a second inner surface 104 facing the first inner surface 102. The cell can 70 includes a first elastic expansion limiter 108 and a second elastic expansion limiter 110 that constrain and limit the outward expansion of the battery stack 100. The first elastic expansion limiter 108 will be described below with reference to Figure 5 , it should be understood that the second elastic expansion limiter 110 includes corresponding structures. In addition, although two expansion limiters are shown, the cell can 70 of the battery cell may also be provided with a single expansion limiter or more than two expansion limiters according to design requirements.

[0044] In a non-limiting example, the first elastic expansion limiter 108 includes a first surface 112 and an opposite second surface 114, between which an elastic expansion medium 116 is defined. The first surface 112 is fixed to the first inner surface 102 of the first side wall 88. Depending on the material used to form the elastic expansion medium 116, various techniques can be used to fix the first surface 112, including adhesives, fusion welding, brazing, overmolding, etc. In a non-limiting example, the first surface 112 may define a first side (not separately marked) of the elastic expansion medium 116, and the second surface 114 may define a second side (also not separately marked) of the elastic expansion medium 116.

[0045] In a non - limiting example, the first elastic expansion medium 116 is a honeycomb member formed of an elastic material such as a metal, including aluminum, steel, and various alloys and composites, the composites including polymer composites that are non - reactive to electrolytes and also exhibit elasticity to absorb the expansion of the battery stack. The first elastic expansion limiter 108 and the second elastic expansion limiter 110 may include spring elements disposed between the first surface 112 and the second surface 114, as shown, for example, Figure 6 in 128 of Figure 6 , and are not formed of an elastic material. Regardless of the material employed, the first elastic expansion limiter 108 and the second elastic expansion limiter 110 are designed to expand and contract with the battery stack 100 without increasing the pressure on the first sidewall 88 and the second sidewall 90 in a manner that would cause a change in the external dimensions of the battery can 70.

[0046] Reference will now be made to Figure 7 、 Figure 8 and Figure 9 to describe a first elastic expansion limiter 144 and a second elastic expansion limiter 146 according to another non - limiting example. Since the first elastic expansion limiter 144 and the second elastic expansion limiter 146 are formed substantially similarly, the first elastic expansion limiter 144 will be described in detail. In a non - limiting example, the first elastic expansion limiter 144 includes a first surface 152 and a second surface 154, between which an elastic expansion medium 156 is defined. The first surface 152 is substantially planar and can be fixed to the first inner surface 102 using various techniques, including adhesives, fusion welding, brazing, overmolding, etc., depending on the material used to form the elastic expansion medium 156.

[0047] In a non - limiting example, the second surface 154 is a wavy or curved surface 158 including peaks 160 and valleys 162. The wavy or curved surface 158 may define a corrugated surface 158. Similarly in a manner similar to that discussed herein, the first surface 152 may define a first side (not separately labeled) of the elastic expansion medium 156, and the second surface 154 may define a second side (also not separately labeled) of the elastic expansion medium 156.

[0048] In a non - limiting example, the elastic expansion medium 156 is a honeycomb member formed of an elastic material such as a metal, including aluminum, steel, and various alloys and composite materials, the composite materials including polymer composite materials that are non - reactive to electrolytes and also exhibit elasticity to absorb the expansion of the battery stack. The first elastic expansion limiter 144 and the second elastic expansion limiter 146 may include such as Figure 9The spring element shown as 180 therein, rather than being formed of an elastic material. Regardless of the material employed, the first elastic expansion limiter 144 and the second elastic expansion limiter 146 are designed to expand and contract with the battery stack 100 without increasing the pressure on the first sidewall 88 and the second sidewall 90 in a manner that would cause a change in the external dimensions of the battery can 70.

[0049] Reference will now be made Figure 10 、 Figure 11 、 Figure 12 and Figure 13 to describe the battery cell 60 according to additional non - limiting examples. Referring to Figure 10 , in addition to the first elastic expansion limiter 108 and the second elastic expansion limiter 110, the battery cell 60 further includes a first extrusion pad 180 and a second extrusion pad 182. The first extrusion pad 180 is disposed between the first elastic expansion limiter 108 and the inner surface 102 of the first wall 88, and the second extrusion pad 182 is disposed between the second elastic expansion limiter 110 and the second inner surface 104 of the second sidewall 90. The first extrusion pad 180 and the second extrusion pad 188 provide additional expansion absorption characteristics for the battery stack 100.

[0050] Referring to Figure 11 , in addition to the first extrusion pad 180 and the second extrusion pad 182, the battery cell 60 further includes a third extrusion pad 190 and a fourth extrusion pad 192. The third extrusion pad 190 is disposed between the first elastic expansion limiter 108 and the battery stack 100, and the fourth extrusion pad 192 is disposed between the battery stack 100 and the second elastic expansion limiter 110. In a non - limiting example, the first extrusion pad 180, the second extrusion pad 182, the third extrusion pad 190, and / or the fourth extrusion pad 192 can be formed of various materials capable of withstanding contact with the electrolyte. In one non - limiting example, the material can be a purpose - made material that not only accommodates dimensional changes in the battery stack 100 but also accommodates volume changes in the electrolyte.

[0051] In addition to accommodating volume changes, one or more of the first extrusion pad 180, the second extrusion pad 182, the third extrusion pad 190, and / or the fourth extrusion pad 192 can include a heat - resistant coating that reduces the temperature at the outer surface of the battery can 70. For example, the second extrusion pad 182 can include a thermal barrier coating 200, as shown in Figure 12 and Figure 13 . Further, although shown as a supplement to the elastic expansion limiter, the extrusion pads can be used alone.

[0052] The term "a" or "an" does not denote a limitation of quantity, but rather denotes the presence of at least one of the referenced items. The term "or" is meant to mean "and / or" unless the context clearly dictates otherwise. References throughout the specification to "an aspect" mean that a particular element (e.g., a feature, a structure, a step, or a property) described in connection with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. Additionally, it should be understood that the described elements can be combined in any suitable manner in the various aspects.

[0053] When an element such as a layer, a film, a region, or a substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, no intervening elements are present.

[0054] Unless stated to the contrary herein, all test standards are the latest standards in effect as of the filing date of the present application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0055] Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0056] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted for its elements without departing from its scope. Additionally, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from its basic scope. Accordingly, it is intended that the disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery cell, comprising: a unit tank including a base, a plurality of side walls connected to the base, the base and the plurality of side walls defining a battery stack accommodation area; a battery cell stack arranged in the cell stack accommodation area; as well as An elastic expansion limiter is arranged at one of the plurality of side walls in the battery stack receiving area, the elastic expansion limiter controlling expansion of the battery stack.

2. The battery cell according to claim 1, wherein: The plurality of side walls include a first side wall, a second side wall spaced apart from the first side wall, a third side wall, and a fourth side wall spaced apart from the third side wall, the third side wall and the fourth side wall extending between and connecting the first side wall and the second side wall, the elastic expansion limiter being mounted to one of the first side wall and the second side wall. 3 . The battery cell of claim 2 , wherein the first side wall comprises a first area and the third side wall comprises a second area, the first area being greater than the second area.

4. The battery cell according to claim 2, wherein: The elastic expansion limiter includes a first surface mounted to the one of the first side wall and the second side wall and a second surface opposite the first surface. The battery cell of claim 4 , wherein the second surface is a substantially flat surface.

6. The battery cell according to claim 4, wherein: The second surface is a curved surface.

7. The battery cell according to claim 2, wherein: The elastic expansion limiter includes a first elastic expansion limiter mounted to the first side wall and a second elastic expansion limiter mounted to the second side wall. 8 . The battery cell according to claim 1 , further comprising a compression pad disposed between the elastic expansion limiter and the one of the plurality of side walls.

9. The battery cell according to claim 1, wherein: The elastic expansion limiter comprises a honeycomb structure.

10. A vehicle comprising: a vehicle body, the vehicle body including a passenger compartment; a plurality of wheels connected to the vehicle body; a drive unit supported in the vehicle body, the drive unit operatively connected to at least one of the plurality of wheels; as well as A battery assembly supported by the vehicle body and electrically connected to the drive unit, the battery assembly comprising the battery cell according to claim 1.

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