CELL STACK CARRIER FOR A VEHICLE BATTERY CELL

Abstract

A battery cell for a vehicle comprises a cell container with a first wall, a second wall, a first side wall, and a second side wall. The first wall, the second wall, the first side wall, and the second side wall define an electrode stack receiving zone. A vent opening is formed in the second wall. The vent opening is spaced apart from the first and second side walls. The vent opening fluidically connects the electrode stack receiving zone to the outside of the cell container. An electrode stack is positioned in the electrode stack receiving zone. The electrode stack is spaced apart from the first side wall by a channel. A cell stack support is arranged in the electrode stack receiving zone and supports the electrode stack above the second wall. The cell stack support includes at least one passage that transports gases from the channel to the vent opening.

Description

INTRODUCTION

[0001] The present disclosure relates to the field of rechargeable energy storage systems and, more particularly, to a cell stack carrier for a rechargeable vehicle battery cell.

[0002] Rechargeable energy storage systems (RESS) typically comprise one or more battery packs with rechargeable energy storage cells. The battery pack can be connected to an external charging system, which recharges the electrical energy lost to a load. The charging system can be part of a vehicle or part of an external charging station. When a vehicle is powered, the battery pack discharges stored electrical energy. The charging and discharging of the stored electrical energy creates gas, which escapes from the battery pack.

[0003] There are a wide variety of systems for venting batteries. For example, many batteries include a spacer sandwiched between a cell container's bottom surface and an electrode stack. The spacer is typically formed from a heat-resistant material. The spacer creates channels in the bottom surface that direct gases to a vent. While existing systems are effective, the current spacers restrict gas flow and thereby impede venting. Accordingly, it would be desirable in the field to develop a spacer that is more open to gas flow to reduce vent flow restrictions. SUMMARY

[0004] A battery cell for a vehicle, according to one non-limiting example, includes a cell container having a first wall, a second wall disposed opposite the first wall, a first sidewall extending between and connecting the first wall and the second wall, and a second sidewall disposed opposite the first sidewall and extending between and connecting the first wall and the second wall. The first wall, the second wall, the first sidewall, and the second sidewall define an electrode stack receiving zone. A vent opening is formed in the second wall, the vent opening being spaced apart from the first sidewall and the second sidewall. The vent opening fluidly connects the electrode stack receiving zone to the exterior of the cell container. An electrode stack is positioned in the electrode stack receiving zone.The electrode stack is spaced from the first side wall by a channel. A cell stack support is arranged in the electrode stack receiving zone, supporting the electrode stack above the second wall. The cell stack support includes at least one passage that transports gases from the channel to the vent opening.

[0005] In addition to one or more of the features described herein, the cell stack support comprises a first member having a first surface and an opposite second surface, the first surface being disposed on the second wall, and a plurality of support members extending from a first end coupled to the second surface to a second end, the at least one passage being defined between adjacent support members of the plurality of support members.

[0006] In addition to one or more of the features described herein, a second member is connected to the second end of each of the plurality of support members.

[0007] In addition to one or more of the features described herein, the first member includes a plurality of openings extending through the first surface and the second surface.

[0008] In addition to one or more of the features described herein, the cell stack carrier comprises a body having a first surface and a second surface, wherein the at least one passage is formed in the body substantially perpendicular to the first surface and the second surface.

[0009] In addition to one or more of the features described in this document, the at least one passage has a circular cross-section.

[0010] In addition to one or more of the features described herein, the body is formed from a porous material, wherein the at least one passageway comprises a plurality of passageways defined between spaces in the porous material.

[0011] In addition to one or more of the features described herein, one of the plurality of support members extends across the second surface at a first angle and another of the plurality of support members extends across the second surface at a second angle, wherein the at least one passageway is a tapered passageway.

[0012] In addition to one or more of the features described in this document, the tapered passage includes an inlet and an outlet, wherein the tapered passage converges from the inlet to the outlet.

[0013] In addition to one or more of the features described herein, one of the plurality of support members is formed from a first plurality of angled ribs spaced from each other across the second surface, and another of the plurality of support members is formed from a second plurality of angled ribs spaced from each other across the second surface, wherein the first plurality of angled ribs and the second plurality of angled ribs are spaced from each other by the at least one passageway.

[0014] A vehicle, according to one non-limiting example, includes a body, an electric motor carried in the body, and a battery pack having a battery cell carried in the body and connected to the electric motor. The battery cell includes a cell container having a first wall, a second wall disposed opposite the first wall, a first sidewall extending between and connecting the first wall and the second wall, and a second sidewall disposed opposite the first sidewall and extending between and connecting the first wall and the second wall. The first wall, the second wall, the first sidewall, and the second sidewall define an electrode stack receiving zone. A vent opening is formed in the second wall. The vent opening is spaced apart from the first sidewall and the second sidewall.The vent fluidically connects the electrode stack receiving zone to the outside of the cell container. An electrode stack is positioned in the electrode stack receiving zone. The electrode stack is spaced from the first side wall by a channel. A cell stack support is arranged in the electrode stack receiving zone and supports the electrode stack above the second wall. The cell stack support includes at least one passage that transports gases from the channel to the vent.

[0015] In addition to one or more of the features described herein, the cell stack support comprises a first member having a first surface and an opposite second surface, the first surface being disposed on the second wall, and a plurality of support members extending from a first end coupled to the second surface to a second end, the at least one passage being defined between adjacent support members of the plurality of support members.

[0016] In addition to one or more of the features described herein, a second member is connected to the second end of each of the plurality of support members.

[0017] In addition to one or more of the features described herein, the first member includes a plurality of openings extending through the first surface and the second surface.

[0018] In addition to one or more of the features described herein, the cell stack carrier comprises a body having a first surface and a second surface, wherein the at least one passage is formed in the body substantially perpendicular to the first surface and the second surface.

[0019] In addition to one or more of the features described in this document, the at least one passage has a circular cross-section.

[0020] In addition to one or more of the features described herein, the body is formed from a porous material, wherein the at least one passageway comprises a plurality of passageways defined between spaces in the porous material.

[0021] In addition to one or more of the features described herein, one of the plurality of support members extends across the second surface at a first angle and another of the plurality of support members extends across the second surface at a second angle, wherein the at least one passageway is a tapered passageway.

[0022] In addition to one or more of the features described in this document, the tapered passage includes an inlet and an outlet, wherein the tapered passage converges from the inlet to the outlet.

[0023] In addition to one or more of the features described herein, one of the plurality of support members is formed from a first plurality of angled ribs spaced from each other across the second surface, and another of the plurality of support members is formed from a second plurality of angled ribs spaced from each other across the second surface, wherein the first plurality of angled ribs and the second plurality of angled ribs are spaced from each other by the at least one passageway.

[0024] The above features and advantages, as well as other features and advantages of the disclosure, will be readily apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Further features, advantages and details are included by way of example only in the following detailed description, which refers to the drawings in which: Fig. 1 is a left side view of a vehicle including a battery pack including a battery cell with a cell stack carrier, according to one non-limiting example; Fig. 2 is a front cross-sectional view of the battery cell with a cell stack carrier according to a non-limiting example; Fig. 3 an end view of the battery cell Fig. 2 according to a non-limiting example; Fig. 4 is an end view of a cell stack carrier according to a non-limiting example; Fig. 5 is an end view of a cell stack carrier according to another non-limiting example; Fig. 6 is a plan view of a cell stack carrier according to a non-limiting example; Fig. 7 is an end view of a cell stack carrier according to another non-limiting example; Fig. 8 is an end view of a battery cell with a cell stack carrier according to another non-limiting example; Fig. 9 is a bottom view of a cell stack carrier according to a non-limiting example; and Fig. 10 is a bottom view of a cell stack carrier according to another non-limiting example. DETAILED DESCRIPTION

[0026] The following description is merely exemplary and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference characters designate like or corresponding parts and features.

[0027] A vehicle according to a non-limiting example is in Fig. 1, generally designated 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. One or more of the plurality of wheels 16 is steerable. The body 12 partially defines a passenger compartment 20 with seats 23 disposed behind an instrument panel 26. A steering controller 30 is disposed between the seats 23 and the instrument panel 26. The steering controller 30 is operated to control the orientation of the steerable wheel(s).

[0028] The vehicle 10 includes an electric motor 34 connected to a transmission 36 and supplying power to one or more of the plurality of wheels 16. A rechargeable energy storage system (RESS) 38 is disposed within the body 12 and supplies power to the electric motor 34. It should be noted that the arrangement of the electric motor 34, the transmission 36, and the RESS 38 within the body 12 may vary. The RESS 38 includes a battery pack 40 that includes a plurality of cell containers 44, one of which is disposed in Fig. 2 and Fig. 3. It should be noted at this point that the battery pack 40 comprises a plurality of battery modules (not shown), each formed from a plurality of battery cells (also not shown) with a cell container 44.

[0029] In one non-limiting example, the cell container 44 includes a first wall 46 and a second wall 48. A plurality of side walls including a first side wall 50, a second side wall 52, a third side wall 54 ( Fig. 3) and a fourth side wall 56 ( Fig. 3) extends between and connects the first wall 46 and the second wall 48. The first wall 46, the second wall 48, and the side walls 50, 52, 54, and 56 define an electrode stack receiving zone 60. In the non-limiting example shown, the first wall 46 is a top wall supporting a first terminal 64 and a second terminal 66. The first terminal 64 and the second terminal 66 are electrically connected to an external load, such as the electric motor 34. The second wall 48, which forms a bottom wall in the non-limiting example shown, includes a vent opening 70.

[0030] In one non-limiting example, an electrode stack 74 is disposed in the electrode stack receiving zone 60. The electrode stack 74 stores electrical energy and releases it, for example, to the electric motor 34 via the first terminal 64 and the second terminal 66. To this end, a first tab 76 and a second tab 78 form an electrical interface between the electrode stack 74 and the corresponding one of the first terminal 64 and the second terminal 66. In one non-limiting example, a channel 80 extends around the electrode stack 74. The channel 80 provides a passage for gases, which may be generated by the electrode stack 74 during charging and / or discharging, from the cell container 44. The gases can flow through the channel 80 and exit the cell 44 through the vent opening 70.

[0031] In one non-limiting example, the electrode stack 74 is supported above the second wall 48 by a cell stack support 84. It should be noted that the number, arrangement, and relative thickness of the cell stack supports may vary. For a description of the cell stack support 84, reference is now made to Fig. 4. The cell stack support 84 includes a first member 94 having a first surface 96 and a second surface 98. The second surface 98 is opposite the first surface 96.

[0032] A plurality of support members 100 extend outwardly from the first surface 96. The support members 100 extend substantially perpendicular to the first member 94. Each support member 100 includes a first end 102 coupled to the first surface 96 and a second end 104. In the non-limiting example shown, the second end 104 cantilevers from the first surface 96. The support members 100 are spaced apart from one another such that passageways 108 are formed when supporting the electrode stack 74. The passageways 108 conduct gases that may escape from the electrode stack 74 to the vent opening 70. The number and arrangement of the passageways 108 may vary.

[0033] As in Fig. 5, the cell stack carrier 84 may also include a second element 112 coupled to the second end 104. In this arrangement, the electrode stack 74 may rest on the second element 112. In Fig. 6, the first member 94 is shown to include a plurality of openings fluidly connecting the electrode stack receiving zone 60 to the passages 108 to further enhance venting of gases that may escape from the electrode stack 74 during charge and discharge cycles or thermal runaway.

[0034] Fig. 7 shows a cell stack support 126 having a body 130 with a first surface 132 and a second surface 134. The second surface 134 opposes the first surface 132. A plurality of passages 136 extend through the body 130 between the first surface 132 and the second surface 134. The passages 136 conduct gases that may escape from the electrode stack 74 during charge and discharge cycles or thermal runaway from the channel 80 through the vent opening 70 to the environment. In the non-limiting example shown, the passages 136 comprise a circular cross-section.

[0035] However, it should be understood that the cross-section of the passages 136 can take a variety of shapes and forms, including circular and non-circular geometries. It should be understood that the number and arrangement of the passages 136 can vary. The passages 136 can be arranged in a single row or in multiple rows, as shown. The passages 136 can be aligned or offset from one another. Fig. Figure 8 shows the body 130 formed from a porous material 143. The porous material 143 includes a plurality of interstices that form passages for the venting of gases.

[0036] Fig. 9 shows a cell stack support 148 according to another non-limiting example. The cell stack support 148 includes a body 150 having a first surface (not shown) supporting the electrode stack 74 and a second surface 154 opposite the first surface. The cell stack support 148 includes a support member 156 and a second support member 158 extending from the second surface 154. The first support member 156 is spaced from the second support member 158 to form a passageway 160.

[0037] The first support member 156 includes a first side surface 162 having a first angle, and the second support member 158 includes a second side surface 165 having a second angle. The passage 160 is defined between the first side surface 162 and the second side surface 165. The first angle and the second angle impart a taper to the passage 160. The taper creates a flow restriction that increases the flow velocity of gases flowing from the channel 80 to the vent opening 70.

[0038] In Fig.10, a cell stack support 170 is shown, including a body 172 with a first surface (shown) supporting the electrode stack 74 and a second surface 180 opposite the first surface. A first plurality of support members 182 protrude from the second surface 180, and a second plurality of support members 182 protrude from the second surface 180 spaced from the first plurality of support members 182. A central passage 186 extends between a first plurality of support members 182 and a second plurality of support members 184 along a central axis "A" of the cell stack support 170.

[0039] The first plurality of support elements 182 are spaced apart by a first plurality of gaps 190, and the second plurality of support elements 184 are spaced apart by a second plurality of gaps 192. Each of the first plurality of support elements 182 is angled relative to the central axis "A." Likewise, each of the second plurality of support elements 184 is angled relative to the central axis "A." As a result of the angling of the first plurality of support elements 182 and the second plurality of support elements 184, each of the first plurality of gaps 190 and the second plurality of gaps 192 is angled. The angling of the first and second pluralities of support elements 182 and 184 creates additional flow paths that increase the flow velocity of gases flowing from the channel 80 to the vent opening 70.

[0040] It should be noted that the cell stack supports according to the disclosed non-limiting example include passages that improve the venting of gases that may escape from the electrode stack during charge and discharge cycles. The improved venting also contributes to temperature reduction in the event that the electrode stack overheats or becomes thermally overloaded.

[0041] The terms "a" and "an" do not imply a limitation of quantity, but denote the presence of at least one of the stated elements. The term "or" means "and / or" unless the context clearly indicates otherwise. References to "an aspect" throughout this specification mean that a particular element (e.g., a feature, structure, step, or property) described in connection with that aspect is included in at least one of the aspects described in this specification and may or may not be present in other aspects. It is also understood that the described elements in the various aspects may be combined in any suitable manner.

[0042] When an element such as a layer, film, region, or substrate is described as lying "on" another element, it may lie directly on top of the other element, or there may be intervening elements. In contrast, when an element is described as lying "directly on" another element, there are no intervening elements.

[0043] Unless otherwise indicated herein, all examination standards are the most recent standard in force on the filing date of this application or, if priority is claimed, on the filing date of the earliest priority application in which the examination standard appears.

[0044] Unless otherwise defined, technical and scientific terms used in this document have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0045] Although the above disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made and equivalent elements may be substituted without departing from the scope thereof. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from its essential scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within its scope.

Claims

[1] Battery cell for a vehicle, comprising: a cell container having a first wall, a second wall disposed opposite the first wall, a first side wall extending between and connecting the first wall and the second wall, and a second side wall disposed opposite the first side wall and extending between and connecting the first wall and the second wall, the first wall, the second wall, the first side wall, and the second side wall defining an electrode stack receiving zone; a vent opening formed in the second wall, the vent opening spaced from a third wall and a fourth wall, the vent opening fluidly connecting the electrode stack receiving zone to the exterior of the cell container; an electrode stack disposed in the electrode stack receiving zone, the electrode stack being spaced from the third wall by a channel; and a cell stack support disposed in the electrode stack receiving zone and supporting the electrode stack above the second wall, the cell stack support comprising at least one passage that transports gases from the channel to the vent opening. [2] The battery cell of claim 1, wherein the cell stack support comprises a first member having a first surface and an opposite second surface, the first surface being disposed on the second wall, and a plurality of support members extending from a first end coupled to the second surface to a second end, the at least one passage being defined between adjacent support members of the plurality of support members. [3] The battery cell of claim 2, further comprising a second member connected to the second end of each of the plurality of support members. [4] The battery cell of claim 2, wherein the first member comprises a plurality of openings extending through the first surface and the second surface. [5] The battery cell of claim 1, wherein the cell stack support comprises a body having a first surface and a second surface, wherein the at least one passage is formed in the body substantially perpendicular to the first surface and the second surface. [6] The battery cell of claim 5, wherein the at least one passage has a circular cross-section. [7] The battery cell of claim 5, wherein the body is formed of a porous material, wherein the at least one passageway comprises a plurality of passageways defined between spaces in the porous material. [8] The battery cell of claim 1, wherein one of the plurality of support members extends across the second surface at a first angle and another of the plurality of support members extends across the second surface at a second angle, wherein the at least one passageway is a tapered passageway. [9] The battery cell of claim 1, wherein one of the plurality of support members is formed from a first plurality of angled ribs spaced from each other across the second surface, and another of the plurality of support members is formed from a second plurality of angled ribs spaced from each other across the second surface, the first plurality of angled ribs and the second plurality of angled ribs being spaced from each other by the at least one passageway. [10] Vehicle comprising: a body, an electric motor carried in the body; and a battery cell according to claim 1, carried in the body and connected to the electric motor.

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