Battery assembly with a selectively decoupling adhesive layer

Abstract

A battery assembly is provided. The battery assembly comprises a first battery component part and a second battery component part. A primary adhesive layer is coupled to the first battery component part and positioned between the first and second battery component parts. A selectively decoupling adhesive layer is positioned between the primary adhesive layer and the second battery component part. The selectively decoupling adhesive layer bonds the second battery component part to the primary adhesive layer and the first battery component part. The selectively decoupling adhesive layer decouples the second battery component part from the primary adhesive layer and the first battery component part in response to a trigger stimulus.

Description

[0001] This description refers generally to battery assemblies and methods for maintaining battery assemblies. Batteries play a crucial role in storing and providing electrical energy for many applications. Examples of applications that utilize batteries include electric vehicles, consumer goods, and energy storage systems.

[0002] Battery assemblies comprise battery cells that can be used to store and deliver electrical energy. A battery cell is an electrochemical device that generates electrical energy from chemical reactions. One of the factors that determines the commercial viability of battery assemblies is their serviceability. This includes removing various battery components from a battery assembly for recycling and / or replacing these components with new ones to extend the battery assembly's lifespan.

[0003] A battery assembly according to one or more embodiments is provided. The battery assembly comprises a first battery component part, a second battery component part, and a primary adhesive layer coupled to the first battery component part and arranged between the first and second battery component parts. A selectively decoupling adhesive layer is arranged between the primary adhesive layer and the second battery component part and couples the second battery component part to the primary adhesive layer and the first battery component part. The selectively decoupling adhesive layer decouples the second battery component part from the primary adhesive layer and the first battery component part in response to a trigger stimulus.

[0004] In some embodiments, the selectively decoupling adhesive layer comprises an adhesive selected from a vitrimer adhesive, a hot melt adhesive, a pressure-sensitive adhesive, a thermosetting adhesive, a thermoplastic adhesive, or a combination thereof.

[0005] In some embodiments, the selectively decoupling adhesive layer also includes ferromagnetic particles incorporated into the adhesive.

[0006] In some embodiments, the ferromagnetic particles in the adhesive are present in an amount of about 1 to about 60 wt.%, based on the total weight of the selectively decoupling adhesive layer.

[0007] In some embodiments, the primary adhesive layer comprises an adhesive selected from a foam adhesive, a thermosetting adhesive, a thermoplastic adhesive, or a combination thereof.

[0008] In some embodiments, the primary adhesive layer is directly coupled to the first battery component part, and the selectively decoupling adhesive layer is directly coupled to the primary adhesive layer.

[0009] In some embodiments, the selectively decoupling adhesive layer is directly coupled to the second battery component sub-component.

[0010] In some embodiments, the selectively decoupling adhesive layer is indirectly coupled to the first battery component part via the primary adhesive layer.

[0011] In some embodiments, the battery assembly also includes an additional primary adhesive layer located between the selectively decoupling adhesive layer and the second battery component part. The selectively decoupling adhesive layer is directly coupled to the additional primary adhesive layer and indirectly, via the additional primary adhesive layer, to the second battery component part.

[0012] In some embodiments, the first battery component part is a battery module and the second battery component part is a battery compartment cover.

[0013] In some embodiments, the first battery component part is a first battery cell and the second battery component part is a second battery cell.

[0014] In some embodiments, the battery assembly also includes a pre-molded foam structure with a circumferential foam wall surrounding an opening. The circumferential foam wall extends between the first and second battery component parts, and the primary adhesive layer and the selectively decoupling adhesive layer are arranged in the opening of the pre-molded foam structure.

[0015] A method for maintaining a battery assembly according to one or more embodiments is provided. The method includes providing the battery assembly. The battery assembly comprises a first battery component part, a second battery component part, and a primary adhesive layer coupled to the first battery component part and arranged between the first and the second battery component part. The battery assembly further comprises a selectively decoupling adhesive layer arranged between the primary adhesive layer and the second battery component part, which connects the second battery component part to the primary adhesive layer and the first battery component part.The method further comprises applying a trigger stimulus to the selectively decoupling adhesive layer, such that the selectively decoupling adhesive layer responds to the trigger stimulus by decoupling the second battery component part from the primary adhesive layer and the first battery component part.

[0016] In some embodiments, the application includes the application of a trigger stimulus selected from heat, high-intensity focused ultrasound, force, or a combination thereof.

[0017] In some embodiments, the triggering stimulus includes heat, wherein the application includes the application of heat to the selectively decoupling adhesive layer using a heat transfer process by forced convection, a heat transfer process by conduction, an induction heating process, a radiative heat transfer process, or a combination thereof.

[0018] In some embodiments, the application involves applying high-intensity focused ultrasound to the selectively decoupling adhesive layer. The high-intensity focused ultrasound causes plastic wave propagation and / or heat generation through the selectively decoupling adhesive layer.

[0019] In some embodiments, the trigger stimulus includes a force, wherein the application includes the application of a force in a plane-lying tensile mode to the selectively decoupling adhesive layer.

[0020] In some embodiments, the method further includes removing the first battery component part and the primary adhesive layer from the battery assembly after applying the trigger stimuli.

[0021] In some embodiments, the method further comprises replacing the first battery component part and the primary adhesive layer in the battery assembly with a first replacement battery component part and a replacement primary adhesive layer after removal. The selectively decoupling adhesive layer is coupled to the replacement primary adhesive layer by applying an additional release stimulus. The primary replacement adhesive layer is then coupled to the first replacement battery component part.

[0022] A device according to one or more embodiments is provided. The device comprises an output battery component and a battery assembly configured to supply electrical energy to the output battery component. The battery assembly comprises a first battery component part, a second battery component part, and a primary adhesive layer coupled to the first battery component part and arranged between the first and second battery component parts. The battery assembly further comprises a selectively decoupling adhesive layer arranged between the primary adhesive layer and the second battery component part, bonding the second battery component part to the primary adhesive layer and the first battery component part.The selectively decoupling adhesive layer decouples the second battery component part from the primary adhesive layer and the first battery component part in response to a trigger stimulus.

[0023] The above features and advantages, as well as other features and advantages of the present description, are readily apparent from the following detailed description of the best embodiments of the disclosure in conjunction with the accompanying drawings. Brief description of the drawings Fig. Figure 1 schematically shows an exemplary device with a battery arrangement according to the present description; Fig. Figure 2 schematically shows a part of an exemplary battery arrangement and a method for maintaining the battery arrangement in accordance with the present description; Fig. Figure 3 schematically shows an exemplary battery arrangement according to the present description; Fig. Figure 4 schematically shows an exemplary battery arrangement according to the present description; Fig. Figure 5A schematically shows a side view of an exemplary battery arrangement according to the present description; Fig. 5B schematically shows a top view of the in Fig. 5A battery arrangement shown; Fig. Figure 6A schematically shows a side view of an exemplary battery arrangement according to the present description; Fig. 6B schematically shows a top view of the in Fig. Battery arrangement shown in 6A; Fig. Figure 7 schematically shows a part of an exemplary battery arrangement and a method for maintaining the battery arrangement in accordance with the present description; and Fig. Figure 8 schematically shows part of an exemplary battery arrangement and a method for maintaining the battery arrangement in accordance with the present description. Detailed description

[0024] As required, detailed embodiments of the present description are disclosed here; however, it should be understood that the disclosed embodiments are merely exemplary of the disclosure, which can be embodied in various and alternative forms. The illustrations are not necessarily to scale; some features may be exaggerated or reduced in size to show details of certain components. Therefore, specific structural and functional details disclosed here are not to be understood as limiting, but merely as a representative basis to show the person skilled in the art how to apply the present description in various ways.

[0025] Unless explicitly stated in the context, the term "approximately" here means within a normal tolerance range, for example, within two standard deviations of the mean. "Approximately" can be understood as within 10%, 5%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. "Approximately" can also be understood as stating the exact value. Unless otherwise indicated in the context, the numerical values ​​given here are modified by the term "approximately."

[0026] In an exemplary embodiment, a battery assembly comprises a first battery component part and a second battery component part. A primary adhesive layer is coupled to the first battery component part and arranged between the first and second battery component parts. A selectively decoupling adhesive layer is arranged between the primary adhesive layer and the second battery component part. The selectively decoupling adhesive layer bonds the second battery component part to the primary adhesive and the first battery component part.

[0027] When a trigger stimulus, such as heat, high-intensity focused ultrasound, and / or force, acts on the selectively decoupling adhesive layer, the layer decouples the second battery component from the primary adhesive layer and the first battery component. In an exemplary embodiment, the selectively decoupling adhesive layer advantageously allows the first battery component to be decoupled and removed from the second battery component to facilitate maintenance of the battery assembly. For example, the battery assembly can be disassembled for recycling. In another example, the first battery component can be replaced with a new or spare battery component to extend the service life of the battery assembly.

[0028] Referring to the drawings, where identical reference numbers refer to identical features in the different views, Fig. Figure 1 schematically shows an exemplary device 200, for example, a battery-powered electric vehicle (BEV), including a battery assembly 205 containing one or more battery packs 210. The battery pack 210 contains a plurality of battery cells 100. The multiple battery cells 100 can be coupled together in various combinations, for example, by connecting some in parallel and some in series, to supply electrical energy at a desired voltage. The battery pack 210 is shown electrically coupled to a motor-generator unit 220, which serves to supply the vehicle 200 with motive power. The motor-generator unit 220 can include an output component, for example, an output shaft, which is supplied with mechanical energy to provide the motive power for the vehicle 200.A number of variants of vehicle 200 are conceivable, and the description is not intended to be limited to the examples given.

[0029] Fig. Figure 2 schematically shows a part of the battery assembly 205 and a method for maintaining the battery assembly 205 in accordance with an exemplary embodiment. The battery assembly 205 comprises the battery components 10 and 12. As explained in more detail below, the battery component part 10 can, for example, be a battery cell 100, a module containing a plurality of battery cells 100, or another battery component part of the battery assembly 205. Likewise, the battery component part 12 can, for example, be a battery cell 100, a module with multiple battery cells 100, a battery pack cover, or another battery component part of the battery assembly 205.

[0030] A primary adhesive layer 14 is coupled to the battery component part 10 and arranged between the battery component parts 10 and 12. As shown, the primary adhesive layer 14 is directly coupled to the battery component part 10. In an exemplary embodiment, the primary adhesive layer 14 comprises an adhesive, such as a gap-filling or foam adhesive, a thermosetting adhesive, and / or a thermoplastic adhesive. Non-limiting examples of adhesives that can form the primary adhesive layer 14 are acrylic adhesive, polyurethane adhesive, epoxy adhesive, cyanoacrylate adhesive, and / or silicone adhesive.

[0031] In specific examples, epoxy adhesives, silicone adhesives and / or polyurethane adhesives, which may or may not be foamable, can be used.

[0032] A selectively decoupling adhesive layer 16 is arranged between the primary adhesive layer and the battery component part 12, connecting the battery component part 12 to the primary adhesive 14 and the battery component part 10. As shown, the selectively decoupling adhesive layer 16 is directly coupled to the primary adhesive layer 14 and independently directly to the battery component part 12. Furthermore, the selectively decoupling adhesive layer 16 is indirectly coupled to the battery component part 10 via the primary adhesive layer 14.

[0033] In an exemplary embodiment, the selectively decoupling adhesive layer 16 comprises an adhesive selected from a vitrimer adhesive, a hot melt adhesive, a pressure-sensitive adhesive, a thermoset adhesive, a thermoplastic adhesive, or a combination thereof. In an exemplary embodiment, vitrimers are polymeric materials that can alter their molecular bonds at elevated temperatures due to thermally activated bond-exchange reactions. This allows them to be initially applied and cured as a liquid to form a strong adhesive bond, but then flow as a liquid upon sufficient heating.

[0034] Furthermore, the selectively decoupling adhesive layer 16 can contain other additives, fillers, or the like. In an exemplary embodiment, the selectively decoupling adhesive layer 16 contains ferromagnetic particles incorporated into the adhesive. In an exemplary embodiment, the ferromagnetic particles are present in the adhesive in an amount of approximately 1 to approximately 60 wt.%, based on the total weight of the selectively decoupling adhesive layer 16.

[0035] In an exemplary embodiment, the selectively decoupling adhesive layer 16 has a composition or formulation, or is otherwise capable of decoupling the battery component part 12 from the primary adhesive layer 14 and the battery component part 10 in response to a trigger stimulus (characterized by an arrowhead 18). In particular, the trigger stimulus 18 is applied to the selectively decoupling adhesive layer 16 such that the selectively decoupling adhesive layer 16 responds to the trigger stimulus 18 by decoupling the battery component part 12 from the primary adhesive layer 14 and the battery component part 10. In an exemplary embodiment, which will be discussed in more detail below, the trigger stimuli 18 can be heat, high-intensity focused ultrasound, force, or a combination thereof.For example, heat can be applied to the selectively decoupling adhesive layer 16 to soften, liquefy or otherwise weaken the selectively decoupling adhesive layer 16, and a force can also be applied to the softened, liquefied or otherwise weakened selectively decoupling adhesive layer 16 to decouple the battery component part 12 from the primary adhesive layer 14 and the battery component part 10 in order to remove the battery component part 10.

[0036] In an exemplary embodiment, the battery assembly 205, or a part thereof, can be removed from the device 200 for maintenance, for example, to recycle it, install replacement battery components for a longer service life, or similar purposes. As shown, the battery component part 10 is removed from the battery assembly 205 together with the primary adhesive layer 14. In an exemplary embodiment, the battery component part 10 and the primary adhesive layer 14 are replaced by a replacement battery component part 110 together with a replacement primary adhesive layer 114. The remaining portion of the selectively decoupling adhesive layer 16 is coupled to the replacement primary adhesive layer 114 by applying an additional release stimulus 118. As shown, the replacement primary adhesive layer 114 is directly coupled to the replacement battery component part 110.

[0037] See also Fig. 3. In an exemplary embodiment, the battery arrangement 205 is configured as, or includes, a modularized package 120 containing a plurality of battery modules 122, each battery module 122 containing a plurality of battery cells 100. The battery modules 122 are enclosed in a battery pack cover 124. In this embodiment, the battery module 122 corresponds to the battery component part 10, and the battery pack cover 124 corresponds to the battery component part 12. As shown, the primary adhesive layer 14 is directly coupled to the battery module 122, and the selectively decoupling adhesive layer 16 is arranged between the primary adhesive layer 14 and the battery pack cover 124 and directly coupled to them.

[0038] In one exemplary embodiment, the trigger stimulus 18 is applied to the selectively decoupling adhesive layer 16 in the form of heat. In another example, heat is supplied indirectly to the selectively decoupling adhesive layer 16 by a conductive heat transfer process and / or a radiative heat transfer process by applying heat along the surface of the battery cover 124. Alternatively, heat is supplied directly or indirectly to the selectively decoupling adhesive layer 16 by blowing heat through the openings 126 adjacent to the selectively decoupling adhesive layer 16 by forced convection.Alternatively, an induction heating method can be used to generate heat in the selectively decoupling adhesive layer 16, for example in combination with the adhesive of the selectively decoupling adhesive layer 16 which is loaded with or contains ferromagnetic particles that convert the inductive energy into heat.

[0039] See also Fig. 5A-6B. In an exemplary embodiment, the modularized package 120 further comprises a pre-molded foam structure 128 with a circumferential foam wall 130 surrounding an opening 132. The circumferential foam wall 130 extends between the battery components 10 and 12, and the primary adhesive layer 14 and the selectively decoupling adhesive layer 16 are arranged in the opening 132 of the pre-molded foam structure 128. As shown in the Fig. As shown in Figures 5A-5B, in an exemplary embodiment, the preformed foam structure 128 has a rectangularly shaped circumferential foam wall 130 that surrounds a rectangular opening 132. Alternatively, more than one preformed foam structure 128 and / or structures with different shapes can be used. As shown in the Fig. As shown in Figures 6A-6B, in an exemplary embodiment several preformed foam structures 128, for example with a donut- or oval-shaped circumferential foam wall 130, can be arranged between the battery component parts 10 and 12. In an exemplary embodiment, the preformed foam structure(s) 128 advantageously enable efficient use of the primary adhesive layer 14 to fill any gaps and / or spaces between the battery component parts 10 and 12.

[0040] As in the Fig. 2 and Fig. As shown in Figure 4, the battery arrangement 205 is configured as a cell pack 140 or contains one containing a plurality of battery cells 100. In this embodiment, one battery cell 100 corresponds to the battery component part 10, and the adjacent battery cell 100 corresponds to the battery component part 12. In an exemplary embodiment, the selectively decoupling adhesive layer 16 also acts as a dielectric insulating layer during normal operation. In this embodiment, the trigger stimulus 18, in the form of heat, is applied to the selectively decoupling adhesive layer 16 to utilize a forced convection heat transfer process in which heat is blown through the openings 126 adjacent to the selectively decoupling adhesive layer 16.

[0041] As in Fig. As shown in Figure 7, in an exemplary embodiment, the trigger stimulus 18 comprises high-intensity focused ultrasound applied to the selectively decoupling adhesive layer 16. Specifically, a plurality of ultrasonic waves (trigger stimuli 18) are focused onto the selectively decoupling adhesive layer 16. A waveguide 201 can be used to provide a sufficient signal path for guiding and focusing the signals to form a focal point 202 at the selectively decoupling adhesive layer 16, thereby causing plastic wave propagation and / or heat generation through the selectively decoupling adhesive layer 16. Guiding and focusing multiple elements onto the focal point 202 allows the ultrasound to penetrate the other parts of the battery assembly 205 without damage. Decoupling can be induced by high-intensity ultrasound in the form of excessive heat, vibration, or cavitation.If a direct path to the selectively decoupling adhesive layer 16 exists, a single signal with a sufficiently high (for example, destructive) amplitude can be used.

[0042] Referring to Fig.In an exemplary embodiment, the battery assembly 205 further comprises an additional primary adhesive layer 114, which is arranged between the selectively decoupling adhesive layer 16 and the battery component part 12. As shown, the selectively decoupling adhesive layer 16 is directly coupled to the additional primary adhesive layer 114 and indirectly coupled to the battery component part 12 via the additional primary adhesive layer 114. In an exemplary embodiment, the trigger stimuli 18 comprise a force exerted on the selectively decoupling adhesive layer 16 in a plane-lying tensile mode, causing it to stretch and decouple the battery component parts 10 and 12. In an exemplary embodiment, the adhesive can be an elastomer with a relatively high elongation at break, for example, adhesives based on natural or synthetic rubber or neoprene.The elastomeric adhesive layer can be single-layered or consist of a foam core layer and elastomeric outer layers.

[0043] While the best modes for carrying out the description have been detailed, those familiar with the prior art to which this description refers will recognize various alternative designs and embodiments for carrying out the description within the scope of the attached claims.

Claims

[1] Battery arrangement comprising: a first battery component part; a second battery component part; a primary adhesive layer that is coupled to the first battery component part and is positioned between the first and second battery component parts; and a selectively decoupling adhesive layer arranged between the primary adhesive layer and the second battery component part, coupling the second battery component part to the primary adhesive layer and the first battery component part, wherein the selectively decoupling adhesive layer decouples the second battery component part from the primary adhesive layer and the first battery component part in response to a trigger stimulus. [2] Battery arrangement according to claim 1, wherein the selectively decoupling adhesive layer comprises an adhesive selected from a vitrimer adhesive, a hot melt adhesive, a pressure-sensitive adhesive, a thermosetting adhesive, a thermoplastic adhesive or a combination thereof. [3] Battery arrangement according to claim 2, wherein the selectively decoupling adhesive layer further comprises ferromagnetic particles incorporated into the adhesive. [4] Battery arrangement according to claim 3, wherein the ferromagnetic particles are present in the adhesive in an amount of about 1 to about 60 wt.%, based on the total weight of the selectively decoupling adhesive layer. [5] Battery arrangement according to claim 1, wherein the primary adhesive layer comprises an adhesive selected from a foam adhesive, a thermosetting adhesive, a thermoplastic adhesive or a combination thereof. [6] Battery arrangement according to claim 1, wherein the primary adhesive layer is directly coupled to the first battery component part and the selectively decoupling adhesive layer is directly coupled to the primary adhesive layer. [7] Battery arrangement according to claim 6, wherein the selectively decoupling adhesive layer is directly coupled to the second battery component part. [8] Battery arrangement according to claim 6, wherein the selectively decoupling adhesive layer is indirectly coupled to the first battery component part via the primary adhesive layer. [9] Battery arrangement according to claim 6, further comprising an additional primary adhesive layer arranged between the selectively decoupling adhesive layer and the second battery component part, wherein the selectively decoupling adhesive layer is coupled directly to the additional primary adhesive layer and indirectly to the second battery component part via the additional primary adhesive layer. [10] Method for maintaining a battery assembly, the method comprising: Providing the battery arrangement, including the battery arrangement: a first battery component part; a second battery component part; a primary adhesive layer that is coupled to the first battery component part and is positioned between the first and second battery component parts; and a selectively decoupling adhesive layer arranged between the primary adhesive layer and the second battery component part, and which connects the second battery component part to the primary adhesive layer and the first battery component part; and Applying a trigger stimulus to the selectively decoupling adhesive layer, such that the selectively decoupling adhesive layer responds to the trigger stimulus by decoupling the second battery component part from the primary adhesive layer and the first battery component part.

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