Battery case

Abstract

A battery is disclosed that includes one or more pouch cells and a pouch cell housing. The pouch unit housing includes a first wall and a second wall spaced apart in a unit stacking direction so as to define a unit receiving space therebetween in which one or more pouch units are received. The pouch unit housing further includes a spring arrangement including a first end at the second wall and a second end extending into the unit receiving space to engage one or more pouch units. The spring arrangement is compressible from an expanded configuration to a compressed configuration in which a distance between the first end and the second end of the spring arrangement decreases in the cell stacking direction. The spring arrangement includes a resilient spring element configured to flex in response to compression of the spring arrangement and to bias the spring arrangement toward an expanded configuration.

Description

Background Technology

[0001] Batteries (such as those used in consumer devices) are typically formed from multiple battery cells (or simply "cells"). Battery cells (such as lithium-ion cells) come in various forms. Known battery cells are generally cylindrical or rectangular (or cuboid) in shape. One type of rectangular battery cell increasingly used in devices is the pouch cell. A pouch cell comprises a laminated battery structure contained within a flexible (i.e., non-rigid) pouch, typically formed from a plastic-coated aluminum film. Tabs are positioned at one end (or both opposite ends) of the pouch cell to provide terminals that allow the pouch cell to be electrically connected to other pouch cells in a pouch cell stack or to electrical components of the device.

[0002] Using bags instead of rigid casings (as is the case with other types of battery cells) reduces the overall weight and volume of the cells. Similarly, when multiple cells are packaged together, rectangular (or cuboid) shapes offer more efficient use of space than cylindrical shapes (i.e., in cell stacking).

[0003] However, the flexible nature of pouch cells means that an outer casing must be provided to protect the pouch cells (or stacks of pouch cells) from damage. A characteristic of pouch cells (such as lithium-ion pouch cells) is that each charge and discharge cycle can cause the pouch cell to expand and contract. Similarly, for performance reasons, it is desirable to maintain compression of the pouch cell through each charge and discharge cycle. Therefore, pouch batteries must be packaged in a way that accommodates this expansion and contraction while maintaining compression.

[0004] To achieve this, the flexible cell stack is typically encapsulated in a rigid housing, with foam positioned between each cell and between the outermost cell and the housing (i.e., the foam is typically arranged in series with the flexible cells). When the cells expand, the foam is compressed, which provides a reaction force to maintain the compression of the cells. Summary of the Invention

[0005] In a first aspect, a soft-pack unit housing for accommodating one or more soft-pack units is disclosed, the soft-pack unit housing comprising:

[0006] A first wall and a second wall, the first wall and the second wall being spaced apart in the cell stacking direction, so as to define a cell receiving space therebetween for receiving one or more soft-pack cells;

[0007] A spring arrangement includes a first end at the second wall and a second end extending into the unit receiving space to engage the one or more flexible units when received in the unit receiving space. The spring arrangement is capable of compressing from an expanded configuration to a compressed configuration, in which the distance between the first and second ends of the spring arrangement decreases in the unit stacking direction.

[0008] The spring arrangement includes an elastic spring element configured to bend in response to compression of the spring arrangement and to bias the spring arrangement toward the expansion configuration.

[0009] One inherent problem with the use of foam is that, for a given cell expansion, it can only be compressed to a certain strain. In other words, at maximum compression (maximum expansion of the cell), the foam still has some residual thickness. This residual thickness must be accounted for in the overall dimensions of the battery in the cell stacking direction, resulting in a larger battery (at least in the cell stacking direction). The fact that pouch cells typically contain multiple cells in a stack with several foam layers exacerbates this problem.

[0010] Another potential problem with using foam is that at least some types of foam materials are prone to decomposition during thermal runaway events. Thermal runaway events occur when a battery reaches elevated temperatures, triggering a chain reaction that ultimately leads to a very rapid rise in battery temperature. Not only is foam decomposition undesirable, but in some cases, using foam between cells can also increase the likelihood of reaching those elevated temperatures, as it acts as an insulator.

[0011] The spring arrangement (and spring elements) of the first aspect eliminates the need for foam in the housing. This can result in a housing with reduced dimensions in the cell stacking direction (as will be further described below). Similarly, the removal of foam can reduce the likelihood of the cell reaching the elevated temperature required for a runaway event, since (in the absence of a foam layer) heat can be transferred from the cell to any surrounding cells and / or the housing.

[0012] Therefore, the soft-pack cell housing of the first aspect can be more compact (at least in the cell stacking direction) and is less likely to experience thermal runaway events.

[0013] The optional features of the first aspect will now be described. These can be applied individually or in any combination with any aspect.

[0014] The expansion configuration of the spring arrangement can be the natural position of the spring arrangement.

[0015] The spring arrangement may include multiple spring elements. Each spring element may be configured to bend in response to compression of the spring arrangement and bias the spring arrangement toward an expanded position.

[0016] Multiple spring elements can be arranged in an array on a reference plane that extends across the cell receiving space perpendicular to the cell stacking direction (the reference plane may, for example, extend across the entire cell receiving space). Providing an array of spring elements allows the force provided by the spring arrangement to be distributed across the cell receiving space (e.g., distributed across the pouch cell engaged at the second end of the spring arrangement). This can reduce the pressure applied to the pouch cell at any single point.

[0017] Spring elements can be arranged in a regular pattern across a reference plane. An array of spring elements can include one or more rows of evenly spaced spring elements. This, too, can contribute to the distribution of force.

[0018] Multiple spring elements can be distributed substantially uniformly across the reference plane (e.g., they can be spaced substantially uniformly apart).

[0019] The spring arrangement can be compressed into a configuration where the first and second ends of the spring arrangement are substantially coplanar along a plane substantially perpendicular to the cell stacking direction. By being compressible to such a configuration, the spring arrangement can be compressed to a configuration (e.g., a compression configuration) in which the spring arrangement has substantially no residual thickness (or has a residual thickness at least smaller than in the case of a foam layer). This can provide a smaller volume cell housing (providing higher energy density). As can be understood, while the spring arrangement can be compressed to such a configuration, this may not always occur in practice (i.e., in normal use). This is because such a position can represent the maximum compression of the spring arrangement, and this can only occur at the maximum (permissible) expansion of the padded cell. This maximum expansion may not always occur in practice (but where it does occur, it may still be desirable to accommodate this expansion).

[0020] The spring arrangement can be compressed into a configuration such that each of one or more spring elements extends substantially along a reference plane perpendicular to the cell stacking direction. Thus, each spring element can be compressed from its position extending out of the plane relative to the reference plane to its position within the plane. Similarly, this can help minimize the volume of the pouch cell housing.

[0021] The spring arrangement may include plate elements. Plate elements may extend substantially perpendicular to the unit stacking direction. Each spring element may engage with or be integral with a plate element. The aforementioned reference plane may be defined by the surface of the plate element. One or more spring elements may extend only from one side of the plate (i.e., the opposite side of the plate may be substantially free of spring elements and therefore substantially planar).

[0022] Therefore, each spring element can be connected to each other to form a single piece (e.g., by connecting plate elements). This facilitates the assembly of the soft-pack unit housing (e.g., ensuring the desired positioning / spaced of the spring elements is maintained).

[0023] In some embodiments, each spring element may be integral with and extend from the plate element. Thus, the plate element and the spring element may form a single integral piece.

[0024] Each spring element can be positioned adjacent to a corresponding recess formed in the plate element, and each spring element can be at least partially received in the corresponding recess when compressed. Each spring element can be a cut-out portion of the plate element (which can bend out of the plane when the plate element is in an expanded configuration). One or more spring elements and plate elements can be formed from stamped sheet metal. This can minimize the complexity (and, for example, cost) of forming the spring arrangement.

[0025] In some embodiments, the plate element may form at least a portion of the second wall. The plate element may provide the second wall. In other words, one or more spring elements may be integrally formed with the second wall. Each of the one or more spring elements may be compressed to a position where the spring element is substantially in-plane (i.e., coplanar with the second wall) relative to the second wall. As described above, this may be achieved, for example, by forming each spring element via a stamping process.

[0026] By incorporating each spring element as part of the second wall, each spring element can be compressed into the second wall, allowing the remaining volume of the bias arrangement to be zero or close to zero. In other words, when in the fully compressed position, the spring arrangement does not occupy any space within the pouch cell housing (because the spring arrangement can be contained within the second wall).

[0027] The plate element can be a first plate element, and the spring arrangement can include a second plate element. The second plate element can be arranged between one or more spring elements and one or more pouch cells when received in the cell receiving space. In such an embodiment, each spring element can extend from the first plate element to the second plate element. In this way, the second plate element can be used to distribute the force applied by the spring arrangement to one or more pouch cells. This avoids high-pressure areas that could, for example, cause punctures to the flexible pouch of the pouch battery. Each spring element can be fixed to the second plate element or can simply contact the second plate element.

[0028] In some embodiments (e.g., such as embodiments that do not necessarily include a second plate element), the plate element (e.g., a first plate element) may be arranged between one or more spring elements and one or more soft-pack units. In such embodiments, each spring element may extend from the plate element toward the second wall (e.g., for contact with the second wall).

[0029] At least one of the spring elements may be a leaf spring or a compression spring (e.g., a conical compression spring). In some embodiments, all spring elements may be leaf springs or compression springs (e.g., conical compression springs).

[0030] Each spring element may include an elongated member having a proximal end mounted to a plate element (e.g., integral with the plate element) and a free distal end (e.g., in the form of a tab). Each elongated member may be rectangular. Alternatively, each elongated member may taper inward from the proximal end to the distal end (e.g., may have a triangular shape). This can reduce root stress (at the proximal end) and provide a substantially constant stress ratio along the length of the elongated member.

[0031] Each leaf spring can be in the form of a straight or curved elongated member, extending out of the plane from the fixed end to the free end (i.e., relative to the reference plane or plate described above). Each conical compression spring can, for example, be in the form of a helical element extending out of the plane in a spiral shape. Each spring.

[0032] In some embodiments, one or more spring elements and plate elements may be separate components. In such embodiments, the plate element may include one or more positioning features configured to cooperate with each of the one or more spring elements to limit the movement of each of the one or more spring elements. This movement limitation may be, for example, along a direction perpendicular to a reference plane perpendicular to the cell stacking direction.

[0033] Each of one or more spring elements may be in the form of a so-called Bass washer (i.e., a washer with a truncated conical shape and a central hole passing through it).

[0034] The first and second walls of the housing may be substantially planar (and may be parallel to each other). The housing may include transverse sidewalls spaced apart from either side of the unit receiving space and extending between (and connecting) the first and second walls. The housing may have a substantially cuboid shape. Opposite ends of the housing may be open to allow access to the terminals of the flexible housing when the flexible housing is in the unit receiving space.

[0035] In some embodiments, the soft-pack unit housing may be provided with more than one spring arrangement. For example, an additional spring arrangement may be provided, having a first end at a first wall and a second end extending into the unit receiving space to engage the soft-pack unit received in the unit receiving space. The additional spring arrangement may be the same as the spring arrangement described above (i.e., it may include one or more optional features of the spring arrangement described above). In such embodiments, one or more soft-pack units may be received between the spring arrangement and the additional arrangement, and both spring arrangements may accommodate the expansion and contraction of the soft-pack unit during use.

[0036] The housing may include one or more inner walls that divide the unit receiving space into multiple regions (or form multiple unit receiving spaces). For example, the housing may include one or more inner walls that extend laterally across the interior space of the housing (between the side walls) and may be parallel to the first and second walls (such walls may be referred to as struts). Alternatively, the housing may include inner walls that extend between (and connect) the first and second walls. In each case, at least one spring arrangement may be provided in each region (or each unit receiving space) to accommodate the expansion and contraction of the padded unit housed therein.

[0037] In some embodiments, the second wall may be the inner wall of the housing (e.g., a support column). In other words, the spring arrangement may be disposed between the support column and the soft-pack unit received in the unit receiving space.

[0038] In any of the above embodiments, at least one of the first wall and the second wall may include a fastener for mounting an external component to the first wall or the second wall. The fastener may include a head that is pressed into the first wall, causing the first wall or the second wall to deform around the fastener to retain the fastener within the first wall or the second wall. The fastener may include a shaft extending from the head to project from and beyond the outer surface of the first wall or the second wall. The shaft or head of the fastener may include teeth (e.g., radially or axially extending). Deformable material may be received between the teeth. The shaft or head of the fastener may include a recess extending circumferentially (e.g., completely) around the shaft or head. Deformable material may be received in the recess. The shaft of the fastener may be threaded. The head of the fastener may be completely received within the first wall or the second wall (i.e., may not project from it).

[0039] In a second aspect, a battery is disclosed, comprising:

[0040] One or more soft package units; and

[0041] The soft-pack unit housing includes:

[0042] A first wall and a second wall, spaced apart in the unit stacking direction, to define a unit receiving space therebetween, in which one or more soft-pack units are received;

[0043] A spring arrangement includes a first end at the second wall and a second end extending into the unit receiving space to engage a soft-pack unit among the one or more soft-pack units. The spring arrangement is compressible from an expanded configuration to a compressed configuration, in which the distance between the first and second ends of the spring arrangement decreases in the unit stacking direction.

[0044] The spring arrangement includes an elastic spring element configured to bend in response to compression of the spring arrangement and to bias the spring arrangement toward the expansion configuration.

[0045] For the same reasons discussed above regarding the first aspect, the second aspect of the battery is advantageous. That is, the second aspect of the battery can be more compact (at least in the cell stacking direction) and is less likely to experience thermal runaway events.

[0046] The optional features of the second aspect will now be described. These can be applied individually or in any combination with any aspect.

[0047] The flexible housing of the second aspect can be as described above with respect to the first aspect. For example, the flexible housing may include one or more of the optional features of the first aspect described above.

[0048] Each flexible cell may have a first main surface and a second main surface, which may face the first compression member and the second compression member, respectively. The main surface of each flexible cell may be substantially perpendicular to the cell stacking direction. The layers of the internal layered structure of each flexible cell may be substantially parallel to the main surface of the flexible cell.

[0049] Each flexible unit may include opposing lateral sides (e.g., aligned with the lateral sides of the housing) and may include opposing ends. Each flexible unit may include at least two terminals, which may be at the same end or opposite ends of the flexible unit. Attached Figure Description

[0050] Figure 1A This is a cross-sectional view of a battery according to the first embodiment, wherein the spring arrangement of the battery casing is in an expanded configuration;

[0051] Figure 1B yes Figure 1A A cross-sectional view of the battery, in which the spring arrangement is in a compressed configuration;

[0052] Figure 1C yes Figure 1A A perspective view of the spring arrangement of the battery;

[0053] Figure 2 This is a perspective view of the spring arrangement of the battery according to the second embodiment;

[0054] Figure 3 This is a perspective view of a pouch cell housing for a battery according to a third embodiment;

[0055] Figure 4A This is a perspective view of the soft-pack cell housing for a battery according to the fourth embodiment;

[0056] Figure 4B yes Figure 4A A perspective view of the spring arrangement of the soft-pack unit housing;

[0057] Figure 5A This is a cross-sectional view of a portion of the battery according to the fifth embodiment;

[0058] Figure 5B yes Figure 5A A perspective view of the spring element of the battery; and

[0059] Figure 6 This is a cross-sectional view of the battery according to the sixth embodiment. Detailed Implementation

[0060] Figure 1A and 1BA battery 100 is shown, comprising a pouch cell housing 101 and six pouch cells 102. The pouch cell housing 101 includes a first wall 103 and a second wall 104 (which are upper and lower walls as shown), spaced apart in a cell stacking direction (vertical direction as shown) to define a cell receiving space 105 therebetween. The pouch cells 102 are disposed within the cell receiving space 105 to be held (and compressed) between the first wall 103 and the second wall 104.

[0061] The flexible housing 101 also includes two sidewalls 109 on opposite sides of the housing receiving space 105, and these two sidewalls 109 extend between the first wall 103 and the second wall 104 (extending vertically as shown). In this way, the flexible housing 101 has a substantially rectangular cross-sectional shape (i.e., in relation to...). Figure 1A and 1B (A cross-section taken from the same plane as the cross-section). Although not obvious from the figure, the soft-pack unit housing 101 (and the unit receiving space 105) has a substantially cuboid shape.

[0062] Each pouch cell 102 also has a generally cuboid shape, with opposing main faces (top and bottom as shown) facing the first wall 103 and the second wall 104 of the pouch cell housing 101. Each pouch cell 102 also includes a plurality of inner layers (not shown) that are substantially parallel to the main faces of the pouch cell 102 and provide the energy storage function of the pouch cell 102.

[0063] The soft-pack unit housing 101 further includes a spring arrangement 106, which includes a first end 107 at the second wall 104 and a second end 108 extending into the unit receiving space 105. In this way, the second end 108 of the spring arrangement 106 engages one of the two outermost (in this case, the bottommost) soft-pack units 102 of the stack of soft-pack units 102.

[0064] Spring arrangement 106 can be configured from expansion (e.g.) Figure 1A (As shown) Compress to a compression configuration (such as) Figure 1B As shown), the distance between the first end 107 and the second end 108 of the spring arrangement 106 decreases in the cell stacking direction. During use, the spring arrangement 106 moves from an expanded configuration to a compressed configuration by the expansion of the pouch cell 102 (which typically occurs throughout the entire charging cycle of the pouch cell).

[0065] Spring arrangement 106 in Figure 1CShown separately. As is evident from this figure, the spring arrangement 106 includes a plurality of resilient spring elements 110. Each spring element 110 is configured to bend in response to compression of the spring arrangement 106 and biases the spring arrangement 106 toward expansion. Thus, this biasing of the spring elements 110 provides a compressive force for compressing the soft-pack unit 102 between the spring arrangement 106 and the first wall 103.

[0066] The spring arrangement 106 also includes a generally planar plate element 111, which is generally parallel to the first wall 103 and the second wall 104. Spring elements 110 extend from the plate element 111 (in the expansion configuration) to the second wall 104. Compression of the spring arrangement 106 thus results in compression of each spring element 110 toward the plate element 111.

[0067] The spring elements 110 are distributed substantially uniformly on the plate element 111. In particular, the spring elements 110 are distributed in four rows of twelve spring elements 110, which form a grid-like array of spring elements 110 distributed on the plate element 111. This substantially uniform distribution of the spring elements 110 helps to distribute the force applied to the soft-pack unit 102 engaged by the spring arrangement 106.

[0068] In the illustrated embodiment, each spring element 110 has a helical (or spiral) shape to resemble a conical compression spring. That is, each spring element 110 is formed by an elongated member 112 that extends along a helical (decreasing radius) path to a free distal end 113 away from the plate element 111 (at least in the expanded configuration).

[0069] In particular, such as from Figure 1C It should be apparent that each spring element 110 is integrally formed with the plate element 111, such that the spring element 110 and the plate element 111 form a single integral piece. Specifically, the spring element 110 and the plate element 111 are formed from stamped sheet metal. One result of this is that each spring element 110 can be compressed to a position where the spring element 110 and the plate element 111 are substantially coplanar (i.e., such that the elongated member 112 lies in a single plane). This position... Figure 1B The thickness of the spring arrangement 106 is obvious (where the thickness of the spring arrangement 106 is actually the thickness of the plate element 111). As discussed above, this minimizes the volume required to provide the spring arrangement 106, and thus minimizes the overall volume of the housing 101.

[0070] To further aid in force distribution on the lowest padded unit 102, a planar force distribution plate 123 is provided between the plate element 111 and the padded unit 102. The force distribution plate 123 contacts substantially the entire lower main surface of the lowest padded unit 102 to distribute force (from the spring element 110) on the lower surface of the lowest padded unit 102. As will be understood, in some embodiments, the plate element 111 may provide sufficient force distribution (and, if so, the force distribution plate 123 may be omitted). While including such a distribution plate 123 may result in some residual thickness (i.e., the thickness of the plate 123) when the spring element 110 is fully compressed, this is generally less than in the case of using foam.

[0071] It should be understood that, Figure 1A , 1B In a variation of the embodiment shown in 1C, the orientation of the spring arrangement 106 can be reversed, such that the plate element 111 rests against the second wall 104 and the spring element 110 protrudes toward the lowermost padded unit 102 (although this arrangement may provide a less efficient force distribution on the padded unit 102 compared to the arrangement shown). In such an embodiment, a force distribution plate may be provided or omitted.

[0072] It should also be understood that the spring element 110 can take various other forms. Figure 2 One such variation is shown in the figure. Figure 2 The spring arrangement 206 includes a plate element 211 and a plurality of spring elements 210a, 210b, which are substantially uniformly distributed on the plate element 211 and extend outward from one side of the plate element 211 into a plane. Similarly, Figure 2 The spring arrangement 206 is formed from stamped sheet metal (so that it can be a single piece).

[0073] Each spring element 210a, 210b is in the form of a leaf spring, which consists of an elongated member 213 that extends from the plate element 211 along a curved path to a free distal end 213 (the curved path lies in a single plane that is substantially perpendicular to the plate element 211).

[0074] The spring arrangement 206 includes a set of first spring elements 210a extending in the width direction of the plate element 211 (extending in the direction between the sidewalls of the housing in use), and a set of second spring elements 210b extending in the length direction of the plate element 211 (extending in the direction between the ends of the housing in use).

[0075] The first spring elements 210a are arranged in pairs. The pairs of first spring elements 210a are spaced apart in the longitudinal direction to form a row of pairs of first spring elements 210a. The pairs of spring elements 210a alternate between each spring element 210a in the pair (in the direction along the row), each spring element 210a in the pair extends out of the plane and away from each other, and the two spring elements 210a extend out of the plane toward each other.

[0076] The second spring elements 210b are also arranged in pairs. In particular, two rows of pairs of second spring elements 210b are provided, each row along a corresponding lateral side 214 of the plate element 211. In each pair of second spring elements 210b, one of the second spring elements 210b extends out of plane toward a first end 215a of the plate element 211, and the other in the pair extends out of plane toward the opposite second end 215b of the plate element 211.

[0077] Figure 3 Another variation of the flexible housing 301 is shown. The housing 301 includes a first wall 303 and a second wall 304 spaced apart in the housing stacking direction to define a housing receiving space 305 therebetween. The housing receiving space 305 is further defined by opposing sidewalls 309 extending between the first wall 303 and the second wall 304.

[0078] Unlike the previously described embodiments, the housing 301 shown here includes a first spring arrangement 306a and a second spring arrangement 306b. The first spring arrangement 306a includes a plate element provided by a first wall 303 and a plurality of spring elements 310 extending from the first wall 303 into the unit receiving space 305. The second spring arrangement 306b includes a plate element provided by a second wall 304 and a plurality of spring elements 310 extending from the second wall 304 into the unit receiving space 305.

[0079] The spring elements 310 of each spring arrangement 306a, 306b are distributed substantially uniformly in a grid-like array on their respective walls 303, 304. Each spring element 310 is in the form of a leaf spring. In particular, each spring element 310 is formed by an elongated member 312 that extends out of the plane along a substantially linear path from the corresponding wall 303, 304 to the free distal end 313. Thus, each spring element 310 is generally in the form of a planar tab that is partially cut out of the wall 303, 304 and bent out of the plane.

[0080] On each of the first wall 303 and the second wall 304, a spring element 310 is arranged such that each spring element 310 extends from the wall 303, 304 toward the end 316 furthest from the outer casing 301. Thus, each spring element 310 is oriented to extend in the longitudinal direction of the outer casing 301 (i.e., the direction in which it extends between the ends), wherein half of the spring element 310 extends toward one end 316 and half extends toward the other end 316.

[0081] Each spring element 310 provides a restoring (biasing) force when pushed against its corresponding wall 303, 304. As can be understood from the figures, when the pouch unit is received in the unit receiving space 305, the distal end 313 of the spring element 310 of the first wall 303 abuts against the uppermost pouch unit (in the orientation shown), and the distal end 313 of the spring element 310 of the second wall 304 abuts against the lowermost pouch unit. In this way, when the pouch unit expands and contracts during use, a compressive force can be applied to the stack of pouch units received in the unit receiving space 305 via the first spring arrangement 306a and the second spring arrangement 306b of the housing 301.

[0082] Although not shown, it should be understood that a force distribution plate may be disposed between the spring element 310 and the soft-pack unit received in the unit receiving space 305 (e.g., one force distribution plate for each of the first wall 303 and the second wall 304).

[0083] Figure 4 shows another soft-pack unit housing 401, which is similar to Figure 3 As shown. Similarly, the soft-pack unit housing 401 includes a first wall 403 and a second wall 404 connected by side walls 409 to form a substantially cuboid shape. The housing also includes a central inner wall 417, which is located between the side walls 409 and again connects the first wall 403 and the second wall 404. The central inner wall 417 forms two unit receiving spaces 405 arranged side by side.

[0084] Each cell receiving space 405 is provided with two spring arrangements 406a, 406b for applying a compressive force to the soft cell when the soft cell is received therein (i.e., to cooperate with the soft cell). Figure 3 (The same manner as in the embodiments). For each unit receiving space 405, one of the spring arrangements 406a extends from the first wall 403 into the corresponding unit receiving space 405, and the other spring arrangement 406b extends from the second wall 404 into the corresponding unit receiving space 405.

[0085] and Figure 3Unlike other embodiments, the spring arrangements 406a and 406b of the housing 401 shown here each include a plate element 411 that is separate from (but attached to) the walls 403 and 404 extending from the spring arrangements 406a and 406b. Figure 4B An exemplary spring arrangement 406a (formed as a single unit) is shown in more detail below. A plate element 411 is elongated to form a spine, from which a plurality of spring elements 410 extend laterally outward on opposite sides of the plate element 411. Each spring element 410 is a leaf spring having an elongated member 412 integral with the plate element 411, the elongated member 412 extending out of plane from the plate element 411 and extending along a substantially linear path to a free distal end 413 (i.e., each spring element 410 is substantially planar).

[0086] Return to Figure 4A Each plate member 411 of each spring arrangement 406a, 406b is fixed within a corresponding recess 418 of the respective walls 403, 404. Each recess 418 is shaped to receive the corresponding plate member 411 and to receive the spring element 410 when the corresponding spring arrangement 406a, 406b is compressed. In other words, each recess 418 has a shape including a central spine (in which the plate member 411 is received) and a plurality of laterally extending fingers that receive the spring element 410 when it is received by the expansion and compression of the soft-pack unit in the unit receiving space 405.

[0087] Similarly, although not shown, it should be understood that a force distribution plate may be provided to distribute the force from the spring element 410 to the pouch cell received in the cell receiving space 405.

[0088] Figure 5A and 5B A portion of spring arrangement 506 is shown, which may be provided as part of the soft-pack unit housing (e.g., spring arrangement that may replace the soft-pack unit housing previously described).

[0089] A spring arrangement 506 is disposed between the second wall 504 of the housing and a plurality of soft-pack units 502 received in the unit receiving space 505. The spring arrangement 506 includes a plate member 511 and a plurality of spring elements 510 (although only one is shown). The plate member 511 abuts against the lowermost soft-pack unit 502 and helps distribute the restoring force applied by the spring elements 510. Each spring element 510 is in the form of a Bavarian washer. Figure 5BA spring element 510 is shown. The spring element 510 includes an annular truncated conical wall 520 defining a central hole 519 formed therein. When the spring element 510 is compressed, the truncated conical wall 520 deforms to flatten (i.e., becomes more flat). When the spring element 510 attempts to return to its natural (non-flat) shape, the spring element 510 provides a restoring force.

[0090] In order to keep each spring element 510 resisting movement in the lateral direction (i.e., resisting movement in a plane substantially parallel to the second wall 404), the plate element 511 includes a plurality of positioning features 521 in the form of protrusions, which are received in the center hole 519 of the spring element 510.

[0091] Figure 6 A battery 600 according to another embodiment is depicted. The battery 600 includes a housing 601 accommodating two stacks of pouch cells, each stack comprising six pouch cells 602. The pouch cell housing 601 includes a first wall 603 and a second wall 604 spaced apart in the cell stacking direction to define a cell receiving space 605 therebetween, and spaced-apart opposing sidewalls 609. The cell receiving space 605 is divided into two regions by a planar strut 622 (each stack of pouch cells 602 is received in a corresponding region), the planar strut 622 extending laterally across the cell receiving space 605 between the sidewalls 609. The strut 622 is fixed to each sidewall 609 to provide a rigid inner plate against which the pouch cells abut during use.

[0092] Although the battery 600 is depicted in an orientation in which the walls 603, 604, the pouch unit 602 and the strut 622 extend horizontally, the battery 600 may alternatively be oriented such that these features of the battery 600 extend substantially vertically (i.e., such that the battery is rotated 90 degrees from its shown orientation).

[0093] The soft-pack unit housing 601 also includes two spring arrangements 606, each spring arrangement being disposed at a corresponding location in the first wall 603 and the second wall 604. Each spring arrangement 606 includes a planar plate member 611 extending between the side walls 609 and used to distribute the forces applied to the soft-pack unit 602.

[0094] Each spring arrangement 606 also includes one or more spring elements 610 (illustrated schematically). Typically, each spring element 610 can take any form that compresses from an expanded configuration to a compressed configuration in the unit stacking direction while also providing a restoring force against such compression. For example, each spring element 610 can be in the form of a compression spring (e.g., a conical compression spring).

[0095] In other embodiments (not shown), spring arrangement 606 (or additional spring arrangement) may be positioned between the support column 622 and the corresponding soft-pack unit.

[0096] Features disclosed in the foregoing description, in the following claims, or in the accompanying drawings, expressed in their particular form or as means for performing the disclosed functions or methods or processes for obtaining the disclosed results, may, as appropriate, be used alone or in any combination of these features to implement the invention in its various forms.

[0097] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art upon presentation of this disclosure. Therefore, the exemplary embodiments of the invention set forth above are to be considered illustrative rather than restrictive. Various changes may be made to the described embodiments without departing from the spirit and scope of the invention.

[0098] To avoid any doubt, any theoretical explanations provided herein are intended to enhance the reader's understanding. The inventor does not wish to be bound by any of these theoretical explanations.

[0099] Any chapter headings used in this article are for organizational purposes only and should not be construed as limiting the topics described.

[0100] Throughout this specification, including the following claims, unless the context otherwise requires, the word "comprising" and its variations shall be understood to imply the inclusion of the said integer or step or group of integers or steps, but not to exclude any other integer or step or group of integers or steps.

[0101] It should be noted that, as used in the specification and appended claims, the singular forms “a,” “an,” and “the” include plural indicators unless the context clearly indicates otherwise. A range herein may be expressed as “about” a particular value and / or to “about” another particular value. When expressing such a range, another embodiment includes from one particular value and / or to another particular value. Similarly, when a value is expressed as an approximation using the antecedent “about,” it should be understood that the particular value forms another embodiment. The term “about” in relation to numerical values ​​is optional and means, for example, + / - 10%.

Claims

1. A battery, comprising: One or more soft package units; and The soft-pack unit housing includes: The first wall and the second wall are spaced apart in the unit stacking direction to define a unit receiving space therebetween, in which the one or more soft-pack units are received; A spring arrangement includes a first end at the second wall and a second end extending into the unit receiving space to engage a soft-pack unit among the one or more soft-pack units. The spring arrangement is compressible from an expanded configuration to a compressed configuration, in which the distance between the first and second ends of the spring arrangement decreases in the unit stacking direction. The spring arrangement includes an elastic spring element configured to bend in response to compression of the spring arrangement and to bias the spring arrangement toward the expansion configuration.

2. The battery according to claim 1, wherein, The spring arrangement includes a plurality of spring elements, each spring element configured to bend in response to compression of the spring arrangement and to bias the spring arrangement toward the expanded position.

3. The battery according to claim 2, wherein, The plurality of spring elements are arranged in an array on a reference plane that extends across the cell receiving space perpendicular to the cell stacking direction.

4. The battery according to claim 3, wherein, The array comprises one or more rows of evenly spaced spring elements.

5. The battery according to any one of the preceding claims, wherein, The spring arrangement can be compressed into a configuration in which the first and second ends of the spring arrangement are substantially coplanar along a plane substantially perpendicular to the stacking direction of the cells.

6. The battery according to any one of the preceding claims, wherein, The spring arrangement can be compressed into a configuration in which each of the one or more spring elements extends substantially along a reference plane perpendicular to the stacking direction of the units.

7. The battery according to any one of the preceding claims, wherein, The spring arrangement includes plate elements extending substantially perpendicular to the stacking direction of the units, and one or more spring elements are engaged with or integrated with the plate elements.

8. The battery according to claim 7, wherein, The one or more spring elements are integral with the plate element and extend from the plate element.

9. The battery according to claim 8, wherein, The one or more spring elements and the plate elements are formed from stamped metal sheets.

10. The battery according to any one of claims 7 to 9, wherein, The plate element forms at least a portion of the second wall.

11. The battery of claim 10, wherein the plate element is a first plate element, and the spring arrangement includes a second plate element arranged between the one or more spring elements and the one or more pouch cells.

12. The battery according to any one of claims 7 to 9, wherein, The plate element is arranged between the one or more spring elements and the one or more soft-pack units.

13. The battery according to any one of the preceding claims, wherein, Each of the one or more spring elements is a leaf spring or a conical compression spring.

14. The battery according to claim 7, wherein, The one or more spring elements and the plate element are separate components, and the plate element includes one or more positioning features configured to cooperate with each of the one or more spring elements to limit the movement of each of the one or more spring elements in a direction perpendicular to a reference plane perpendicular to the stacking direction of the units.

15. The battery according to claim 14, wherein, Each of the one or more spring elements is a Bass washer.

16. A soft-pack unit housing for accommodating one or more soft-pack units, the housing comprising: The first wall and the second wall are spaced apart in the unit stacking direction so as to define a unit receiving space for receiving the one or more soft package units between the first wall and the second wall; A spring arrangement includes a first end at the second wall and a second end extending into the unit receiving space to engage the one or more flexible units when received in the unit receiving space. The spring arrangement is capable of compressing from an expanded configuration to a compressed configuration, in which the distance between the first and second ends of the spring arrangement decreases in the unit stacking direction. The spring arrangement includes an elastic spring element configured to bend in response to compression of the spring arrangement and to bias the spring arrangement toward the expanded position.

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