Component removal method

Abstract

A method of removing components from a battery pack may comprise passing a wire 108 through an adhesive component 106 located between first and second components 102, 104, thereby separating the compo

Description

14 04 25 TECHNICAL FIELD 5 The present disclosure relates to a component removal method and particularly, but not exclusively, to a method of removing components from a battery pack. Aspects of the invention relate to a method and to a battery, and to a vehicle incorporating such a battery. BACKGROUND 10 It is known to provide batteries, for example for electric vehicles, which include a number of cells which are arranged in a stack and / or a module and individually housed, adhered together and provided within a thermal insulator such as expanding foam. Such an arrangement is referred to as a battery pack. The pack arrangement protects the cells from external shocks, 15 heat or vibration. However, in the event that one of the cells within the pack becomes damaged or otherwise reaches the end of its useful life, it is a laborious task to remove the individual cell and so it often becomes necessary to replace the entire battery. It is desirable to recycle the valuable components of a battery at the end of its life. Present 20 methods of recycling are labour and energy intensive. An example of one method involves an operative or team breaking down the battery with tools. A less labour-intensive method involves destroying the battery in a shredder, melting or burning off the less valuable components, such as the housing, and recovering the valuable components, e.g. of the cells and connectors. A disadvantage of this approach is that impurities may be retained within the 25 recovered components. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. 30 SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a method and a battery as claimed in the appended claims. 14 04 25 According to an aspect of the present invention there is provided a method of removing one or more components from a battery pack. The battery pack may comprise: a first component; a second component; and an adhesive component disposed between the first component and the second component. The method may comprise passing a cutting means or member, for 5 example a cutting wire or wire, through the adhesive component. In this way it may be possible to loosen the connection between the first component and the second component, thereby enabling the first component to be separated from the second component. The method may comprise removing at least one of the first component and the second component from the battery pack. 10 In one aspect of the invention there is provided a method of removing components from a battery pack, the battery pack including: a first component; a second component; and an adhesive component disposed between the first component and the second component, the method including (a) passing a wire through the adhesive component, thereby separating the 15 first component from the second component, and (b) removing at least one of the first component and the second component from the battery pack. The adhesive component holds the first component and the second component together within the battery pack. Passing a wire through the adhesive component at least partially destroys 20 the adhesive component, thereby breaking the connection or joint between the first component and the second component. This method advantageously enables the removal of one or more individual components, for example one or more cells or one or more cell stacks or one or more cell modules, from a battery pack. It is, therefore, not necessary to break down or destroy a battery if it is necessary or desirable to remove one or more components from the battery 25 pack, for example if repair or replacement of a component of the battery is required. In addition, the method improves the efficiency with which battery components can be recycled. The wire can be shaped and configured such that it can be easily and accurately positioned relative to the adhesive component within the battery pack. This is particularly beneficial for 30 removing battery components from regions of the battery pack which are difficult to access using hand tools. Such battery components may, for example, be held in position by adhesives, within a housing or part of the chassis of a vehicle, and covered in an expanding foam. The wire can be configured to have the mechanical properties, for example bending or flexural strength or tensile strength, which allow it to be deformed, e.g. bent, to enable it to be 35 correctly positioned within the battery pack but not stretch excessively whilst being passed, or pushed, through the adhesive component. Once in position the free ends of the wire can be 14 04 25 manipulated or fitted with handles, or other equipment to allow a user to apply force to the wire and therefore the adhesive component. A further benefit of using a wire is that a slicing action can be used to shear the adhesive 5 component, for example into two relatively clean parts. In an embodiment, the method includes inserting the wire between the first component and the second component. 10 The method may include inserting the wire around the adhesive component. In some embodiments of the invention, for example, the wire may be inserted adjacent to a periphery or outer edge of the adhesive component. In other embodiments of the invention, the wire may be inserted distal to a periphery or outer edge of the adhesive component, for example adjacent to a central portion of the adhesive component. 15 In an embodiment, the method includes attaching a first end of the wire to a first spindle or handle and rotating the first spindle or handle, e.g. about an axis, in order to twist or wind the wire and cause the wire to move, or pass, through the adhesive component. 20 In some embodiments of the invention, step (b) includes anchoring a second end of the wire such that the second end of the wire remains stationary. In alternative embodiments, step (b) includes attaching a second end of the wire to the first spindle or handle, or to a second spindle or handle and rotating the respective spindle or 25 handle, e.g. about an axis, in order to twist or wind the wire and cause the wire to move, or pass, through the adhesive component. The method may comprise moving the wire relative to the adhesive component, thereby breaking bonds within the adhesive component such that the adhesive component is at least 30 partially destroyed. In this way, the connection between the first component and the second component may be disrupted or destroyed. The first component may then be separated from the second component. Either or both of the first component and the second component may be removed from the battery pack. 35 The wire may be inserted during manufacture of the battery pack. A wire may, for example, be inserted or positioned between two components, e.g. the first component and the second component, of the battery pack before the adhesive component is introduced or applied 14 04 25 between the first and second components of the battery pack. In other examples, the wire may be inserted or positioned between two components, e.g. the first component and the second component of the battery pack, after the adhesive component is introduced or applied between the first and second components of the battery pack. In such examples, the wire may be 5 inserted before or after the adhesive component forms a strong enough hold to prevent the first and second components from separating, e.g. by curing. Alternatively, the wire may be inserted after manufacture of the battery pack.The battery pack includes a guide hole for receiving the wire. The guide hole may be positioned between two 10 components, e.g. the first component and the second component, of the battery pack. Alternatively, the guide hole may be positioned between one component, e.g. the first component or the second component, of the battery pack and the adhesive component. The guide hole is positioned within the adhesive component. The guide hole is configured to receive the wire. The guide hole may include a guide. The guide may be provided or positioned 15 on an outer portion of a component of a battery adjacent to the guide hole. The guide may facilitate or enable the introduction of the wire into the guide hole. The method may include engaging the wire with the guide and pulling the wire through the guide hole. In an embodiment, at least one of the first component and the second component is a cell or 20 a cell stack or a cell module. Each of the first component and the second component may be a cell or a cell stack or a cell module. Alternatively, the first component or the second component may be a cell or a cell stack or a cell module, and the other of the first component and the second component may be a 25 structural component or a housing member or a bracket or a thermal interface layer or a cooling plate of the battery pack. In some embodiments, at least one of the first component and the second component is a structural component or a housing member or a bracket or a thermal interface layer or a 30 cooling plate of the battery. Each of the first component and the second component may be a structural component or a housing member or a bracket or a thermal interface layer or a cooling plate of the battery pack. It will be understood, that in embodiments of the invention the battery pack may comprise any 35 number of components. The adhesive component may be positioned or provided between any adjacent components of the any number of components of the battery pack. In an embodiment, the battery pack may comprise at least one further component. The adhesive 14 04 25 component may be provided between the at least one further component and at least one of the first component and the second component. The adhesive component may be configured to secure the at least one further component to at least one of the first component and the second component. The at least one further component and / or any one of the any number of 5 components of the battery pack may be any one of a cell, a cell stack, a cell module, a structural component or a housing member or a bracket or a thermal interface layer or a cooling plate of the battery pack. In an embodiment the method comprises moving the wire relative to the adhesive component, 10 thereby breaking bonds within the adhesive component such that the adhesive component between adjacent components is at least partially destroyed. In this way, the connection between any adjacent components may be disrupted or destroyed. The adjacent components may then be separated from each other. Either or both or all of the adjacent components may be removed from the battery pack. 15 The wire may comprise any suitable material. The wire may include, for example a metal or metal alloy, e.g. stainless steel or nichrome, and / or a polymer or polymeric material, e.g. ultra-high molecular weight polyethylene. 20 Additionally or alternatively, the wire may comprise a braided or abrasive portion. In a further aspect of the invention, there is provided a battery or a battery pack, the battery or battery pack including a first component, a second component and an adhesive component, wherein the adhesive component is provided between the first component and the second 25 component and is configured to secure the first component to the second component, the battery or battery pack further including a guide hole, wherein the guide hole is provided between the first component and the second component and is configured to receive a wire. By providing a battery or battery pack with a guide hole that is configured to receive a wire, 30 the method of the preceding aspects of the invention can be applied efficiently and effectively to the battery or battery pack. In an alternative embodiment there is provided a battery pack comprising a first component, a second component and an adhesive component, wherein the adhesive component is provided 35 between the first component and the second component and is configured to secure the first component to the second component, the battery pack further comprising a wire disposed in the adhesive component between the first component and the second component, which wire 14 04 25 is configured to enable ends of the wire to be grasped by a tool and for the wire to be drawn through the adhesive component to cut the adhesive component and separate the first and second components. 5 The invention further provides a vehicle incorporating a battery pack as defined above. Batteries, particularly electric vehicle batteries, are designed to minimise the amount of unused volume. The effect of this minimised free volume is that when breaking down a battery it can be difficult to bring a tool to bear on the correct component of the battery, such as an 10 adhesive component. By providing a guide hole in the battery, the wire can be pushed into the guide hole and into the correct position around the adhesive component. Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims. 15 Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or 20 features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other clam although not originally claimed in that manner 25 BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 30 Figure 1 shows a battery pack; Figures 2A-2D show side views of battery packs within the scope of the present invention and demonstrating a method of removing a first component from a second component; 35 Figures 3A-3C show a flowchart for a method of removing a first component from a second component and optional method steps; and Figure 4 shows a vehicle according to the present invention. 14 04 25 DETAILED DESCRIPTION 5 Figure 1 shows a known battery pack 10 comprising a plurality of first components in the form of cell modules 12, a plurality of second components in the form of cell modules 14 and a connecting component 16 which holds the first and second components 12,14 together. Such battery packs 10 are cumbersome and, when used in vehicles, difficult to access, to either 10 repair or replace components or to remove components for recycling. Figure 2A is a schematic representation of components within a battery pack (such as shown in Figure 1). The battery pack includes first component 102 in the form of a cell stack, which is connected to second component 104 in the form of a portion of a housing by an adhesive 15 component 106 in the form of an adhesive strip. The cell stack 102 can be detached from the housing 104 using a wire 108. The wire 108 follows a perimeter (not shown) of the adhesive component 106 and a portion 108A of the wire protrudes from the adhesive strip 106 and is accessible to a user. In the version shown in Figure 2A, the wire 108 is arranged to bisect the adhesive component 106. In other examples, the wire 108 may be arranged to be closer to 20 the first component (cell stack) 102 to reduce the residual adhesive left on the first component (cell stack) 102. Alternatively, the wire 108 may be arranged to be closer to the second component (portion of the housing) 104 to reduce the residual adhesive left on the second component (portion of the housing) 104. The protruding portion 108A can be manipulated by a user to pull the wire through the adhesive component 106, thereby slicing the adhesive 25 component 106. In other examples, the wire 108 includes an abrasive portion which can be rubbed against the surface of the adhesive component 106 to cut through the adhesive component 106. Each adhesive component 106 in the cell stack 102 can be provided with a wire 108 such that 30 individual cells (not shown) can be removed from the cell stack 102. Alternatively, a single wire 108 could be used in multiple operations to break the connection between adjacent cells or components (by at least partially destroying or slicing the adhesive component), thereby enabling the removal of multiple cells from the cell stack 102 or the removal of multiple components from the battery pack. 35 14 04 25 The portion 108A may in fact be two portions, one portion being the first end of the wire 108 and the other portion being the second end of the wire 108, both of which are accessible to the user, such as a technician breaking down the battery for repair. A load can be applied to one or both portions or ends of the wire 108 in order to generate a slicing force on the adhesive 5 component 106. The wire 108 can be a thread, a filament, or any other appropriate means for cutting through the adhesive component 106. Figure 2B shows the cell stack 102 shown in figure 2A with the wire 108 having partially cut through the adhesive component 106, leading to a cut portion 110 which shows how the 10 adhesive component is destroyed by the wire 108. Various means of pulling the end portion 108A of the wire 108 to cut the adhesive component 106 are detailed below. Ideally, all or nearly all of the adhesive component 106 will have a cut portion, but when more than half of the adhesive component 106 is cut, it may be possible to pull the first and second components 102, 104 apart, e.g. by holding the second component 104 in position and pulling the first 15 component 102 away from the second component 104. Figure 2C shows the final step of the method of removing the first component 102 from the second component 104. When the wire 108 has cut through all (or a sufficient portion) of the adhesive component 106, a first remainder portion 106A of the adhesive component 106 20 remains on, or is still attached to, the first component 102 and a second remainder portion 106B of the adhesive component 106 remains on, oris still attached to, the second component 104. Figure 2D shows a side view of a section through first and second components 102,104 joined 25 by an adhesive component 106, wherein the adhesive component 106 is provided with a through hole 107 one end of which is provided with a guide 109. The guide facilitates loading of a wire (not shown) from one end of the hole 107, prior to application of the method described above with reference to Figures 2A to C. 30 Figure 3A shows a two-step flowchart detailing a method according to the present invention. The first step 501 involves passing a wire through the adhesive component 106, thereby separating the first component 102 from the second component 104. The second step 502 involves removing at least one of the first component 102 and the second component 104 from the battery pack (not shown). 35 Figures 3B and 3C show additional optional steps which can be included in the flowchart shown in Figure 3A. Step 500 involves inserting a wire 108 between the first component 102 14 04 25 and the second component 104. Step 500A involves inserting the wire 108 around the adhesive component 106. Steps 500 and 500A can occur during or after manufacture of the battery pack (not shown). 5 Steps 504-510 relate to means which can make performing step 501 easier. Steps 504-510 can occur before or after step 501. Step 504 involves attaching a first end 108A of the wire to a first spindle (not shown) and rotating the first spindle in order to pass the wire 108 through the adhesive component 106. The spindle can be attached to a workbench or similar. As the spindle rotates the wire is wound around the spindle such that slack is taken up and the taught 10 un-wound portion of the wire 108 begins cutting through the adhesive component 106. This method helps the user apply a consistent amount of force to the wire 108 to prevent excess strain being applied to the wire 108. The spindle may be turned by hand or using a power tool. The tool can be used to wind the spindle at a constant speed and / or to stop winding when excessive force is applied. In this way, in the event that the wire 108 becomes engaged with 15 the first component 102 or the second component 104, the operation will be paused until the wire 108 is realigned. Steps 506 to 510 relate to the second end of the wire 108. Step 506 involves anchoring the second end of the wire 108 such that the second end of the wire 108 remains stationary. This 20 means that the second end of the wire 108 is prevented from being pulled through the battery pack when a force is applied to the first end of the wire 108. Alternatively, step 508 involves attaching the second end of the wire 108 to the first spindle. In this way, a single turn of the first spindle winds twice as much of the length of the wire 108, speeding up the procedure. Step 510 provides a further alternative, in which the second end of the wire 108 is attached to 25 a second spindle (not shown) and the second spindle is rotated. Attaching both ends of the wire 108 to different spindles allows for an alternative method in which the spindles are turned alternately or in turn, causing the wire to move across the surface of the adhesive component 106 in a sawing action. It may be advantageous to provide the wire 108 with a braided or abrasive portion (not shown), such that as the wire 108 moves across the surface of the 30 adhesive component 106, the adhesive component 106 is abraded. The wire can comprise or include a metal portion, a polymer portion or be made entirely from either a metal or a polymer. The metal can be steel, tungsten, titanium or any metal with appropriate mechanical properties to slice or otherwise cut through the adhesive component. 35 An example of a suitable polymer is ultra-high molecular weight polyethylene. 14 04 25 In optional step 512, the wire 108 is inserted into the battery pack during manufacture. The battery pack can be designed to accommodate the wire 108 within it in such a way that the ends of the wire 108 can be easily accessed when required. Alternatively, step 514 involves inserting the wire 108 after manufacture of the battery pack. 5 The battery pack (not shown) can include a guide hole (107 in Figure 2D) as included in optional step 516 of the method. There may be a guide (109) within or adjacent to the guide hole, which guide may be lighter than the wire. In this way, when the battery is in use it can be lighter because the wire is not yet present. Step 518 can be performed when the battery is 10 in need of repair, or ready to be recycled, the wire 108 can be attached to the guide and pulled through the guide hole such that it is in position, ready to cut through the adhesive component 106. According to step 520, the first component 102 or the second component 104 can be one of 15 a cell or a cell stack or a cell module. Alternatively, the first component 102 or the second component 104 may be a structural component or a housing member or a bracket or a thermal interface layer or a cooling plate of the battery pack. The method can therefore, advantageously, be used to detach any component from within the battery pack or to detach the battery pack from the vehicle. 20 The battery pack may include any number of components connected by the adhesive component 106, such that one or more additional components (not shown) may be adhered to at least one of the first component 102 and the second component 104. Each subsequent component can be removed using the inventive method by inserting a wire 108 between the 25 at least one further component (not shown) and at least one of the first component 102 and the second component 104; and passing the wire 108 through the adhesive component 106, thereby detaching the at least one further component from the at least one of the first component 102 and the second component 104 and removing the component from the battery pack. 30 Figure 4 illustrates a vehicle 600 which includes a battery pack as described above. The vehicle may be an electric vehicle or a hybrid vehicle. It is explicitly intended that the present invention is applicable to vehicle batteries as well as 35 domestic storage batteries, uninterruptible power supplies and any other applicable form of battery. It will be clear to the skilled person that the adhesive component need not be an adhesive or a glue. The adhesive component can be any wet applied structural component which sets, dries or cures after application, including but not limited to expanding foams, a thermal 5 interface material, anti-thermal propagation material, intumescent material, mastic, silane material an epoxy material or any combination thereof. One purpose of the adhesive component is to attach the components, but there may also be a requirement to prevent or reduce the impact of thermal events in cells as well as reduce the impact of vibrations on the battery pack. The adhesive component could, in some embodiments, be an adhesive tape. 10 It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application. 14 04 25

Claims

14 04 251. A method of removing components from a battery pack, the battery packcomprising: a first component; a second component; and an adhesive component disposed 5 between the first component and the second component, wherein the battery pack comprises a guide hole configured to receive a wire, the guide hole being provided within the adhesive component, the method comprising:receiving a wire within the guide hole;passing the wire through the adhesive component, thereby separating the first 10 component from the second component; andremoving at least one of the first component and the second component from the battery pack.

2. A method according to claim 1, the method comprising inserting the wire15 between the first component and the second component.

3. A method according to claim 1 or claim 2, the method comprising inserting thewire around the adhesive component.20 4. A method according to any preceding claim, the method comprising attachinga first end of the wire to a first spindle and rotating the first spindle in order to pass the wire through the adhesive component.

5. A method according any one of claims 1 to 4, the method comprising anchoring25 a second end of the wire such that the second end of the wire remains stationary.

6. A method according to any one of claims 1 to 4, the method comprisingattaching a second end of the wire to the first spindle.30 7. A method according to any one of claims 1 to 4, the method comprisingattaching a second end of the wire to a second spindle and rotating the second spindle.

8. A method according to any one of claims 2 to 7 wherein the wire is insertedduring manufacture of the battery pack.

359. A method according to any one of claims 2 to 7 wherein the wire is insertedafter manufacture of the battery pack.14 04 2510. A method according to claim 9 wherein the guide hole comprises a guide,wherein the method comprises engaging the wire and the guide and pulling the wire through the guide hole.

511. A method according to any one of claims 1 to 10 wherein at least one of thefirst component and the second component is a cell or a cell stack or a cell module.

12. A battery pack comprising a first component, a second component and an10 adhesive component, wherein the adhesive component is provided between the first component and the second component and is configured to secure the first component to the second component, the battery pack further comprising a guide hole, wherein the guide hole is provided in the adhesive component between the first component and the second component and is configured to receive a wire.1513. A battery pack as claimed in claim 12, wherein the guide hole is terminated bya guide to facilitate loading of the wire in the guide hole.

14. A battery pack as claimed in claims 12 or 13, the battery pack comprising a first20 component, a second component and an adhesive component, wherein the adhesive component is provided between the first component and the second component and is configured to secure the first component to the second component, the battery pack further comprising a wire disposed in a guide hole provided in the adhesive component between the first component and the second component, which wire is configured to enable ends of the 25 wire to be grasped by a tool and for the wire to be drawn through the adhesive component to cut the adhesive component and separate the first and second components.

15. A vehicle comprising a battery pack as claimed in any of claims 12 to 14.30

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