Systems and methods for the durability of lithium-ion batteries

Abstract

A battery configured to have improved stability and structural stability. The battery includes a battery pack structure comprising at least one battery cell spacer having a first surface that contacts substantially all of the bottom surface of a first battery cell and a second surface that contacts substantially all of the top surface of a second battery cell, the battery cell spacer comprising an adhesive component. The battery may further include a battery management system (BMS) electrically communicating with the first and second battery cells, the BMS having one or more thermal components configured to dissipate heat from the BMS, and the battery also has one or more thermal components and thermal epoxy in contact with the battery housing. The battery further includes a stabilizing cage that at least partially surrounds the battery pack structure and is positioned between the battery cells and the battery housing.

Description

Technical Field

[0001] (Cross - reference to related applications) This application claims priority to U.S. Patent Application No. 18 / 330523, filed on June 7, 2023, which is hereby incorporated by reference in its entirety.

[0002] This disclosure relates to batteries. Specifically, this disclosure relates to lithium - ion batteries having features that enhance durability.

Background Art

[0003] Lithium - ion batteries are the mainstream type of rechargeable batteries used in many commercial applications today. Due to their wide range of applications, lithium - ion batteries are required to have various sizes, shapes, configurations, and chemistries depending on the intended use. Unfortunately, lithium - ion batteries can pose safety problems if not properly designed, improperly charged, or subjected to strong mechanical forces (e.g., vibration).

[0004] One way lithium - ion batteries degrade is due to thermal abuse caused by insufficient cooling. If a lithium - ion cell overheats, it can undergo thermal runaway, leading to cell rupture. Since many lithium - ion batteries contain flammable electrolytes, a degraded lithium - ion cell can potentially cause an explosion or fire. To address this issue, some lithium - ion battery designs typically include a heat sink associated with a battery management system (BMS) that includes a printed circuit board (PCB) and electronic circuitry. The heat generated in the circuit is transferred to the heat sink and further dissipated depending on convection by the air contained within the battery housing.

[0005] Another common way lithium-ion batteries degrade is through mechanical stress resulting from their movement (for example, a vehicle carrying the battery hitting a bump in the road, or a boat carrying the battery going over waves). To physically protect the battery, large lithium-ion batteries are typically housed in a polymer shell (sometimes called a battery housing), which helps to mitigate some of the mechanical stress that the lithium-ion cells will eventually experience during use. [Overview of the project] [Means for solving the problem]

[0006] This disclosure relates to systems and methods for improving the thermal and mechanical stability of batteries, such as lithium-ion batteries. In one embodiment, a battery management system having improved thermal cooling by conduction is provided. By utilizing conductive heat transfer from the battery management system, such as transferring energy via a thermal resin in contact with the battery housing, improved cooling can be achieved compared to existing convection-based designs. Furthermore, structural improvements through the use of dedicated battery spacers, specific battery cell bonding, and battery stabilization cages help ensure that battery cells do not degrade due to forces applied to the battery during use.

[0007] In one embodiment, the disclosure provides a battery configured to have improved stability. The battery may include a battery pack structure comprising a first battery cell having a top and bottom surface, a second battery cell having a top and bottom surface, and a battery cell spacer having a first surface in contact with substantially all of the bottom surface of the first battery cell and a second surface in contact with substantially all of the top surface of the second battery cell, wherein the first and second surfaces each include an adhesive component. The battery may further include a battery management system (BMS) electrically communicating with the first and second battery cells, the BMS having one or more thermal components configured to dissipate heat from the BMS, and the battery may further include a battery housing surrounding the battery pack structure and the BMS, and a thermal epoxy in contact with one or more thermal components and the battery housing. The battery may also include a stabilizing cage that at least partially surrounds the battery pack structure and is positioned between the battery cells and the battery housing. The stabilizing cage may include a polymer frame having four sidewalls positioned in a rectangular shape, each sidewall including a plurality of openings forming a mesh pattern.

[0008] In another embodiment, the disclosure provides a battery configured to have improved stability. The battery may include a battery management system (BMS) that electrically communicates with a plurality of battery cells, the BMS having one or more thermal components configured to dissipate heat from the BMS, and the battery may further include a battery housing surrounding the battery cells and the BMS, and a thermal epoxy in contact with one or more thermal components and the battery housing.

[0009] In one embodiment, the present disclosure provides a method for manufacturing a battery configured to have improved stability. The method includes the steps of providing a battery management system (BMS) electrically communicating with a plurality of battery cells, the BMS having one or more thermal components configured to dissipate heat from the BMS; arranging a battery housing surrounding the battery cells and the BMS; and applying a thermal epoxy between the BMS and the battery housing, the thermal epoxy in contact with the one or more thermal components and the battery housing.

[0010] In other embodiments, the disclosure provides a battery configured to have improved stability. The battery may include a first battery cell having a top and a bottom surface, a second battery cell having a top and a bottom surface, and a battery cell spacer having a first surface in contact with substantially all of the bottom surface of the first battery cell and a second surface in contact with substantially all of the top surface of the second battery cell, wherein the first and second surfaces of the battery cell spacer each include an adhesive component.

[0011] In one embodiment, the present disclosure provides a method for manufacturing a battery configured to have improved stability. The method may include the steps of: arranging a plurality of battery cell spacers between a plurality of battery cells to form a battery pack; wrapping the battery pack in a first adhesive tape layer, the first adhesive tape layer in contact with substantially all of the top surface of the battery pack; arranging a plurality of protective plates along a plurality of geometric sides of the battery pack, the protective plates configured to substantially cover the plurality of geometric sides; and wrapping the battery pack, the first adhesive tape layer and the protective plates in a second adhesive tape layer.

[0012] In yet another embodiment, the disclosure provides a battery configured to have improved stability. The battery may include a plurality of battery cells, a battery housing configured to surround the battery cells, the battery housing having a body and a cover, and a stabilizing cage that at least partially surrounds the battery cells and is positioned between the battery cells and the battery housing. The stabilizing cage may include a polymer frame having four side walls positioned in a rectangular shape, each side wall including a plurality of openings that form a mesh pattern. [Brief explanation of the drawing]

[0013] [Figure 1]One aspect of the present disclosure shows a side view of a battery having a thermal resin layer positioned along substantially the entire length of the bottom surface of the battery housing cover, the associated battery management system including a plurality of metal plates in contact with the thermal resin layer. [Figure 2] One aspect of the present disclosure shows a side view of a battery having a thermal resin layer positioned along a specific section of the bottom surface of the cover of the battery housing, wherein the associated battery management system includes a plurality of metal plates in contact with the thermal resin layer section, and the thermal resin layer does not extend laterally beyond the edges of the metal plates. [Figure 3] The present disclosure shows a side view of a battery having a thermal resin layer positioned along a section of the bottom surface of the battery housing cover, wherein the associated battery management system includes a printed circuit board (PCB) in contact with the thermal resin layer, and the thermal resin layer extends laterally beyond the edge of the PCB but does not cover the entire length of the bottom surface of the battery housing cover. [Figure 4] A side view of a battery relating to one aspect of the present disclosure, which has a thermal resin layer positioned along a section of the bottom surface of the battery housing cover, the associated battery management system comprising a printed circuit board and a plurality of field-effect transistors (FETs), both of which are in contact with the thermal resin, the thermal resin layer extending laterally beyond the edge of the PCB but not covering the entire length of the bottom surface of the battery housing cover. [Figure 5A] The bottom view of a battery housing cover having a thermal resin layer positioned along most of the bottom surface according to one aspect of the present disclosure is shown, and the associated battery management system includes a plurality of metal plates in contact with the thermal resin layer. [Figure 5B] Figure 5A shows a perspective view of the battery housing cover. [Figure 6] This is a process flowchart of a method for manufacturing a battery configured to have improved stability, according to one aspect of the present disclosure. [Figure 7A] This shows a partially exploded view of a battery housing and associated battery stabilization cage according to one aspect of the present disclosure. [Figure 7B]Shows a partial cutaway view of the battery housing and battery stabilization cage of FIG. 7A, along with the associated battery management system and thermal epoxy layer, according to one aspect of the present disclosure. [Figure 7C] Shows an isometric view of the battery stabilization cage of FIGS. 7A - 7B, according to one aspect of the present disclosure. [Figure 7D] Shows a front view of the battery stabilization cage of FIGS. 7A - 7C, according to one aspect of the present disclosure. [Figure 7E] Shows a side view of the battery stabilization cage of FIGS. 7A - 7D, according to one aspect of the present disclosure. [Figure 8] Shows a side view of a battery pack structure having a plurality of battery cell spacers positioned at three locations between each battery cell, with two adhesive tape compartments wrapped around the battery pack between the battery cell spacers, according to one aspect of the present disclosure. [Figure 9] Is a process flowchart of a method for manufacturing a battery configured to have improved stability, according to one aspect of the present disclosure. [Figure 10] Shows a perspective view of a battery cell having a pouch shape, according to one aspect of the present disclosure. [Figure 11] Shows a perspective view of a battery pack formed of a plurality of battery cells, with interconnecting portions providing an electrical communication path between the battery cells, according to one aspect of the present disclosure. [Figure 12] Shows a side view of a battery pack structure having a plurality of battery cell spacers extending along substantially the entire length of the battery cell, according to one aspect of the present disclosure. [Figure 13] Shows a perspective view of a battery pack structure formed of a plurality of battery cells, with an adhesive tape layer surrounding the entire battery pack including the battery cells and battery cell spacers (if any), according to one aspect of the present disclosure. [Figure 14] Shows a perspective view of the battery pack structure of FIG. 13, further surrounded within protective plates positioned along a plurality of geometric sides of the battery pack structure, according to one aspect of the present disclosure. [Figure 15]A perspective view of a battery pack structure 1400 of FIG. 14 according to one aspect of the present disclosure is shown, further surrounded by a second adhesive tape layer, thereby further fixing the protection plate to the first adhesive tape layer, which helps to further ensure the stability of the battery pack. [Figure 16] A perspective view of a battery pack structure of FIG. 15 according to one aspect of the present disclosure is shown, at least partially surrounded by a shrink-wrapped polymer film.

[0014] The present subject matter will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings that form a part hereof.

Mode for Carrying Out the Invention

[0015] As used herein, unless specifically stated otherwise or clear from the context, the terms “a,” “an,” and “the” are understood to be singular or plural. The terms “include(s)” or “such as” are intended to convey inclusion without limitation, unless specifically indicated otherwise. The terms “or” and “and” can be used interchangeably and are understood to mean “and / or.”

[0016] As used herein, the terms “substantially” and “essentially” refer to a qualitative state indicating all or substantially all of a range or degree. The terms “substantially” and “essentially” may refer to the minimum degree understood in the art. For example, substantially (essentially) all of a value (e.g., surface area) may refer to at least 80%, at least 85%, at least 90%, at least 95%, or specifically at least 99% of that value.

[0017] As used herein, a “Battery Management System” (BMS) may refer to a group of battery components that manages a rechargeable battery, often by preventing the battery from operating outside its safe operating range. Various configurations of a Battery Management System are disclosed, for example, in U.S. Patent Application Publication No. 2022 / 0209307, “Lithium-Ion Battery Management System (BMS) Having Diagonal Arrangement,” the contents of which are incorporated herein by reference in their entirety.

[0018] As used herein, "thermal epoxy" may refer to a polymer resin having an injectable viscosity and high thermal conductivity. "Thermal epoxy" may also be used as a general term and does not necessarily indicate the composition of a product unless otherwise specified in the context. For example, as used herein, thermal epoxy does not necessarily have to be formed from polyepoxides, but may instead comprise alternative or additional polymer resins such as urethane.

[0019] (Heat transfer in battery management systems) Lithium-ion battery management systems (BMSs) require electronic circuitry to disconnect the internal battery pack from the external battery terminals in the event of a malfunction. This circuitry consumes a significant amount of power, generating heat that needs to be dissipated to the outside of the battery housing. Due to exposure concerns, such BMSs are often enclosed within a battery housing with limited external ventilation to provide airflow. Because heat removal by limited natural convection within the battery housing may be slow, such structures can lead to stagnant hot air inside the battery housing. This stagnant hot air accumulates near the BMS, eventually transferring heat from the internal air to the battery housing cover and then to the external environment.

[0020] This disclosure provides a battery system that enables direct and efficient heat transfer from heat-generating components of a BMS to the battery housing via a thermal resin conduction path (e.g., a coated thermal epoxy layer). By providing a direct conduction path instead of relying on the limited natural convection typically available within the battery housing, a more efficient heat removal structure can be achieved. Furthermore, by relying on a thermally conductive viscous liquid that can be injected or injected to conform to the shape of the surface it covers, thermal contact can be achieved over a large area of ​​the BMS, even for irregularly shaped components. Due to the improved heat transfer, a battery system incorporating the teachings of this disclosure may be able to operate at higher currents in a structure of similar size.

[0021] Accordingly, a battery configured to have improved stability can be provided, which comprises a battery management system electrically communicating with a plurality of battery cells, a battery housing surrounding the battery cells and BMS, and one or more thermal components and thermal epoxy in contact with the battery housing. The thermal components of the BMS may be specially configured to dissipate heat from the BMS. For example, one or more thermal components in contact with the thermal epoxy may include electrical components configured to generate heat when an electric current is applied, such as field-effect transistors (FETs), more specifically metal-oxide-semiconductor field-effect transistors (MOSFETs). Alternatively, one or more thermal components in contact with the thermal epoxy may include conductive components such as metal (e.g., copper) plates. Such metal plates may be in contact with electrical components (e.g., MOSFETs) configured to generate heat when an electric current is applied. Figures 1 to 5B show various battery configurations that enable conductive heat transfer from the BMS in a sealed battery system.

[0022] Figure 1 shows a battery 100 configured to have improved stability. The battery 100 may have a positive battery terminal 102 and a negative battery terminal 104. The battery 100 may include a battery management system 110 that is electrically connected to a plurality of battery cells 120. The BMS 110 has a printed circuit board 112 and one or more thermal components (e.g., MOSFETs 114A, 114B and metal plates 116A, 116B, 116C shown) configured to dissipate heat from the BMS 110. A battery housing 130 may enclose the battery cells 120 and the BMS 110. A thermal epoxy layer 140 may be at least partially interposed between the metal plates 116A, 116B, 116C and the battery housing 130 and be in contact with them. As shown in the figure, the thermal resin layer 140 can substantially cover the entire bottom surface of the cover of the battery housing 130, thereby enabling sufficient energy dissipation from the metal plates 116A, 116B, 116C and the BMS 110.

[0023] Figure 2 shows a battery 200 configured to have improved stability through an alternative thermal epoxy arrangement compared to battery 100 in Figure 1. Battery 100 shares many common components with battery 200. For example, battery 200 may also include a positive battery terminal 202, a negative battery terminal 204, multiple battery cells 220, a battery housing 230, a thermal epoxy layer 240, a printed circuit board 212, a BMS 210 having multiple MOSFETs 214A, 214B and metal plates 216A, 216B, 216C. However, unlike the thermal epoxy layer 140 of battery 100 in Figure 1, the thermal epoxy 240 of battery 200 does not extend laterally beyond the edges of the metal plates 216A, 216B, 216C of the BMS. Rather, the thermal epoxy 240 may be substantially limited to the areas of the metal plates 216A, 216B, and 216C, thereby enabling proper heat transfer from the metal plates 216A, 216B, and 216C without the inclusion of excess thermal resin.

[0024] Figure 3 shows battery 300 configured to have improved stability through an alternative thermal epoxy arrangement compared to batteries 100 and 200 in Figures 1 and 2. Batteries 100 and 200 share many common components with battery 300. For example, battery 300 may also include a positive battery terminal 302, a negative battery terminal 304, multiple battery cells 320, a battery housing 330, a thermal epoxy layer 340, a printed circuit board 312, and a BMS 310 having multiple MOSFETs 314A and 314B. However, contrary to the above description, the BMS 310 does not necessarily have to include a metal plate and instead relies on heat transfer from the MOSFETs 314A and 314B to the thermal resin layer 340 via the PCB 312, with the MOSFETs 314A and 314B positioned on the bottom side of the PCB 312. Furthermore, as shown in the figure, the thermal epoxy layer 340 may extend laterally beyond the edge of the PCB 312, but it does not have to occupy the entire bottom surface of the battery housing 330 cover.

[0025] Figure 4 shows a battery 400 configured to have improved stability through an alternative thermal epoxy arrangement compared to battery 300 in Figure 3. Battery 300 shares many common components with battery 400. For example, battery 400 may also include a positive battery terminal 402, a negative battery terminal 404, multiple battery cells 420, a battery housing 430, a thermal epoxy layer 440, a printed circuit board 412, and a BMS 410 having multiple MOSFETs 414A, 414B. However, contrary to the above description, the MOSFETs 414A, 414B and PCB 412 may be in direct contact with the thermal epoxy layer 440. Since the thermal epoxy layer is in direct contact with the heat-generating MOSFETs 414A, 414B, thermal energy can be more easily transferred to the outside of battery 400.

[0026] The application of thermal epoxy layers 140, 240, 340, and 440 can be critical to the performance and durability of individual batteries 100, 200, 300, and 400. Generally, the thermal epoxy layer can be configured to avoid voids, thereby providing direct contact between the BMS and the battery housing. As previously mentioned, the thermal epoxy layer may cover the entire underside of the battery housing cover, be placed only on the underside of the copper plate or PCB, or be limited to a smaller area where a lot of heat is generated. Instead of containing polyepoxide, the thermal epoxy layer may be formed of urethane or other thermally conductive resin having a viscosity that allows it to be injected into the area between the BMS and the battery housing to provide a heat conduction path. To provide sufficient heat transfer, the thermal epoxy may have a thermal conductivity of at least 0.8 W / mK, at least 1 W / mK, and more specifically about 1.2 W / mK.

[0027] It is recognized that the use of rigid epoxy can prevent damage to the BMS system when the battery is exposed to external forces, by providing improved structural stability and preventing movement during shock and vibration. Thus, the introduction of rigid thermal epoxy can provide both structural and thermal stability to the battery system. Specifically, rigid thermal epoxy with a curing hardness of at least 70 Shore A, at least 75 Shore A, at least 80 Shore A, and more specifically 85-90 Shore A can be used. Furthermore, the rigid thermal epoxy should have a curing hardness of at least 15 N / mm². 2 , at least 20 N / mm 2 Specifically, approximately 23 15 N / mm 2 It may have a tensile strength of [value missing].

[0028] Experiments have shown that when MOSFETs are embedded in rigid thermal epoxy, they may be damaged over time due to thermal cycling. MOSFETs, metal plates, and thermal epoxy may all have different coefficients of thermal expansion, which can stress the MOSFETs and potentially damage their leads. Therefore, when using rigid thermal epoxy, it may be necessary to specially position it so that it only contacts the metal plates of the BMS and not the MOSFETs themselves. Conversely, to avoid damage to the BMS, a flexible thermal epoxy may be specially used in structures where the thermal epoxy layer contacts the MOSFETs, and the thermal epoxy layer may substantially cover the entire BMS. The flexible thermal epoxy may have a curing hardness of less than 60 Shore A, less than 50 Shore A, or more specifically, less than 40 Shore A. Depending on the properties of the epoxy used, the heat-generating components of the BMS (e.g., MOSFETs) may be mounted facing downwards away from the thermal epoxy, or facing upwards within the thermal epoxy.

[0029] Figures 5A and 5B show the battery housing cover arrangement 500 and specific components of the BMS 510 that contact the thermal epoxy layer 540. The battery housing cover arrangement 500 is similar to the arrangements of batteries 100 to 400 in Figures 1 to 4, and these share many common components. For example, the battery housing cover arrangement 500 may include a positive battery terminal 502, a negative battery terminal 504, a battery housing cover body 530 (which may or may not be easily removable), and a thermal epoxy layer 540. The BMS 510 may include multiple MOSFETs 514 (two groups of eight MOSFETs) and multiple metal plates 516A, 516B, 516C, and 516D. As shown, the thermal resin layer 540 may contact most of the battery housing cover 530 and may be in direct contact with all four metal plates 516A, 516B, 516C, and 516D, but not with the MOSFETs 514. In this way, the thermal epoxy layer 540 can be kept out of contact with electrical components configured to generate heat (MOSFET 514 in this figure). Generally, a MOSFET 514 generates heat when current flows through it. The heat is first transferred to a series of metal plates 516A, 516B, 516C, and 516D, then transferred to the thermal resin layer 540 via the metal plates 516A, 516B, 516C, and 516D, and finally transferred to the battery housing cover 530.

[0030] Figure 6 shows a battery manufacturing method 600 configured to have improved stability, consistent with the battery configurations shown in Figures 1 to 5B. In 602, a battery management system can be provided that is electrically connected to a plurality of battery cells. The BMS may have one or more thermal components configured to dissipate heat from the BMS. In 604, a battery housing can be arranged to surround the battery cells and the BMS. In 606, a thermal epoxy can be applied between the BMS and the battery housing. The thermal epoxy may be in contact with one or more thermal components and the battery housing.

[0031] (Battery stabilization cage) To improve the mechanical stability of a battery pack within a sealed battery system, a battery stabilization cage is provided. Examples of battery stabilization cage configurations are shown in Figures 7A to 7E. The stabilization cage may include features that minimize the likelihood of external forces from the outside of the battery damaging the battery cells of the battery pack, and can be positioned between the battery housing and the battery pack.

[0032] As shown in the exploded view of various battery components 700 in Figure 7A, and in Figures 7B to 7D, the battery stabilization cage 710 can partially enclose an internal area for a battery pack that houses multiple battery cells, which can be connected to the positive battery terminal 702 and the negative battery terminal 704. The stabilization cage 710 can be positioned between the area for the battery cells and the battery housing, which includes the battery housing body 720 and the battery housing cover 722.

[0033] As shown in the figure, the battery stabilization cage 710 may be a polymer frame having four rectangularly positioned side walls, and may have various specific structural features that allow the battery stabilization cage 710 to protect the battery cells and connect to other components of the battery. For example, as shown in the figure, each side wall of the battery stabilization cage 710 includes a plurality of openings 716 that form a mesh pattern, thereby providing sufficient structural stability without adding extra material and weight to the battery. Specifically, the openings 716 may include hexagonal openings, or alternatively, structurally equivalent notches. The polymer frame may include a plurality of horizontal supports 712 positioned along each corner of the polymer frame. As shown in the figure, the horizontal supports 712 may project outward at least partially from at least one surface of the side wall adjacent to the corner.

[0034] The battery stabilization cage 710 may also include one or more cover mounting mechanisms 714 configured to connect the stabilization cage to the battery housing cover 722. In embodiments, the cover mounting mechanisms 714 can be connected to the battery housing cover 722 using a tongue-and-groove joint structure. To secure the battery stabilization cage 710 to the housing body 720, a body mounting mechanism 715 may be included near the bottom of the stabilization cage, as shown in the figure. In embodiments, the body mounting mechanism 715 can be connected to the housing body 720 using a tongue-and-groove joint structure. To further secure the battery stabilization cage 710 in place, adhesive may be applied to the mounting mechanisms 714, 715 to secure these connections to the individual housing components. Furthermore, to further ensure a secure connection with the housing body 720, additional adhesive or mechanical mounting configurations may be provided along the sides of the battery stabilization cage 710.

[0035] Figure 7B shows a partial cross-sectional view of the battery housing and battery stabilization cage 710 of Figure 7A, along with the associated battery management system 730 and thermal epoxy layer 740. As shown, the BMS 730 may include four electrically connected metal plates 732A, 732B, 732C, and 732D. The thermal epoxy layer 740 may be in contact with only a portion of the metal plate 732B, which may be in contact with all of the BMS electrical components configured to generate thermal energy. The BMS 730 may be positioned above the battery stabilization cage 710, or it may be housed within the battery housing cover 722 and the battery housing body 720.

[0036] Figures 7C to 7E show various diagrams of the battery stabilization cage 700. The illustrated battery stabilization cage 710 is formed substantially by four side walls, but it should be understood that the stabilization cage 710 may further include a bottom wall or a top wall. As shown in Figure 7C, the stabilization cage 710 may have an upper lip 718 or a similar component. The upper lip 718 can be configured to prevent the enclosed battery pack from moving upward. As shown, the upper lip 718 helps to prevent the enclosed battery pack from contacting, damaging, or damaging the BMS system positioned above the battery pack. Force-absorbing components, such as foam pads, may be positioned between the battery stabilization cage 710 and the housing body 720 to provide further mechanical stability for the enclosed battery cells.

[0037] (Battery pack structure) Battery packs are formed from multiple battery cells, and the specific arrangement and connection between these cells are crucial to prevent battery failure due to external forces. Experiments have shown that, particularly when battery packs are formed from laminated pouch-type battery cells, movement within the battery pouch (e.g., slippage due to vibration) or unstable forces can lead to failure. Therefore, this disclosure provides a battery pack structure with improved structural integrity and a method for forming the same. In particular, the battery pack structure can restrain and prevent movement of the battery cells by providing uniform pressure across the entire surface of the battery pack. Furthermore, spacers with adhesive components further help to restrict the movement of the battery cells.

[0038] Figure 8 shows a wrap-around battery pack structure 800 with three sets of spacers 802 positioned in the left, middle, and right columns. The spacers 802 are generally included to isolate the battery cells 810 and promote heat dissipation. The battery pack structure 800 also includes two adhesive tape sections 804 provided between the columns of spacers 802 and configured to fix the battery cells 810 together in a rigid structure. Experiments have shown that if non-uniform forces are provided by the battery cell spacers 802 and adhesive tape sections 804, the battery pack 800 may generate cell movement and deformation during vibration, which could ultimately lead to internal damage and rupture of the cells. Specifically, experiments have shown that the battery cells 810 remain together along the adhesive tape sections 804, but may deform between the tape sections 804 where the spacers 802 are installed. Therefore, this disclosure addresses these drawbacks by providing a battery pack structure that generates more consistent forces during vibration and prevents internal movement of the battery cells.

[0039] Figure 9 shows a method 900 for manufacturing a battery configured to have improved stability. In 902, a plurality of battery cell spacers are placed between a plurality of battery cells to form a battery pack. To generate a consistent force along the surface of each battery cell, each battery cell spacer may be configured to contact substantially all of the surface of an adjacent battery cell. In 904, the battery pack may be wrapped in a first adhesive tape layer. The first adhesive tape layer may contact substantially all of the plurality of geometric sides of the battery pack. In 906, a plurality of protective plates may be placed along the plurality of geometric sides of the battery pack. The protective plates may be positioned and configured to substantially cover the plurality of geometric sides. In 908, the battery pack, the first adhesive tape layer, and the protective plates may all be wrapped in a second adhesive tape layer. Although not shown, this method may further include shrink-wrapping the battery pack, the first adhesive tape layer, the protective plates, and the second adhesive tape layer with a polymer film.

[0040] Figure 10 shows an example of a pouch-shaped battery cell 1000 that, in consistency with Method 900, can be stacked with other similar battery cells to form a battery pack. The battery cell 1000 can be connected in series, parallel, or a combination of series and parallel with other battery cells. As shown, the battery cell has a substantially flat body 1002 having a certain length and a certain width, both of which are considerably longer than its height. Specifically, the battery cell body 1002 may have a length and width that are both at least five times its height. The battery cell 1000 may also have a number of connectors 1004 configured to interconnect the battery cell 1000 with other battery cells and battery terminals. The battery cell 1000 may specifically be a lithium-ion cell.

[0041] Figure 11 shows a perspective view of a battery pack 1100 formed of multiple battery cells 1110, with interconnectors 1106 providing electrical conductivity between the battery cells 1110. The illustrated battery pack has 16 battery cells stacked together. However, it should be noted that a different number of battery cells can be easily used depending on the intended application, and that the battery cells 1110 can adopt alternative arrangements (e.g., multiple side-by-side stacks).

[0042] Figure 12 shows a side view of another battery pack 1200 having a plurality of battery cell spacers 1202 extending along substantially the entire length of a battery cell 1210. Thus, each of the battery cells 1210 may have a top and a bottom surface, and each of the battery cell spacers 1202 may have a first surface that contacts substantially all of the bottom surface of an adjacent battery cell and a second surface that contacts substantially all of the top surface of another adjacent battery cell. For example, a battery cell spacer 1202 may contact at least 80%, at least 90%, or specifically at least 95% of an adjacent battery cell. Thus, each battery cell pair may have only one battery cell spacer positioned between them. Each of the battery cell spacers 1202 may have a thickness less than the thickness of each of the battery cells 1210.

[0043] Each battery cell spacer 1202 may have at least one adhesive component configured to engage with and attach to the surface of an adjacent battery cell, thereby preventing movement of the battery cell 1210. The adhesive component may cover a portion of one surface of the battery cell spacer 1202, or substantially the entire surface of one surface of the battery cell spacer 1202. Each battery cell spacer 1202 may include at least two adhesive components, namely a first adhesive component positioned on the top surface of each battery cell spacer 1202 and a second adhesive component positioned on the bottom surface. By providing adhesive components to secure each battery cell spacer 1202, each battery cell 1210 can be prevented from sliding or moving within the battery pack or relative to the battery cell spacer 1202. Specifically, the adhesive components may include double-sided adhesive tape, adhesive paste, adhesive, or similar forms of adhesive attachments.

[0044] Figure 13 shows a perspective view of a battery pack structure 1300 formed of multiple battery cells 1310, where an adhesive tape layer 1304 surrounds the entire battery pack, including the battery cells 1310 and optionally included battery cell spacers. By providing a consistent layer of adhesive tape 1304 rather than individually spaced tape loops, the battery cells 1310 are subjected to more evenly applied pressure, thus reducing the likelihood of failure. The adhesive tape 1304 may be provided as a single layer of tape or as multiple overlapping layers as shown. The adhesive tape 1304 may be in contact with substantially all of the top surface of the battery pack structure 1300, or with substantially all of at least four of the sides of the battery pack structure 1300, or with substantially all of the six sides of the battery pack structure 1300.

[0045] Figure 14 shows a perspective view of the battery pack structure 1300 of Figure 13, which is further surrounded within protective plates 1430 positioned along each geometric side of the new battery pack structure 1400. The protective plates 1430 can be formed from a metal such as aluminum. Alternatively, they can be formed from a rigid plastic or similar material such as phenolic material. The protective plates 1430 may be formed by bending one large metal plate and joining it to form each of the individual metal plates 1430. Alternatively, the protective plates 1430 may be formed from divided individual plates corresponding to each side of the battery pack structure 1400. The protective plates 1430 can be configured to contact and protect substantially all of the top surface of the battery pack structure 1400, or substantially all of at least four sides of the battery pack structure 1400, or substantially all of the six sides of the battery pack structure 1400.

[0046] Figure 15 shows a perspective view of the battery pack structure 1400 of Figure 14, further surrounded by a second adhesive tape layer 1540, which further secures the protective plate 1430 to the first adhesive tape layer 1304 and helps ensure the stability of the new battery pack structure 1500. Similar to the first adhesive tape layer 1304, the second adhesive tape layer 1540 may be provided as a single layer of tape or as multiple overlapping layers as shown. The adhesive tape 1540 may be in contact with at least substantially all of the top surface of the battery pack structure 1500, or with at least substantially all of the four sides of the battery pack structure 1500, or with substantially all of the six sides of the battery pack structure 1500.

[0047] Figure 16 shows a perspective view of the battery pack structure 1500 of Figure 15, further forming a new battery pack structure 1600 that is at least partially surrounded and protected within a shrink-wrapped polymer film 1650. The shrink-wrapped polymer film can be formed from polyolefin, polyvinyl chloride, polyethylene, polypropylene, or other similar compositions. By shrink-wrapping the battery pack structure 1500, an outer layer can be provided that substantially avoids gaps and holes along most of the battery pack structure 1600.

[0048] While many of the various techniques and features for providing a battery configured to have improved stability are discussed here in separate embodiments, it should be understood that any combination of these techniques and features is possible. For example, the battery according to this disclosure may include BMS thermal dissipation components, battery stabilization cages, and proprietary battery pack components. For example, the battery may include a battery pack structure with battery cell spacers having surfaces that contact substantially all of the surfaces of adjacent battery cells, a battery stabilization cage, and thermal epoxy that contacts one or more thermal components of the battery housing and BMS. By combining multiple configurations for superior thermal management and structural stability, a battery with improved safety can be manufactured.

[0049] In the above description and claims, phrases such as “at least one” or “one or more” may follow a linked list of elements or features. The term “and / or” may also appear in a list of two or more elements or features. Unless implicitly or explicitly contradicted by the context in which they are used, such phrases are intended to mean any of the enumerated elements or features individually, or any of the enumerated elements or features in combination with any of the separately enumerated elements or features. For example, the phrases “at least one of A and B,” “one or more of A and B,” and “A and / or B” are intended to mean “A only,” “B only,” or “A and B together,” respectively. A similar interpretation is intended for lists containing three or more items. For example, the phrases "at least one of A, B, and C," "one or more of A, B, and C," and "A, B, and / or C" are intended to mean "A only, B only, C only, A and B together, A and C together, B and C together, or A, B, and C together," respectively. Furthermore, the use of the term "based on" in the above and claims is intended to mean "based at least partially on," and therefore unlisted features or elements are also permitted.

[0050] The subject matter described herein can be embodied in systems, apparatus, methods, and / or articles, depending on the desired configuration. The implementation examples described herein do not represent all implementation examples that correspond to the subject matter described herein. Rather, they are merely some examples that correspond to embodiments relating to the subject matter described herein. Although several modifications have been described in detail above, other modifications or additions are possible. In particular, further features and / or modifications can be provided in addition to those described herein. For example, the above implementation examples relate to various combinations and partial combinations of the disclosed features, and / or combinations and partial combinations of the plurality of further features disclosed herein. Other implementation examples may be included within the scope of the following claims.

Claims

1. A battery configured to have improved stability, • Battery pack structure, A first battery cell having an upper surface and a lower surface, A second battery cell having an upper surface and a lower surface, A battery cell spacer having a first surface that contacts almost the entire bottom surface of a first battery cell and a second surface that contacts almost the entire top surface of a second battery cell, wherein the first surface and the second surface each include an adhesive component, and a battery pack structure including the battery cell spacer, A battery management system (BMS) that is electrically connected to a first battery cell and a second battery cell, and having one or more thermal components configured to dissipate heat from the BMS, - Battery pack structure and battery housing surrounding the BMS, - A thermal epoxy that comes into contact with one or more thermal components and the battery housing, - A stabilizing cage that at least partially surrounds the battery pack structure and is positioned between the battery cells and the battery housing, A battery comprising a stable cage including a polymer frame having four side walls positioned in a rectangular shape, each side wall including a plurality of openings that form a mesh pattern.

2. The battery according to claim 1, wherein the thermal epoxy is a hard thermal epoxy having a hardness of at least 70 Shore A.

3. The one or more heat components that come into contact with the heat epoxy include a metal plate. The battery according to claim 1, wherein the metal plate is in contact with an electrical component configured to generate heat when subjected to electric current.

4. The one or more parts that come into contact with the thermal epoxy include two metal plates, The battery according to claim 3, wherein a metal oxide semiconductor field-effect transistor (MOSFET) is electrically connected to both of the two metal plates.

5. The battery according to claim 1, wherein the metal plate is a copper plate.

6. The battery pack structure further includes a first battery cell, a second battery cell, and a first adhesive tape layer surrounding the battery cell spacer. The battery according to claim 1, wherein the first adhesive tape layer is in contact with substantially the entire upper surface of the first battery cell.

7. The battery pack structure further includes a first protective plate having a top surface and a bottom surface. The battery according to claim 1, wherein the bottom surface is in contact with the first adhesive tape layer along the upper surface of the first battery cell.

8. The battery pack structure further includes a first battery cell, a second battery cell, a battery cell spacer, a first adhesive tape layer, and a second adhesive tape layer surrounding the first protective plate. The battery according to claim 1, wherein the adhesive tape is in contact with almost the entire upper surface of the first protective plate.

9. The stabilization cage further includes a mounting mechanism configured to connect the stabilization cage to the battery housing. The battery according to claim 1, wherein the battery housing surrounds the battery frame and a plurality of battery cells.

10. A battery configured to have improved stability, A battery management system (BMS) that is electrically connected to multiple battery cells, and having one or more thermal components configured to dissipate heat from the BMS, The battery housing surrounding the battery cells and BMS, A battery comprising one or more thermal components and a thermal epoxy that contacts the battery housing.

11. The battery according to claim 10, wherein one or more thermal components in contact with the thermal epoxy include an electrical component configured to generate heat when subjected to an electric current.

12. The battery according to claim 10, wherein the electrical component is a metal oxide semiconductor field-effect transistor (MOSFET).

13. The one or more heat components that come into contact with the heat epoxy include a metal plate. The battery according to claim 10, wherein the metal plate is in contact with an electrical component configured to generate heat when subjected to electric current.

14. The one or more thermal components that come into contact with the thermal epoxy include two metal plates, The battery according to claim 13, wherein a metal oxide semiconductor field-effect transistor (MOSFET) is electrically connected to two metal plates.

15. The battery according to claim 14, wherein the metal plate is a copper plate.

16. The battery according to claim 14, wherein the thermal epoxy is not in contact with electrical components configured to generate heat.

17. The battery according to claim 10, wherein the thermal epoxy is positioned between the battery housing and the first surface of one or more thermal components and does not extend laterally beyond the first surface of one or more thermal components.

18. The battery according to claim 10, wherein the thermal epoxy extends laterally along the surface of the battery housing beyond the first surface of one or more thermal components.

19. The battery according to claim 10, wherein the thermal epoxy is in contact with the battery housing.

20. The battery according to claim 10, wherein the plurality of battery cells are lithium-ion battery cells.

21. A method for manufacturing a battery configured to have improved stability, A battery management system (BMS) that is electrically connected to multiple battery cells, wherein the BMS has one or more thermal components configured to dissipate heat from the BMS, The steps include arranging the battery housing that surrounds the battery cells and BMS, A method comprising the steps of applying thermal epoxy between a BMS and a battery housing, wherein the thermal epoxy is in contact with one or more thermal components and the battery housing.

22. A battery configured to have improved stability, A first battery cell having an upper surface and a lower surface, A second battery cell having an upper surface and a lower surface, The battery cell spacer includes a first surface that contacts almost the entire bottom surface of the first battery cell and a second surface that contacts almost the entire top surface of the second battery cell, A battery in which the first and second surfaces of the battery cell spacer each include adhesive components.

23. The battery according to claim 22, wherein the adhesive component covers substantially all of the first and second surfaces of the battery cell spacer.

24. A first adhesive tape layer surrounding a first battery cell, a second battery cell, and a battery cell spacer, The battery according to claim 22, wherein the adhesive tape is in contact with almost the entire upper surface of the first battery cell.

25. Further comprising a first protective plate having an upper surface and a lower surface, The battery according to claim 22, wherein the bottom surface is positioned to contact the first adhesive tape layer and substantially cover the top surface of the first battery cell.

26. The system further comprises a first battery cell, a second battery cell, a battery cell spacer, a first adhesive tape layer, and a second adhesive tape layer surrounding the first protective plate. The battery according to claim 25, wherein the second adhesive tape layer is in contact with substantially the entire upper surface of the first protective plate.

27. Further comprising multiple additional protective plates surrounded by a second adhesive tape layer, The battery according to claim 22, wherein the first protective plate and a plurality of additional protective plates are positioned to substantially cover each geometric side of the battery pack formed from the first battery cell, the second battery cell, and the battery cell spacers.

28. The third battery cell, The system further comprises a second battery cell spacer having a first surface that contacts the second battery cell and a second surface that contacts the third battery cell, The battery according to claim 22, wherein the first surface and the second surface each include an adhesive component.

29. The battery according to claim 22, wherein the battery cell has a pouch shape.

30. The battery according to claim 22, wherein the battery cell spacer has a thickness smaller than the thickness of the first battery cell and the second battery cell.

31. The battery according to claim 10, wherein the first battery cell and the second battery cell are lithium-ion cells.

32. A method for manufacturing a battery configured to have improved stability, The steps include: arranging multiple battery cell spacers between multiple battery cells to form a battery pack; A step of wrapping the battery pack in a first adhesive tape layer, wherein the first adhesive tape layer is in contact with substantially the entire upper surface of the battery pack, A step of arranging multiple protective plates along multiple geometric sides of a battery pack, wherein the protective plates are configured to substantially cover the multiple geometric sides, A method comprising the steps of wrapping a battery pack, a first adhesive tape layer, and a protective plate in a second adhesive tape layer.

33. The method according to claim 32, wherein each battery cell spacer is configured to contact substantially all of the surface of each adjacent battery cell.

34. The method according to claim 32, further comprising the step of shrink-wrapping a battery pack, a first adhesive tape layer, a protective plate, and a second adhesive tape layer onto a polymer film.

35. The method according to claim 32, wherein the protective plate is positioned to substantially cover each geometric side of the battery pack.

36. The method according to claim 32, wherein the battery cell has a pouch shape.

37. The method according to claim 32, wherein the battery cell spacer has a thickness smaller than the thickness of the first battery cell and the second battery cell.

38. The method according to claim 32, wherein the first battery cell and the second battery cell are lithium-ion cells.

39. A battery configured to have improved stability, Multiple battery cells, A battery housing configured to surround a battery cell, comprising a main body and a cover, A stabilizing cage that at least partially surrounds the battery cell and is positioned between the battery cell and the battery housing, The stabilizing cage includes a polymer frame having four side walls positioned in a rectangular shape, each side wall containing multiple openings that form a mesh pattern, for the battery.

40. The battery according to claim 39, wherein the polymer frame includes a plurality of horizontal support portions positioned along each corner of the polymer frame.

41. The battery according to claim 39, wherein the horizontal support portion protrudes at least partially outward from the surface of the side wall.

42. The battery according to claim 39, further comprising a mounting mechanism configured to connect the stabilization cage to the battery housing.

43. The battery according to claim 39, wherein the multiple openings include hexagonal openings.

Images