Battery assembly and method for forming battery assembly

Abstract

The battery assembly defines a vertical axis and a longitudinal axis, and includes a first electrode having a tab on a first end thereof in a first direction along the longitudinal axis, a second electrode in a stacked structure with the first electrode along the vertical axis, and a separator disposed between the first electrode and the second electrode. The separator covers at least a second end portion of the first electrode in a second direction along the longitudinal axis.

Description

Technical Field

[0001] The present disclosure relates to vehicles, and more particularly to batteries for vehicles. Background Art

[0002] Vehicle batteries are subjected to different conditions. A reliable battery that can withstand different conditions may be required. Summary of the Invention

[0003] In one exemplary embodiment, a battery assembly defines a vertical axis and a longitudinal axis, and includes a first electrode, a second electrode, and a separator. The first electrode includes a tab at its first end in a first direction along the longitudinal axis. The second electrode is stacked with the first electrode along the vertical axis. The separator covers at least a second end of the first electrode in a second direction along the longitudinal axis.

[0004] In addition to one or more features described herein, the separator includes a first portion located between the first electrode and the second electrode and a folded portion extending from the first portion, the folded portion covering the second end of the first electrode.

[0005] In addition to one or more features described herein, the first portion of the separator covers an upper side of the first electrode along the vertical axis. The separator further includes a second portion extending from the folded portion and covering a lower side of the first electrode along the vertical axis.

[0006] In addition to one or more features described herein, the battery assembly further defines a width axis. The separator covers both ends of the first electrode along the width axis.

[0007] In addition to one or more features described herein, the first end of the first electrode is not covered by the separator.

[0008] In addition to one or more features described herein, the second electrode includes a tab at its end in the second direction.

[0009] In addition to one or more features described herein, the first electrode is an anode and the second electrode is a cathode.

[0010] In another exemplary embodiment, a battery assembly defines a vertical axis and a longitudinal axis, and includes a plurality of first electrodes and a plurality of second electrodes. The plurality of first electrodes and the plurality of second electrodes are alternately stacked along the vertical axis to form a stacked structure. Each first electrode includes a tab on its first end in a first direction along the longitudinal axis and a separator covering at least a second end of each first electrode in a second direction along the longitudinal axis.

[0011] In addition to one or more features described herein, the separator includes a first portion located on the upper surface of each of the first electrodes and a folded portion extending from the first portion, the folded portion covering the second end of each of the first electrodes.

[0012] In addition to one or more features described herein, the separator further includes a second portion, the second portion extending from the folded portion and covering the lower side of each of the first electrodes along the vertical axis.

[0013] In addition to one or more features described herein, the battery assembly further defines a width axis. The separator covers both ends of each first electrode along the width axis.

[0014] In addition to one or more features described herein, the first end of each first electrode is not covered by the separator.

[0015] In addition to one or more features described herein, each of the second electrodes includes a tab at its end in the second direction.

[0016] In addition to one or more features described herein, the battery assembly further defines a width axis. The wrapping portion of the separator wraps around both ends of the stack along the vertical axis and wraps around both ends of the stack along the width axis.

[0017] In addition to one or more features described herein, a band is disposed on the wrapping portion to hold the battery assembly together.

[0018] In addition to one or more features described herein, the number of first electrodes is one more than the number of second electrodes.

[0019] In addition to one or more features described herein, the first electrodes are anodes and the second electrodes are cathodes.

[0020] In addition to one or more features described herein, the battery assembly further defines a width axis. The wrapping portion of the separator wraps around both ends of the stack along the vertical axis and wraps around both ends of the stack along the width axis. The first portion, second portion, and folded portion of the separator covering each first electrode and the wrapping portion of the separator are integrally formed from a single separator sheet.

[0021] In yet another exemplary embodiment, a vehicle includes a rechargeable energy storage system that includes a battery assembly defining a vertical axis, a longitudinal axis, and a width axis. The battery assembly includes a plurality of anodes and a plurality of cathodes that are alternately stacked along the vertical axis to form a stack. Each of the anodes includes an anode tab at its first end in a first direction along the longitudinal axis, and each of the cathodes includes a cathode tab at its end in a second direction along the longitudinal axis, and a separator. The separator includes a first portion positioned on an upper surface of each of the anodes along the vertical axis, a second portion positioned on a lower surface of each of the anodes along the vertical axis, and a folded portion that extends from the first portion to the second portion. The folded portion covers a second end of each of the anodes in the second direction along the longitudinal axis. The separator covers both ends of each anode along the width axis. The first end of each anode is not covered by the separator.

[0022] In addition to one or more of the features described herein, a wrapping portion of the separator wraps around both ends of the stack along the vertical axis and around both ends of the stack along the width axis.

[0023] The above 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 pack assembly having a battery according to one or more embodiments;

[0026] Figure 2 is a top view of a battery assembly according to one or more embodiments;

[0027] Figure 3 is a perspective view of a battery assembly according to one or more embodiments;

[0028] Figure 4 is at Figure 3 a schematic cross-sectional view of the battery assembly taken along 4-4 in;

[0029] Figure 5 is at Figure 3 a schematic cross-sectional view of the battery assembly taken along 5-5 in;

[0030] Figure 6is a flowchart showing the formation process of a battery assembly according to one or more embodiments;

[0031] Figure 7A is Figure 6 a side view of step S1 in;

[0032] Figure 7B is Figure 6 a top view of step S1 in;

[0033] Figure 8A is Figure 6 a side view of step S2 in;

[0034] Figure 8B is Figure 6 a top view of step S2 in;

[0035] Figure 9 is Figure 6 a side view of step S3 in;

[0036] Figure 10 is Figure 6 a side view of step S4 in;

[0037] Figure 11 is Figure 6 a side view of step S5 in;

[0038] Figure 12A is a side view of the first and second steps of the formation process of a battery assembly according to one or more embodiments;

[0039] Figure 12B is from Figure 12A the opposite side of Figure 12A the first step and the second step shown in;

[0040] Figure 12C is at Figure 12B a schematic cross-sectional view taken at 12C-12C in; and

[0041] Figure 12D is at Figure 12B a schematic cross-sectional view taken at 12D-12D in. DETAILED DESCRIPTION

[0042] 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 components and features.

[0043] Figure 1Vehicle 10 according to a non - limiting example is shown. Vehicle 10 includes a body 12 supported on a plurality of wheels 16. One or more of the plurality of wheels 16 are steerable. 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. Steering controller 30 is operated to control the orientation of the steerable wheel(s) 16.

[0044] Vehicle 10 includes an electric motor 34 connected to a transmission 36, and transmission 36 provides power to one or more of the plurality of wheels 16. A rechargeable energy storage system 38 is disposed in body 12 and provides power to electric motor 34. Although the Figure 1 specific locations of electric motor 34, transmission 36, and rechargeable energy storage system 38 are shown, these locations are merely exemplary and not limiting, and the locations of these structures may vary.

[0045] Figure 2 and Figure 3 a battery assembly 100 according to one or more embodiments is shown. Figure 4 and Figure 5 are, respectively, schematic cross - sectional views of battery assembly 100 taken at 4 - 4 and 5 - 5 in Figure 3 . According to one or more embodiments, battery assembly 100 may be part of the rechargeable energy storage system 38 shown in Figure 1 .

[0046] Battery assembly 100 defines a vertical axis V, a longitudinal axis L, and a width axis W. According to a non - limiting example, battery assembly 100 may have a length along longitudinal axis L that is greater than the width along width axis W, and battery assembly 100 may have a width along width axis W that is greater than the thickness along vertical axis V. Alternatively, the width along width axis W may be greater than or equal to the length along longitudinal axis L. Battery assembly 100 includes a plurality of anodes 300 and a plurality of cathodes 400. Anode 300 may be an example of a first electrode, and cathode 400 may be an example of a second electrode. Although Figures 2 - 5 five anodes 300 and four cathodes 400 are shown for illustrative purposes, the present disclosure is not limited thereto, and battery assembly 100 may include any number of anodes 300 and cathodes 400. Battery assembly 100 may include one more anode 300 than cathode 400. That is, battery assembly 100 may have n cathodes 400 and n + 1 anodes 300, where n is a plural integer.

[0047] According to one or more embodiments, in the battery assembly 100, each of the anodes 300 includes an anode core 303 and an anode outer layer 305. The anode core 303 has an anode tab 301 at its first end 351 in a first direction L1 along the longitudinal axis L. The anode outer layer 305 covers both sides of the anode core 303, where the anode tab 301 is exposed. Each of the cathodes 400 includes a cathode core 403 and a cathode outer layer 405. The cathode core 403 has a cathode tab 401 at one of its ends in a second direction L2 along the longitudinal axis L. The cathode outer layer 405 covers both sides of the cathode core 403 when the cathode tab 401 is exposed.

[0048] The battery assembly 100 further includes at least one separator 200. The anodes 300 and cathodes 400 are in a stacked configuration, stacked alternately along the vertical axis V with the separator 200 therebetween. Specifically, as Figure 4 and Figure 5 shown, each anode 300 has a first part 203 of the separator 200 located on the upper side along the vertical axis V and a second part 204 of the separator 200 located on the lower side along the vertical axis V. The first part 203 of the separator 200 may be located on the upper surface of the anode 300, and the second part 204 of the separator 200 may be located on the lower surface of the anode 300. When the anodes 300 and cathodes 400 are stacked alternately, the first part 203 and the second part 204 of the separator 200 separate the anodes 300 and cathodes 400 along the vertical axis V. The separator 200 may be formed of an electrically insulating material.

[0049] In addition, the separator 200 includes a folded portion 205, and the folded portion 205 is positioned on the second end 352 of each anode 300 in the second direction L2 along the longitudinal axis L. The folded portion 205 may extend continuously between the first part 203 and the second part 204. The folded portion 205 may extend perpendicular to the first part 203 and the second part 204. The folded portion 205 may be curved. When viewed along the width axis W, that is, in a plane including the vertical axis V and the longitudinal axis L, each anode 300 may be covered by the separator 200 on three sides, where the first part 203 covers the upper side of the anode 300 along the vertical axis V, the second part 204 covers the lower side of the anode 300 along the vertical axis V, and the folded portion 205 covers the second end 352 in the second direction L2 along the longitudinal axis L.

[0050] The separator 200 may further include a wrapping portion 201, which wraps the stacked structure of the anodes 300 and cathodes 400 along the vertical axis V and the width axis W. Thus, as Figure 4As shown, when viewed along the length axis L, i.e., in a plane including the vertical axis V and the width axis W, the wrapping portion 201 covers all four sides of the stacked structure of the anode 300 and the cathode 400. The separator 200 including the first portion 203, the second portion 204, the folding portion 205, and the wrapping portion 201 can be integrally formed from a single separator sheet.

[0051] The separator 200 can cover both ends of each anode 300 along the width axis W. That is, in Figure 4 the plane including the vertical axis V and the width axis W shown, the separator 200 can cover all four sides of each anode 300 along the vertical axis V and the width axis W. When the folding portion 205 covers the end of the anode 300 in the second direction L2 along the longitudinal axis L, each anode 300 can have five sides covered by the separator 200, with an open end in the first direction L1 along the longitudinal axis L, through which the anode tab 301 extends.

[0052] The tape 250 can be disposed along the width axis W at the ends of the separator 200 to fix the battery assembly 100 together. Although Figure 3 the tapes 250 are shown on both sides of the separator 200 along the width axis W, the tapes 250 can alternatively be disposed only on one side of the separator 200 along the width axis W.

[0053] As described above, the folding portion 205 of the separator 200 can cover the end of the anode 300 extending between the first portion 203 and the second portion 204 of the separator 200 in the second direction L2. Thus, even if the battery assembly 100 undergoes deformation, contact between the cathode tab 401 and the anode 300 is prevented by the folding portion 205 of the separator 200.

[0054] Figure 6 is a flowchart showing the formation process of the battery assembly 100 according to one or more embodiments.

[0055] In Figure 7A and 7B shown in step S1, the anode 300 is positioned on the separator 200. For example, the separator 200 can be a separator sheet. Although four anodes 300 are shown disposed on the separator 200 for illustrative purposes, this is not intended to be limiting, and any number of anodes 300 can be disposed on the separator 200. As Figure 7A and Figure 7BAs shown, the anodes 300 are placed side by side on the separator 200 in a row, where the anode tabs 301 extend outward from the separator 200. The separator 200 is sized to have a first redundant portion 211 that is not covered by the anodes 300 on one side of the row of anodes 300, and a second redundant portion 213 that is not covered by the anodes 300 on the other side of the row of anodes 300.

[0056] In Figure 8A and 8B In step S2 shown, the first redundant portion 211 is folded over the row of anodes 300 such that each of the anodes 300 is covered on three sides, where the anode tab 301 is exposed from the uncovered side. As Figure 8A shown, by folding the first redundant portion 211 over the row of anodes 300, a folded portion 205 of the separator 200 is formed that covers the side of the anode 300 opposite the anode tab 301.

[0057] In Figure 9 In step S3 shown, the cathode 400 is inserted between the anodes 300 in an alternating zigzag pattern to form a stacked structure of anodes 300 and cathodes 400 with the separator 200 therebetween.

[0058] In as Figure 10 shown in step S4, the second redundant portion 213 of the separator 200 is wrapped around the stacked structure of the anodes 300 and the cathodes 400 to form a wrapped portion 201 of the separator 200. According to one or more embodiments, the second redundant portion 213 of the separator 200 can be wrapped around the entire stacked structure of the anodes 300 and the cathodes 400 such that the wrapped portion 201 surrounds the entire stacked structure of the anodes 300 and the cathodes 400 along the vertical axis V and the width axis W. The second redundant portion 213 of the separator 200 can be partially wrapped around the stacked structure of the anodes 300 and the cathodes 400 such that the wrapped portion 201 surrounds only a portion of the stacked structure of the anodes 300 and the cathodes 400 along the vertical axis V and the width axis W.

[0059] In Figure 11 In step S5 shown, the tape 250 is disposed around the separator 200 to hold the battery assembly 100 together. Although Figure 11 the tape 250 surrounding the entire separator 200 is shown as a non-limiting example, several pieces of tape 250 can be disposed on the ends of the separator 200 along the width axis W to hold the battery assembly 100 together. Alternatively, the tape 250 can be disposed only on one side of the separator 200 along the width axis W.

[0060] Figure 12A and Figure 12Bis a view observed from the opposite side, showing the first step and the second step of the formation process of the battery assembly 100 according to one or more embodiments, and Figure 12C and Figure 12D are respectively schematic cross-sectional views taken at 12C-12C and 12D-12D in Figure 12B . The process includes a separator 200 that is pre-folded and wound around a rotatable core 221 to form a winding 220 of the separator 200. In the first step, the separator 200 is unwound from the winding 220, and a plurality of anodes 300 are inserted into the cavities 222 in the folded separator 200, where the anode tabs 301 of the anodes 300 face away from the cavities 222. The portion of the separator 200 opposite to the anode tabs 301 forms a folded portion 205 of the separator 200. In the second step, the separator 200 is cut at the cutting line 225. The portion of the separator 200 between the cutting line 225 and the anode 300 forms a second redundant portion 213. After the second step, the third, fourth, and fifth steps may correspond to Figures 9 - 11 shown in Figure 6 the third step S3, the fourth step S4, and the fifth step S5.

[0061] The above process can provide an efficient and effective method for forming the battery assembly 100, where even if the battery assembly 100 undergoes deformation, the folded portion 205 of the separator 200 prevents contact between the anode 300 and the cathode tab 401.

[0062] According to one or more embodiments, the positions of the anode 300 and the cathode 400 can be exchanged in the above battery assembly 100 and the process of forming the battery assembly 100.

[0063] The term "a" does not denote a limitation of quantity, but rather denotes the presence of at least one of the referenced item. Unless the context clearly dictates otherwise, the term "or" means "and / or". References to "aspect" throughout the specification mean that the particular elements (e.g., features, structures, steps, or properties) described in connection with that aspect are 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.

[0064] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or there can also be intervening elements. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements.

[0065] Unless otherwise stated herein, all test standards are the latest standards in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0066] 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.

[0067] Although the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may 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 that it will include all embodiments falling within its scope.

Claims

1. A battery assembly, the battery assembly defining a vertical axis and a longitudinal axis, the battery assembly comprising: A first electrode, the first electrode including a tab at its first end in a first direction along the longitudinal axis; A second electrode, the second electrode being stacked with the first electrode along the vertical axis; And A separator, the separator covering at least the second end of the first electrode in a second direction along the longitudinal axis.

2. The battery assembly according to claim 1, wherein the separator includes a first portion located between the first electrode and the second electrode and a folded portion extending from the first portion, the folded portion covering the second end of the first electrode.

3. The battery assembly according to claim 2, The first portion of the separator covers the upper side of the first electrode along the vertical axis, Among them, The separator further includes a second portion, the second portion extending from the folded portion and covering the lower side of the first electrode along the vertical axis.

4. The battery assembly according to claim 1, Wherein the battery assembly further defines a width axis, and Wherein the separator covers both ends of the first electrode along the width axis.

5. The battery assembly according to claim 1, wherein the first end of the first electrode is not covered by the separator.

6. The battery assembly according to claim 1, wherein the second electrode includes a tab at its end in the second direction.

7. The battery assembly according to claim 1, wherein the first electrode is an anode and the second electrode is a cathode.

8. A battery assembly, the battery assembly defining a vertical axis and a longitudinal axis, the battery assembly comprising: A plurality of first electrodes and a plurality of second electrodes, the plurality of first electrodes and the plurality of second electrodes being alternately stacked along the vertical axis to form a stacked structure, each of the first electrodes including a tab at its first end in a first direction along the longitudinal axis; and A separator, the separator covering at least the second end of each of the first electrodes in a second direction along the longitudinal axis.

9. The battery assembly according to claim 8, wherein the separator includes a first portion and a folded portion, the first portion being positioned on the upper surface of each of the first electrodes, the folded portion extending from the first portion, the folded portion covering the second end of each of the first electrodes.

10. The battery assembly according to claim 9, wherein the separator further includes a second portion, the second portion extending from the folded portion and covering the lower side of each of the first electrodes along the vertical axis.

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