Battery cell separator

Abstract

Battery module (220, 230), comprising: a battery cell separator (224, 234) comprising a body with front and back sides for stacking against respective battery cells (202), the body having a cross-section between the front and back sides with a sawtooth wave pattern, the battery cell separator (224, 234) further comprising columns 228, 238 extending between the front and back sides of the body, the sawtooth wave pattern having multiple saw teeth, each of which has two sides radiating from its corner, characterized in that the columns 228, 238 are arranged between the sides of the saw teeth and extend away from the corner of the respective saw tooth.

Description

[0001] The present invention relates to separators or spacers for battery cells of a battery module. Separators or spacers for battery cells of a battery module are disclosed in US 2006 / 0 240 318 A1, US 2006 / 0 246 348 A1, US 2007 / 0 134 550 A1 and US 2008 / 0 160 395 A1.

[0002] A battery module can comprise battery units (i.e., battery cells) and separators (i.e., spacers) arranged together to form the module. The cells can each have a prismatic shape, so the module is designed as a prismatic structure. The cells can be electrically connected in series to increase the output power and form a high-voltage (HV) battery module. Such battery modules can be used in electric and hybrid vehicles. The separators are positioned between adjacent cells and physically isolate neighboring cells from each other.

[0003] Simple prismatic battery cell designs may lack features to retain, support, separate, and / or isolate the battery cells. In such cases, the cells must be redesigned to provide the missing properties, or interface components must perform these functions.

[0004] According to the invention, a battery module comprising a battery cell separator is provided according to claim 1. Furthermore, according to the invention, a battery module comprising a battery cell separator is provided according to claim 6. Advantageous embodiments of the invention are specified in the dependent claims.

[0005] In general, embodiments of the present invention provide battery cell separators for the battery cells of a battery module, in which the separators can be used to hold and support the cells, to separate the cells to effect cooling, and / or to isolate the cells from adjacent cells or other conductive surfaces.

[0006] Embodiments of the present invention provide battery cell separators for a battery module containing battery cells, in which the separators relate to a stackable, alternating separator-cell design and are configured to separate adjacent battery cells from one another and provide fluid flow paths between them to facilitate cooling. Embodiments of the present invention provide battery cell separators for a battery module containing battery cells, in which the separators relate to a cartridge-like separator design and are configured to be stacked side-by-side with other cartridge and cell subassemblies. Embodiments of the present invention provide battery cell separators for a battery module containing battery cells, in which the separators are configured as cartridge-like holders for the cells.In these latter embodiments, each holder can have one or more features that separate it from an adjacent cartridge, so that fluid flow paths are established between the cells.

[0007] In accordance with one embodiment of the present invention, a battery module is provided. The module comprises a battery cell separator having a body with front and back faces for stacking against the respective battery cells. The body has a cross-section between the front and back faces with either a sawtooth wave pattern, a rectangular pattern, or a sine wave pattern.

[0008] In an unclaimed embodiment, the separator can be a single piece of electrical insulator or a single piece of plastic.

[0009] In one embodiment, the body can include a shell section to trap moisture.

[0010] According to the invention, the separator further comprises columns extending between the front and back sides of the body. In this case, the body can consist of a single piece of electrical insulator, and the columns are thermal conductors.

[0011] Furthermore, in accordance with one embodiment of the present invention, another battery module is provided. This module comprises a battery cell separator having a thermally conductive body and an electrical insulator. The body has a front for stacking against a battery cell and a back. The insulator is positioned against the back of the body for stacking between another battery cell and the back of the body.

[0012] In one embodiment, the body has a cross-section between the front and back surfaces with a crenellated pattern. In this case, the electrical insulator can comprise a plurality of electrical insulators positioned against respective sections of the back surface of the body, for stacking between the further battery cell and the back surface of the body. Alternatively, the electrical insulator can be a single insulating layer.

[0013] In one embodiment, the body has a cross-section between the front and back surfaces with a sinusoidal wave pattern. In this case, the electrical insulator can comprise a plurality of electrical insulators positioned against respective sections of the back surface of the body, for stacking between the further battery cell and the back surface of the body. Alternatively, the electrical insulator can be a single insulating layer. The insulating layer can have a cross-section with the sinusoidal wave pattern.

[0014] In accordance with one embodiment of the present invention, another battery module is provided. This module comprises a battery cell separator with a first and a second thermally conductive body and an electrical insulator. Each body has a front face for stacking against a respective battery cell, and each body further has a back face. Each body has a cross-section between the front and back faces with a crenellated pattern. The insulator is positioned between the back faces of the bodies. Fig. Figure 1 shows a schematic view of a battery cell and a battery cell separator in accordance with a first one; Fig. Figure 2 shows a top view of a battery module with battery cells and battery cell separators in accordance with the first; Fig. Figure 3 shows a perspective view of a battery cell separator in accordance with a second embodiment; Fig. Figure 4A shows a perspective view of a battery cell, which is shown in the battery cell separator shown in Figure 4A. Fig. 3, can be introduced; Fig. 4B shows a perspective view of the battery cell separator, as shown in Fig. 3, inserted battery cell; Fig. Figure 5A shows a side view of a battery module with battery cells and battery cell separators in accordance with the second embodiment; Fig. 5B shows a perspective view of the in Fig. 5A battery module shown; Fig. Figure 6 shows perspective front and rear views of a battery cell separator in accordance with a third embodiment; Fig. Figure 7A shows a cross-sectional view of joined ribs of battery cell separators arranged side-by-side, in accordance with the third embodiment; Fig. Figure 7B shows a cross-sectional view of joined ribs of battery cell separators arranged side-by-side, in accordance with the third embodiment; Fig. Figure 8 shows a perspective view of a battery module with battery cells and battery cell separators in accordance with the third embodiment; Fig. Figure 9A shows a perspective view of a battery module with battery cells and battery cell separators in accordance with a variation of the third embodiment; Fig. Figure 9B shows a sectional view of the battery module shown in Figure 9A; Fig. 10A shows a side view of a variety of battery cell separators that are in Fig. 6 are shown, stacked side by side, in accordance with the third embodiment; Fig. Figure 10B shows a straightening tool for the manufacture of a battery cell separator, which is used in Fig. 6 is shown; Fig. Figure 11 shows an alternative set of joined ribs for battery cell separators, which are used in Fig. 6 are shown to be stacked side by side, in accordance with the third embodiment; Fig. Figure 12 shows another alternative set of joined ribs for battery cell separators, which are used in Fig. 6 are shown to be stacked side by side, in accordance with the third embodiment; Fig. 13A shows a battery cell separator in accordance with a fourth embodiment; Fig. 13B shows a cross-sectional view of the battery cell separator, which is located in Fig. 13A is shown; Fig. 14A, Fig. 14B and Fig. Figures 14C each show different views of a battery cell separator in accordance with a variation of the fourth embodiment; Fig. Figure 15 shows a schematic view of a battery cell and a battery cell separator in accordance with a fifth embodiment; Fig. Figure 16 shows a side view of a battery module with battery cells and battery cell separators in accordance with the fifth embodiment; Fig. Figure 17A shows a perspective view of a representative battery module with alternating separator-cell design, which includes battery cells and battery cell separators in accordance with embodiments; Fig. Figure 17B shows an isometric view of a battery cell separator of the representative battery module; Fig. Figure 18A shows a sectional view of a battery cell separator and adjacent battery cells of a battery module in which the battery cell separator is in accordance with a first variation of the sixth embodiment; Fig. Figure 18B shows a sectional view of a battery cell separator and adjacent battery cells of a battery module in which the battery cell separator is present according to a second variation of the sixth embodiment according to the invention; Fig. Figure 18C shows a sectional view of a battery cell separator and adjacent battery cells of a battery module, in which the battery cell separator is arranged in accordance with a third variation of the sixth embodiment according to the invention; Figure 19A shows a sectional view of a battery cell separator and adjacent battery cells of a battery module, in which the battery cell separator is arranged in accordance with a first variation of a seventh embodiment according to the invention; Fig. Figure 19B shows a sectional view of a battery cell separator and adjacent battery cells of a battery module, in which the battery cell separator is in accordance with a second variation of the seventh embodiment; Fig. Figure 20A shows a sectional view of a battery cell separator and adjacent battery cells of a battery module, in which the battery cell separator is in accordance with a first variation of an eighth embodiment; Fig. Figure 20B shows a sectional view of a battery cell separator and adjacent battery cells of a battery module, in which the battery cell separator is arranged in accordance with a second variation of the eighth embodiment according to the invention; and Fig. Figure 20C shows a sectional view of a battery cell separator and adjacent battery cells of a battery module, in which the battery cell separator is arranged in accordance with a third variation of the eighth embodiment according to the invention.

[0015] Detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the invention, which can be implemented in various and alternative forms. The figures are not necessarily to scale; some features may be enlarged or reduced to show details of certain components. Therefore, specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis to inform a person skilled in the art of the various ways in which the present invention can be used.

[0016] The examples of implementation of Fig. Figures 1 to 18A and 19B do not fall within the scope of the claimed invention, but are useful for illustrating the claimed invention.

[0017] With reference to the Fig. 1 and Fig. 2 A battery cell separator or spacer 10 is described in accordance with a first embodiment. Fig. Figure 1 shows a schematic view of the battery cell separator 10 and a battery cell 12. Fig. Figure 2 shows a top view of a battery module with the battery cells 12 and the battery cell separators 10.

[0018] The battery cell separator 10 relates to a stackable, alternating separator-cell-separator-cell, etc. design. The stackable separator design is stackable with separators 10 and battery cells 12, which are arranged side-by-side and stacked alternately (e.g., separator 10, cell 12, separator 10, cell 12, separator 10, etc.), as shown in Fig. 2 shown.

[0019] The battery cell separator 10 comprises a plurality of insulating ribs 16. In this example, the separator 10 comprises five ribs 16. The ribs 16 act as supports for a battery cell 12 and as separators of the cell 12 from adjacent cells 12, as shown in Fig. 2 visible (only one cell 12 is in Fig. (1 shown). Separator 10 further comprises two rib supports 18 and 20. The first rib support 18 is located at the left end of the separator 10, and the second rib support is located at the right end of the separator 10. The ribs 16 extend between the rib supports 18 and 20. The ribs 16 and the rib supports 18 and 20 form a pair of pockets 22 on the respective front and back sides of the separator 10. Each pocket 22 is configured to receive a cell 12. The cells 12 sit in corresponding pockets 22. In particular, each pocket 22 has a prismatic shape (for example, rectangular, box-shaped) because the cell 12 has a prismatic shape.

[0020] In the battery cell separator 10, the rib supports 18, 20 connect the ribs 16, prevent forward-backward movement of the battery cell 12 when the cell 12 is in the pocket 22, provide a distributed load-bearing surface to transfer it to adjacent rib supports in front of and behind the cells, and provide a converging fluid inlet 24 and a diverging fluid outlet 26 for heating or cooling the fluid flow. The separator 10 can include upper and lower flanges to prevent up-and-down cell movement. The inlet 24 and outlet 26 can be parabolically shaped to help reduce the pressure drop as the cooling fluid flows from a larger-cross-section inlet chamber in front of adjacent cells 12 to smaller-cross-section spaces between them and back to a larger-cross-section outlet chamber behind the cells.

[0021] As stated above, shows Fig. 2 A top view of a battery module with the battery cell 12 and the battery cell separators 10, which are stacked alternately. As in Fig. As shown in Figure 2, each set of fluid inlets 24 and fluid outlets 26 is formed by the union of two separators 10. The conditioning fluid 28 flows together to enter between adjacent battery cells 12, flows between the fins 16 to supply or remove heat to / from the cells, and distributes itself in the outlet lines 30 leading away from the battery module.

[0022] With reference to Fig. In Figures 3 to 5B, a battery cell separator 32 is described in accordance with a second embodiment. Separator 32 refers to a cartridge-shaped separator design which, together with a battery cell 44, forms a cartridge and cell subassembly. The cartridge and cell subassembly are intended to be stacked side-by-side with identical cartridges and cell subassemblies.

[0023] Fig. Figure 3 shows a perspective view of the battery cell separator 32. The separator 32 has similar rib features to the battery cell separator 10 in the Fig. 1 and Fig. 2. The separator 32 differs from separator 10 in that the separator 32 is designed as a cartridge pocket configured to receive a battery cell 44 (in the Fig. 4A and Fig. 4B shown). As in Fig. As shown in Figure 3, the separator 32 comprises a first set of ribs 34 and 36 and a second set of ribs 38, 40, and 42. The first set of ribs 34 and 36 forms one side of the cartridge pocket of the separator 32, and the second set of ribs 38, 40, and 42 forms the other side of the cartridge pocket of the separator 32. The cartridge pocket of the separator 32 accommodates a battery cell 44 when loaded from top to bottom – see Figure 3. Fig. 4A and Fig. 4B. In particular, the cartridge pocket of the separator 32 has a prismatic shape (for example, rectangular, box-shaped) because the cell 44 has a prismatic shape.

[0024] The battery cell separator 32 further comprises two relatively small, molded-in snap-in features 46. The snap-in features 46 are positioned on the upper inner side of the cartridge pocket of the separator 32 (one is not visible). When the battery cell 44 is inserted into the cartridge pocket, there is slight resistance from the snap-in features 46 until the cell 44 is fully inserted to the bottom of the cartridge pocket. At this point, the snap-in features 46 engage the upper edges of the cell 44, thereby locking the cell 44 in the separator 32 – see [reference]. Fig. 4B. As such, the snap-in features 46 prevent the cell 44 from slipping out of the top of the separator 32 during handling. The separator 32 also has two depth stops 48 on the underside of the cartridge pocket. The cell 44 rests on the depth stops 48 at the end of the insert – see Fig. 4A. The separator 32 further comprises four triangular retaining walls 50. The retaining walls 50 reinforce the four corner channels.

[0025] The battery cell separator 32 may further include a sensor holder 43 on the rib 42. The holder 43 is configured to receive and retain a temperature sensor, which is intended to monitor the temperature of a battery cell that is contained in the cartridge pocket of the separator 32. The separator 32 may further include a pair of retaining clips 45 on the rib 42. The clips 45 are configured to retain a collection chamber for the cell exhaust gases and / or to retain an electrical wiring harness.

[0026] The Fig. 5A and Fig. Figure 5B shows views of a battery module comprising a plurality of battery cells 44 and battery cell separators 32. Each separator 32 has one cell 44, which is contained in the cartridge pocket of the separator, as shown in Fig. Figure 5B shows that each separator 32 with the inserted cell 44 in it forms a cartridge and cell subassembly. As such, the battery module comprises a plurality of cartridges and cell subassemblies stacked side by side, as shown in the Fig. 5A and Fig. 5B shown.

[0027] The 32 dividers, arranged side by side, nestle together as best as in Fig. Figure 5A shows that this provides a total of five ribs between adjacent cells 44 (i.e., ribs 34, 36 of one separator 32 and ribs 38, 40, and 42 of the adjacent separator 32). Five ribs are provided between adjacent cells 44, although there are only either two or three ribs per side for each individual cartridge and cell subassembly. In particular, for two separators 32 arranged side-by-side, the side of one separator 32, which has ribs 34, 36, meets the side of the other separator 32, which has ribs 38, 40, and 42. Ribs 34, 36 and ribs 38, 40, and 42 of the side-by-side adjacent separators 32 form the fluid channels 52 between these separators, as shown in the Fig. 5A and Fig. 5B is shown. As such, the channels 52 run between the cells 44, which in turn are held within the separators 32.

[0028] With reference to the Fig. In Figures 6 to 12, a battery cell separator 54 in accordance with a third embodiment is now described. Separator 54 refers to a cartridge-like design, which is an alternative to the cartridge-like design of separator 32. As such, separator 54 is designed as a cartridge pocket configured to receive a battery cell inserted therein.

[0029] Fig. Figure 6 shows perspective front and rear views of a battery cell separator 54. The separator 54 is similar to the separator 32 and includes many of the same features. The separator 54 comprises a first set of ribs 53, 55, and 56 and a second set of ribs 57, 58, and 59. The first set of ribs 53, 55, and 56 forms one side of the cartridge pocket of the separator 54, and the second set of ribs 57, 58, and 59 forms the other side of the cartridge pocket of the separator 54. The cartridge pocket of the separator 54 also accommodates a battery cell, which is inserted into the cartridge pocket of the separator 54 from top to bottom. Again, the cartridge pocket of the separator 54 has a prismatic shape (for example, rectangular, box-shaped) because the cell to be inserted into it has a prismatic shape.

[0030] The separators 54 are stacked side-by-side with the ribs on one side of the cartridge pocket of a separator 54, abutting the corresponding ribs on the same side of the cartridge pocket of an adjacent separator 54. For example, the ribs 53, 55, 56 on the first side of a first separator 54 each abut the ribs 53, 55, 56 on the first side of a second separator 54 when these separators are stacked side-by-side with the second separator 54, which is stacked against the first side of the first separator 54. Likewise, the ribs 57, 58, 59 on the second side of the first divider 54 each abut the ribs 57, 58, 59 on the second side of a third divider 54 when these dividers are stacked side-by-side with the third divider 54, which is stacked next to the second side of the first divider 54.

[0031] Because the ribs on both sides of the battery cell separator 54 abut adjacent separator ribs, the rib thickness is half the desired conditioning fluid gap. Fig. 7A and Fig. Figure 7B shows cross-sectional views of two joined ribs of the two battery cell separators 54, arranged side-by-side. As an example, the ones shown in the Fig. 7A and Fig. The ribs shown in Figure 7B are the ribs 55 of the first and second separators 54. The joined ribs 55 together form a desired coolant gap. In this example, the desired gap (D1) is approximately 3 mm. To achieve this, each rib 55 measures approximately 1.5 mm in cross-section (D2). The pair of ribs 55 shown in Figure 7B represents the first and second separators 54. Fig. The rib 55 shown in Figure 7A is approximately 2 mm high (D3). When arranged together and inserted in the direction of the arrow, the 2 × 3 mm rib pair can tend to shift if not perfectly compensated, with one rib sliding upwards and the other sliding downwards to release some of the compression pressure. To prevent this lateral column-like error, the ribs 55 can be made taller than in the pair of ribs 55 shown in Figure 7A. Fig. Figure 7B shows that the parts are approximately 5 mm high (D4).

[0032] To further reduce the probability of the ribs shifting relative to each other and to facilitate rib alignment from separator to separator, an alignment feature with a locating pin 63 and a corresponding hole (slot) 65 can be integrated into each rib. This feature can be incorporated into the ribs 55 in Fig. 7B can be recognized in which the pin 63 of one rib 55 is inserted into the hole 65 of the other rib 55 when these ribs 55 are joined together. This feature can be seen further back in an isometric view in Fig. 6A and Fig. 6B will be studied. With reference to the Fig. 6A and Fig. 6B could have multiple pin and hole configurations, and the holes could be slots to reduce fitting difficulties. The pin and hole features could aid in both positioning during assembly and in preventing creep as the battery cell heats up and charges the separators.

[0033] Given the increasing height of the in Fig. As shown in Figure 7B, fewer ribs can be used for the same cell arrangement compression load on the battery cell separator 55. For this reason, the battery cell separator 54 is shown with only three ribs (load transfer areas) per cell side, instead of five ribs per cell side as with separators 10 and 32.

[0034] Fig. Figure 8 shows a perspective view of a battery module with battery cells 44 and battery cell separators 54. Each separator 54 has one cell 44, which is held in the cartridge pocket of the separator, as shown in Fig. Figure 8 shows each separator 54 with the inserted cell 44 forming a cartridge and cell subassembly. As such, the battery module comprises a plurality of cartridges and cell subassemblies stacked side by side, as shown in the battery module in Fig. 5B is shown.

[0035] As in Fig. 8 as well as in Fig. As shown in Figure 6, the end walls of the adjacent separators 54 are not of the same height. Rather, the end walls 60 on the separator side with the positive terminal are larger than the end walls 62 on the separator side, which have the negative terminal. Accordingly, the battery cell itself can be designed with a lug 64 extending away from the negative end. The lug 64 is designed to collide with the raised end wall 60 of the separator 54 to prevent the cell from being fully inserted into the separator if the negative terminal of the cell is incorrectly inserted at the positive end of the separator. As such, the raised end wall 60 of the separator 54 is provided for the "poka-yoke" fault checking with the lug 64 of the battery cell. The lug 64 of the battery cell can be formed in the plastic casing that insulates and supports the negative terminal.

[0036] The Fig. 9A and Fig. Figure 9B shows a perspective view and a sectional view of a battery module comprising the battery cells 44 and the battery cell separators 54 in accordance with a variation of the third embodiment. Again, the battery module comprises a plurality of cartridges and cell subassemblies stacked side by side.

[0037] The battery module, as in Fig. 9A shown is a variation of the battery module, as shown in Fig. 8 is shown insofar as the separator wall 66 and the cell nose feature 68 are located on the side (long side) of the subarray, instead of at the end, as in Fig. Figure 8 shows this. This eliminates obstructions to the two upper corners, which can be used to restrain the row of cells in a battery assembly.

[0038] Moving these features to the side also allows the negative terminal nose to extend toward the neighboring cell's positive terminal. If the nose is designed to butt against the neighboring cell terminal, it can act as an anti-rotation feature to resist terminal twisting during battery assembly. Since cell polarities are reversed when assembled in a row, the nose also rotates away from the negative terminal. The net effect is that half of the cell terminals load a neighboring cell terminal during connector tightening. The cell's negative terminal can have a nose that extends in both directions to provide a secure grip for all cell terminals during connector tightening. This solution also acts as a kind of safeguard for the correct isolator-to-isolator alignment during cell assembly, as two negative terminals placed side by side would have colliding noses.

[0039] Fig. 9B is a cross-sectional view of a section of the in Fig. Figure 9A shows the series and represents some dimensions for the series. A single fin can have a thickness D5 of approximately 1.5 mm, so two fins abutting each other provide an approximately 3 mm (D6) flow path for cooling fluid. In this configuration, D7 can be approximately 6 mm and D8 approximately 18.5 mm.

[0040] Fig. Figure 10A shows a side view of a large number of battery cell separators 54, which are stacked side by side. As in Fig. As shown in Figure 10A, the first set of ribs 53, 55 and 56 and the second set of ribs 57, 58 and 59 are offset in the Z-direction for the two sides of each separator 54. Therefore, the same separator 54 looks different in the Fig. 6A and Fig. 6B does not look the same when viewed from two different perspectives.

[0041] One reason for the offset ribs is to allow a setup casting tool to produce the battery cell separator 54. This means the ribs are offset in the Z-direction to facilitate a simplified tool design. Fig. Figure 10B shows a tool for one direction with shapes 70, 72 for producing the separator 54. Fig. Figure 10B shows an example of how shapes 70 and 72 can be engaged to achieve tool simplicity and cost reduction. The dashed outlines illustrate what it looks like when the tool is nearly closed. It is also made of Fig. Figure 10A shows that the developed cooling fluid channels 74 are slightly offset from each other. This is expected to have a negligible effect on the cooling performance.

[0042] The Fig. 11 and Fig. Figure 12 shows alternative sets of matching ribs for the battery cell separators 54. Fig. 11. The ribs 76 are configured with an exaggerated rib orientation on the same side as the adjacent battery cell separators 54. Fig. The ribs 78 on the same side as the adjacent battery cell separators 54 are configured with a thin rib orientation. Both configurations allow separator-to-separator alignment and aligned ribs under compressive stress. Both configurations can support rotation about the Z-axis so that the two identical parts find each other and join together.

[0043] As described, a battery cell separator 54 according to the third embodiment may offer one or more of the following advantages: error prevention for inserting a battery cell into the separator and from the separator to the adjacent separator; fabrication using a simple setup tool; a self-aligning design so that only one separator design is required instead of two versions; a design that holds a battery cell with a single piece and does not fall out of engagement or fall apart; a design with ribs configured to distribute pressure loads and resist slippage or sagging; and a design with a feature to resist torques acting on the cell terminals during battery module assembly.

[0044] As also described, a battery module comprises a plurality of battery cell separators in accordance with the first embodiment, as shown in the Fig. 1 and Fig. Figure 2 illustrates the converging and diverging features for reducing the pressure drop of a fluid through the series of battery cells. As also described, a battery cell separator in accordance with the second embodiment, as shown in the Fig. Figures 3 to 5B show features at each corner for engaging a retaining rail or other support structure.

[0045] With reference to the Fig. 13A and Fig. In 13B, a battery cell separator 84 is described in accordance with a fourth embodiment. The separator 84 is not a cartridge-like structure. Rather, it is similar to the battery cell separator 10 shown in Fig. 1. The separator 84 surrounds a battery cell. The separator 84 has flanges 86 which restrict the end movement of the battery cell.

[0046] In a battery module, separators between adjacent battery cells can be used for one or more of the following reasons: 1) a separating gap between the cells prevents cell casings from touching, thus preventing leakage currents and cell damage; 2) a separating gap between the cells allows for liquid cooling of the cells; and 3) separators can be used to insulate the battery contacts. Additionally, prismatic cells (e.g., rectangular, box-shaped, etc.) may require that the cell sides be enclosed with a certain pressure or bond to prevent the internal spring forces of the cell windings from expanding and damaging themselves, thereby reducing cell lifespan. Battery cell separators, such as Battery Cell Separator 84, create sufficient bonding on the cell sides without covering so much of the cell surface that cooling becomes ineffective.

[0047] The battery cell separator 84 can comprise: 1) a separator thickness that creates a cell spacing of approximately 2.5 mm; 2) longitudinally running, discontinuous ribs 88 to increase the exposed surface area for cooling (see cross-sectional view in Fig. 13B); Fig. 3) Ribs 88, at least some of which are geometrically positioned on cell winding areas to maximize bonding effectiveness; 4) Openings 90 (windows) between the ribs, which reduce fluid flow restriction; 5) Sides 92 extending over a distance (D9) beyond where a battery cell terminates to prevent accidental tool contact, thus reducing the risk of cell damage; 6) Flanges 94, 86, which extend on the top and sides of the separator 84 respectively to prevent exposed surfaces; 7) An upper lamellar rib 96 acts as positive cell restraint to ensure cell spacing during operation;8) the upper lamellar rib 96 extends above the cell top to contact a cell clamp (stud) assembly to improve the common torque capability, to create a barrier against conductive tracking (electrical leakage currents) between cell tops, and / or to prevent thermal coolant and gas exchange via the top of the separator 84; 9) cross-shaped patterns formed by ribs or walls between cell sides, creating a barrier against conductive tracking between cell sides; and 10) seven evenly spaced supports 98 with ribs 88 featuring discontinuous line protrusions, the protrusions being spaced apart to optimize bonding pressure while reducing surface coverage.

[0048] The Fig. 14A, Fig. 14B and Fig. Figure 14C illustrates different views of a battery cell separator 100 in accordance with a variation of the fourth embodiment. The separator 100 is similar to the one shown in the Fig. 13A and Fig. Battery cell structure 84 shown in Figure 13B. The separator 100 has continuous ribs 102, 104, 106. The separator 100 also has discontinuous ribs 108, 110, 112, 114, 116, 118. Each rib can have a height of approximately 3 mm (as shown in Figure 13B). Fig. (14A seen). The disconnector 100 can have a total height of approximately 130 mm, extending 5 mm beyond a 120 mm high battery cell at each end. The upper rib 102 also extends beyond the top of a battery cell used with the disconnector 100. Ribs 108 and 112 are approximately 20 mm wide, while ribs 114 and 118 are approximately half that width. Rib 110 is approximately 40 mm wide, and rib 116 is approximately 30 mm wide. At the top of the disconnector 100, lugs 120 and 122 extend upwards; they can connect to a busbar and withstand torque loads. Fig. Figure 14B is a view of separator 100 from below. The ends 124 and 126 are tapered at approximately 45 degrees to form a point, but this is only the case at ribs 104, 106, 108, 110, and 112 – see [reference]. Fig. 14C.

[0049] With reference to the Fig. 15 and Fig. 16 describes a battery cell separator 128 in accordance with a fifth embodiment. Fig. Figure 15 shows a schematic view of a battery cell 129 and a separator 128. Fig. Figure 16 shows a side view of a battery module having cells 129 and separators 128.

[0050] The separator 128 has insulator / separator ribs 130, 132, 134, which are held together by a support 136. Supports such as the support 136 can be located on only one side, as shown, or on the front and back sides, or anywhere it is possible to maintain coolant flow. An optional concave rib 138 can be used to capture any free electrolyte and keep it away from the intercellular space. The rib 138 can be configured with a clearance angle 140 to facilitate manufacturing. The entire separator 128 can be manufactured as a single-piece cast fixture.

[0051] Fig. Figure 16 shows a battery module formed from a multitude of battery cells 129 and a multitude of battery cell separators 128. The separators 128 separate individual cells 129, as shown in Fig. 16 shown.

[0052] As indicated by the grouped arrows in the Fig. 15 and Fig. As shown in Figure 16, the fluid flows between the battery cells 129, being conveyed by the inlet features 142 and outlet features 144. Inlet features 142 and outlet features 144, as described above, can generally be parabolic or of another shape to facilitate the flow.

[0053] As described, a battery cell separator intended for use with a battery module containing battery cells arranged in a row, according to embodiments of the present invention, can include one or more holding and separating features for the cells. The ribs can be used to support the cells and provide separation between adjacent cells. The rib separation can be configured to create flow paths between the cells for a heat or cooling fluid (where "fluid" can be air or liquid). The separators can also have one or more geometric features to help ensure correct alignment during assembly and eliminate assembly errors.

[0054] Further configurations of battery modules formed with battery cells and battery cell separators in accordance with embodiments of the present invention may include separators formed from insulators and conductors arranged in various ways. Various types of folded or stamped materials may be used for battery cell separators in addition to cast materials as described herein.

[0055] With reference to Fig. Figure 17A shows a perspective view of a representative battery module 200 with battery cells 202 and battery cell separators 204 in accordance with embodiments. The battery module 200 relates to a stackable alternating separator-cell-separator-cell, etc. design. The stackable separator design is stackable with battery cells 202 and separators 204, which are stacked side-by-side and alternately (for example, cell 202, separator 204, cell 202, separator 204, cell 202, etc.), as shown in Figure 17A. Fig. 17A shown.

[0056] The cells 202 have the same prismatic shape. The separators 204 have the same design. Each separator 204 has a plurality of ribs 206. The ribs 206 of a separator 204 run longitudinally between the laterally extending rib supports (not designated) at the ends of the separator. The ribs 206 of a separator 204 form a kind of divider (i.e., "separator") on each of the front and rear faces of the separator. The cells 202 are each arranged against the ribs 206 of a separator 204 on the corresponding front and rear faces of the separator. As such, in the battery module 200, a pair of cells 202 is placed between a separator 204 and the separator 204, and another separator 204 encloses one of these cells 202, as shown in Fig. 17A shown.

[0057] With reference to Fig. Figure 17B shows an isometric view of a battery cell separator 204 of the battery module 200. Fig. 17B includes section line XX. As described below, section line XX is a reference point for the section views of the Fig. 18, Fig. 19 and Fig. 20.

[0058] With reference to the Fig. 18A, Fig. 18B and Fig. 18C with continued reference to the Fig. 17A and Fig. Figure 17B shows cross-sectional views of a battery cell separator and adjacent battery cells 202 from a battery module, in which the battery cell separator is arranged in accordance with respective variations of a sixth embodiment of the present invention (only Fig. 18B and Fig. 18C). A battery cell separator in accordance with the sixth embodiment generally has a “sawtooth” separator design.

[0059] In Fig. In 18A, a battery module 210 comprises a battery cell separator 214 in accordance with a first variation of the sixth embodiment. The separator 214 is a single separator piece 216, which is composed only of an insulator (for example, a plastic molded part). The separator piece 216 has a simple sawtooth wave design when viewed in cross-section according to line XX of the Fig. 17B is considered. The separator piece 216 has a shell section 218 at its upper end to trap moisture and direct it away from the battery cells 202.

[0060] In Fig. In 18B, a battery module 220 has a battery cell separator 224 in accordance with a second variation of the sixth embodiment of the present invention. The separator 224 is a single separator element 226, which is composed only of an insulator (e.g., another plastic molded part). Similar to the separator element 216 of Fig. 18A the separator piece 226 has a sawtooth shaft device if the cross-section corresponds to line XX of the Fig. 17B is considered. However, unlike the separator piece 216, the separator piece 226 has additional horizontally aligned columns 228. The columns 228 are provided to enable the separator 224 to withstand relatively larger pressure loads between battery cells 202 (conventionally pressed against each other in a row arrangement).

[0061] In Fig. 18C comprises a battery module 230 and a battery cell separator 234 in accordance with a third variation of the sixth embodiment of the present invention. The separator 234 is formed from two components: a separator piece 236, which consists of an insulator, and a series of conductive, horizontally oriented columns 238. The conductive columns 238 assist in the heat transfer surface (i.e., dissipating heat from the battery cell wall into the fin for a comparatively larger surface area distribution for the cooling medium). The separator 234 generally has the same configuration as the separator 224 of Fig. 18B with the difference that the columns 238 of the separator 234 are conductive, whereas the columns 228 of the separator 224 are insulators, since the columns 228 are part of the insulator separator piece 226 of the separator 224.

[0062] With reference to the Fig. 19A and Fig. 19B with continuous reference to the Fig. 17A and Fig. Figure 17B shows cross-sectional views of a battery cell separator and adjacent battery cells 202 from a battery module, in which the battery cell separator is arranged in accordance with corresponding variations of a seventh embodiment of the present invention (only Fig. 19A). A battery cell separator in accordance with the seventh embodiment generally has a “rectangular wave” separator design.

[0063] In Fig. 19A comprises a battery module 240 and a battery cell separator 244 in accordance with a first variation of a seventh embodiment of the present invention. The separator 244 is formed from two components: a crenellated conductor 246 and an arrangement of individual insulators 248. The conductor 246 is crenellated if, in cross-section, it is shaped according to line XX of the Fig. 17B is considered. The insulators 248 are added to one side of the respective sections of the cinder-like conductor 246 to electrically insulate the two canisters of battery cells 202.

[0064] In Fig. In 19B, a battery module 250 comprises a battery cell separator 254 in accordance with a second variation of the seventh embodiment. The separator 254 is formed from three components: a first and a second tin-like conductor 256a and 256b, respectively, and an insulating layer 258. The insulating layer 258 separates the first and the second tin-like conductors 256a and 256b to electrically isolate them from each other. This variation provides a relatively better balanced cooling arrangement for multiple battery cells 202.

[0065] With reference to the Fig. 20A, Fig. 20B and Fig. 20C with continuous reference to the Fig. 17A and Fig. Figure 17B shows cross-sectional views of a battery cell separator and adjacent battery cells 202 from a battery module in which the battery cell separator is installed in accordance with the respective ( Fig. 20B and Fig. 20C: Variations of an eighth embodiment of the present invention according to the invention. A battery cell separator in accordance with the eighth embodiment generally has a "sine wave" separator design.

[0066] In Fig. 20A comprises a battery module 260 and a battery cell separator 264 in accordance with a first variation of an eighth embodiment. The separator 264 is a corrugated separator formed from a corrugated conductor 266 and an insulating layer 268. The conductor 266 is corrugated if its cross-section corresponds to line XX of the Fig. 17B is considered. The insulating layer 268 is added to one side of the conductor 266 between a battery cell 202 and the side of the conductor 266.

[0067] In Fig. 20B comprises a battery module 270 and a battery cell separator 274 in accordance with a second variation of the eighth embodiment of the present invention. The separator 274 is a corrugated separator formed from a corrugated conductor 276 and an arrangement of discrete insulator sections 278. The insulator sections 278 are added to the respective comb sections on one side of the conductor 276 between a battery cell 202 and the side of the conductor 276. For example, the insulator sections 278 are attached to the respective vertex sections of the conductor 276 by means of push pins or are applied to the surface of the respective vertex sections of the conductor 276 by pouring or by immersion.

[0068] In Fig. 20C comprises a battery module 280 and a battery cell separator 284 in accordance with a third variation of the eighth embodiment of the present invention. The separator 284 is a corrugated separator formed from a corrugated conductor 286 and a corresponding corrugated insulating layer 288. The insulating layer 288 is added to one side of the conductor 286 between a battery cell 202 and the side of the conductor 286.

[0069] With regard to the Fig. 18, Fig. 19 and Fig. In all design variations, the intention is to enable battery cells without insulating shrink wrap or other barrier layers wrapped around the cells, in order to save the costs associated with such wrappings. Consequently, cell spacing, the creation of cooling air channels, and cell-to-cell insulation are achieved in a single insulating piece.

[0070] All designs, including all cross-sectional profiles described herein, can be achieved using only one insulating layer, enabling a simpler and more cost-effective solution with fewer parts. The designs of Fig. 18C, Fig. 19A, Fig. 19B, Fig. 20A, Fig. 20B and Fig. 20C are examples of how (thermal) conductors can be integrated into battery cell separators when additional heat transfer is required. In each of these designs, it is still desirable to maintain electrical insulation between two adjacent battery cells to avoid the need for a shrink-wrap insulation layer. Some designs emphasize fewer parts per separator, while others incorporate spacers, and still others prioritize less volume / mass per spacer.

Claims

[1] Battery module (220, 230), comprising: a battery cell separator (224, 234) comprising a body with front and back sides for stacking against respective battery cells (202), the body having a cross-section between the front and back sides with a sawtooth wave pattern, the battery cell separator (224, 234) further comprising columns 228, 238 extending between the front and back sides of the body, the sawtooth wave pattern having multiple saw teeth, each of which has two sides radiating from its corner, characterized by , that the columns 228, 238 are arranged between the sides of the saw teeth and extend away from the corner of the respective saw tooth. [2] Battery module (220) according to claim 1, wherein: the battery cell separator (224) is a single piece of an electrical insulator. [3] Battery module (220) according to claim 1, wherein: the battery cell separator (224) is a single piece of plastic. [4] Battery module (230) according to claim 1, wherein: The columns are heat conductors. [5] Battery module (220, 230) according to claim 1, further comprising: a second battery cell separator (216, 224, 234, 240, 254, 264, 274, 284) comprising a body with front and back faces for stacking against respective battery cells (202), wherein the body of the second battery cell separator (216, 224, 234, 240, 254, 264, 274, 284) has a cross-section between the front and back faces having either a sawtooth wave pattern, a square wave pattern, or a sine wave pattern; and a battery cell (202) which is stacked against the front of the body of one of the battery cell separators 224, 234 and against the rear of the other of the battery cell separators (216, 224, 234, 240, 254, 264, 274, 284). [6] Battery module (240, 270, 280), comprising: a battery cell separator (244, 274, 284) comprising only a first thermally conductive body (246, 276, 286) and an electrical insulator (248, 278, 288), wherein the body has a front for stacking against a respective battery cell (202), wherein the body further comprises a back, wherein the body has a cross-section between the front and back of the body having a crenellated or sinusoidal pattern, wherein the insulator 248, 278 is formed from discrete insulator sections located exclusively on the rear sections of the body which, without the insulator sections, would contact one of the battery cells (202), or wherein the insulator (288) is an insulating layer on the back of the body designed as a wave-shaped conductor.

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