Battery cells, battery module assemblies, and fixture assemblies having thermally conductive sidewalls
Thermally conductive sidewalls and members in battery cells enhance heat dissipation, addressing overheating issues by efficiently transferring heat away from battery modules.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- WISK AERO LLC
- Filing Date
- 2024-07-12
- Publication Date
- 2026-07-29
AI Technical Summary
Battery cell modules generate significant heat, which can lead to overheating due to insufficient cooling, especially in space and weight-constrained environments.
Implementing battery cells with thermally conductive sidewalls and members to enhance heat dissipation, using thermally conductive shells and adhesives to form conductive sidewalls, and coupling these with cooling fins for efficient heat transfer.
Effectively dissipates heat from battery modules, preventing overheating and ensuring safe operation under space and weight constraints.
Smart Images
Figure 2026525337000001_ABST
Abstract
Description
Technical Field
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 527,979, filed on July 20, 2023, "Battery Cell with Thermally Conductive Side Walls, Battery Module Assembly, and Tooling Assembly", under 35 U.S.C. § 119(e), the disclosure of which is hereby incorporated by reference in its entirety for all purposes.
Background Art
[0002] Many battery cell modules include a plurality of battery cells connected in series and / or in parallel. In battery modules with space and / or weight constraints, it is preferable to pack the battery cells closely. However, the battery cells in a battery module can generate a significant amount of heat, and if there is not sufficient cooling of the battery module, there is a risk that the battery module will overheat.
Summary of the Invention
Means for Solving the Problems
[0003] To enhance a basic understanding of the present invention, a simplified summary of some embodiments of the present invention is presented below. This summary is not an extensive overview of the present invention. Nor is it intended to identify key / important elements of the present invention or to delineate the scope of the present invention. The sole purpose of this summary is to present some embodiments of the present invention in a simplified form prior to the more detailed description that follows.
[0004] This specification describes a plurality of battery cells having thermally conductive sidewalls, methods and fixtures for forming a plurality of battery cells having thermally conductive sidewalls, and a plurality of battery modules comprising a plurality of battery cells having thermally conductive sidewalls. In many embodiments, each of the plurality of battery cells having thermally conductive sidewalls includes a thermally conductive shell surrounding the energy storage portion of the battery cell. The thermally conductive shell includes a thermally conductive base membrane and a thermally conductive cover membrane, both membranes bonded along the periphery of the thermally conductive shell. In many embodiments, a thermally conductive adhesive is applied to the sides of the periphery of the thermally conductive shell, and each side is bent and bonded to the side of the thermally conductive shell via the thermally conductive adhesive to form one of the thermally conductive sidewalls. In many embodiments, the battery module includes an array of battery cells having thermally conductive sidewalls and a thermally conductive member configured to be thermally coupled to the thermally conductive sidewalls and to transfer heat collected from the battery cells through the thermally conductive sidewalls to the outside of the battery module. Any suitable method can be used to thermally bond the thermally conductive member to the thermally conductive sidewall. For example, in some embodiments, a thermally conductive interface material (e.g., thermally conductive paste) is placed between the thermally conductive member and the thermally conductive sidewall and makes contact with them. In many embodiments, the peripheral sidewall portion of the thermally conductive shell is bent after the thermally conductive adhesive is applied, and a jig assembly is used to hold the bent sidewall portion while the thermally conductive adhesive cures.
[0005] Accordingly, in one embodiment, the battery includes an energy storage section, a thermally conductive shell, and a first thermally conductive adhesive layer. The thermally conductive shell surrounds the energy storage section. The thermally conductive shell includes a base membrane and a cover membrane. The thermally conductive shell includes a first outer periphery, which includes a first outer periphery of the cover membrane attached to the first outer periphery of the base membrane. The folded portion of the first outer periphery of the thermally conductive shell is joined to a first side surface of the thermally conductive shell by the first thermally conductive adhesive layer to form a first thermally conductive sidewall of the battery cell.
[0006] In many embodiments, the thermally conductive shell includes a second outer periphery, which includes a second outer periphery of a cover membrane attached to the second outer periphery of a base membrane. The battery cell may include a second thermally conductive adhesive layer, and the folded portion of the second outer periphery of the thermally conductive shell is bonded to the second side surface of the thermally conductive shell via the second thermally conductive adhesive layer to form a second thermally conductive sidewall of the battery cell. In many embodiments, the second thermally conductive sidewall is located on the opposite side of the battery cell from the first thermally conductive sidewall. The second thermally conductive sidewall may be parallel to the first thermally conductive sidewall.
[0007] In many embodiments, the first and second thermally conductive adhesive layers contain a thermally conductive adhesive. The thermally conductive adhesive can have any suitable configuration. In many embodiments, the thermally conductive adhesive contains a thermally conductive metal component suspended in the adhesive matrix.
[0008] In another embodiment, the battery module includes a plurality of battery cells and a first thermal conductive member. Each of the plurality of battery cells includes an energy storage section, a thermal conductive shell, and a first thermal conductive adhesive layer. The thermal conductive shell surrounds the energy storage section. The thermal conductive shell includes a base membrane and a cover membrane. The thermal conductive shell includes a first outer periphery, which includes a first outer periphery of the cover membrane attached to the first outer periphery of the base membrane. The folded portion of the first outer periphery of the thermal conductive shell is bonded to a first side surface of the thermal conductive shell by the first thermal conductive adhesive layer to form a first thermal conductive sidewall of the battery cell. The first thermal conductive member is thermally bonded to the first thermal conductive sidewall of each of the plurality of battery cells. The first thermal conductive member is configured to transfer heat collected from the battery cells through the first thermal conductive sidewall to the outside of the battery module.
[0009] The first thermally conductive member can be thermally bonded to the first thermally conductive sidewall using any suitable method. For example, in many embodiments, a thermally conductive paste thermally bonds the first thermally conductive member to the first thermally conductive sidewall.
[0010] The first thermal conductive member can have any suitable configuration for transferring heat to the outside of the battery module. For example, in many embodiments, the first thermal conductive member includes a plurality of cooling fins.
[0011] In many embodiments, the battery module includes a second thermal conductive member. The second thermal conductive member is thermally coupled to the second thermal conductive sidewall of each of the multiple battery cells. The second thermal conductive member is configured to transfer heat collected from the multiple battery cells to the outside of the battery module via the second thermal conductive sidewall.
[0012] The first and second thermal conductive members can be thermally bonded to the battery cell using any suitable method. For example, a thermal conductive paste can be used to thermally bond the first thermal conductive member to the first thermal conductive sidewall and to thermally bond the second thermal conductive member to the second thermal conductive sidewall.
[0013] The first and second thermal conductive members may have any suitable configuration for removing heat from the battery module. For example, in some embodiments, each of the first and second thermal conductive members includes a plurality of cooling fins.
[0014] In another embodiment, a method for forming a thermally conductive sidewall of a battery is provided. This method includes receiving a battery cell comprising an energy storage section and a thermally conductive shell surrounding the energy storage section. The thermally conductive shell includes a base membrane and a cover membrane. The thermally conductive shell includes a first outer periphery, the first outer periphery of which includes a first outer periphery of the cover membrane attached to the first outer periphery of the base membrane. A thermally conductive adhesive is applied to the first outer periphery of the thermally conductive shell. The first outer periphery of the thermally conductive shell, to which the thermally conductive adhesive is attached, is bent relative to a first sidewall of the thermally conductive shell. As the thermally conductive adhesive cures, the first outer periphery of the thermally conductive shell is bonded to the first sidewall of the thermally conductive shell, forming a first thermally conductive sidewall of the battery cell. The thermally conductive adhesive may include a thermally conductive metallic component suspended in an adhesive matrix.
[0015] In many embodiments of the method, the thermally conductive shell includes a second outer periphery, the second outer periphery including a second outer periphery of a cover membrane attached to the second outer periphery of a base membrane. The first and second outer peripheries are positioned on opposite sides of the battery cell. A thermally conductive adhesive is applied to the second outer periphery of the thermally conductive shell. The second outer periphery of the thermally conductive shell, to which the thermally conductive adhesive is attached, is bent relative to the second sidewall of the thermally conductive shell. As the thermally conductive adhesive hardens, the second outer periphery of the thermally conductive shell is bonded to the second sidewall of the thermally conductive shell, forming the second thermally conductive sidewall of the battery cell.
[0016] In many embodiments of the method, the second thermally conductive sidewall is positioned on the opposite side of the battery cell from the first thermally conductive sidewall. The second thermally conductive sidewall can be parallel to the first thermally conductive sidewall.
[0017] In another embodiment, a manufacturing jig for forming the conductive sidewall of a battery cell includes a base member and a second side support assembly. The base member includes a bottom surface, a first side battery cell support surface, and a first side support wall. The second side support assembly includes a second side support base member and a second side support wall member slidably mounted to the second side support base member. The second side support wall member is spaced apart from the first side support wall. The second side support wall member includes a second side battery cell support surface and a second side support wall. The second side support wall member is spring-biased away from the second side support base member. The first side battery cell support surface and the second side battery cell support surface are coplanar. The first side support wall and the second side support wall include parallel sidewall surfaces configured to hold the folded side portion of the peripheral edge of the thermal conductive shell engaged with the respective sidewall of the thermal conductive shell during the curing of a conductive adhesive used to bond the folded side portion of the peripheral edge of the thermal conductive shell to the respective sidewall of the thermal conductive shell.
[0018] In many embodiments of the manufacturing jig, the base member includes a second recess extending along the first battery cell support surface. The bottom of the second support wall member can be housed within the second recess. The second recess can be configured to allow relative movement between the second support wall member and the second support base member.
[0019] In many embodiments of the manufacturing jig, the second side support base member is detachably attached to the base member to support the second side support wall member spaced apart from the first side support wall. For example, to accommodate threaded fasteners used to secure the second side support base member to the base member, the second side support base member may include holes for non-threaded fasteners, and the base member may include holes for threaded fasteners.
[0020] In many embodiments, the manufacturing fixture is configured such that a bend occurs in each side portion of the peripheral edge of the thermally conductive shell of the battery cell. For example, each of the first side support wall and the second side support wall is configured to bend each side portion of the peripheral edge of the thermally conductive shell in the battery cell and engage with each side wall of the thermally conductive shell when the battery cell is advanced into the manufacturing fixture between the first side support wall and the second side support wall while the battery cell is in contact with the first side battery cell support surface and the second side battery cell support surface, and may include a curved portion formed to be shaped like this.
[0021] To more fully understand the nature and advantages of the present invention, reference should be made to the following detailed description and the accompanying drawings.
Brief Description of the Drawings
[0022] [Figure 1] A photograph of a battery cell having a thermally conductive side wall according to various embodiments. [Figure 2] A cross-sectional view through the thermally conductive side wall of the battery cell of FIG. 1. [Figure 3] An enlarged cross-sectional view through one of the thermally conductive side walls of the battery cell of FIG. 2. [Figure 4] A view showing internal components of a battery module including a plurality of battery cells having thermally conductive side walls according to various embodiments, wherein the thermally conductive side walls are thermally coupled to a thermally conductive member configured to transfer heat from the thermally conductive side walls to the outside of the battery module. [Figure 5] A photograph showing a state in which a thermally conductive adhesive is applied to the side peripheral edge of the thermally conductive shell of the battery cell during formation of the thermally conductive side wall of the battery cell. [Figure 6] A photograph showing a state in which a thermally conductive adhesive is applied to the side peripheral edge of the thermally conductive shell of the battery cell during formation of the thermally conductive side wall of the battery cell. [Figure 7] A photograph of the state in which a thermally conductive adhesive is applied to the side peripheral edge of the thermally conductive shell in the battery cells of FIGS. 5 and 6. [Figure 8] A cross-sectional view through the battery cell to which the thermally conductive adhesive is applied as shown in FIG. 7. [Figure 9] Partial exploded view of a jig assembly for bending the side peripheral portion of a battery cell coated with a thermally conductive adhesive as shown in FIG. 7 and holding the battery cell during curing of the thermally conductive adhesive, according to various embodiments. [Figure 10] An enlarged view showing a curved portion configured to bend the side peripheral portion of a battery cell coated with a thermally conductive adhesive as shown in FIG. 7 in the jig assembly of FIG. 9. [Figure 11] A photograph showing the state in which the battery cell of FIG. 7 is inserted into the jig assembly of FIG. 9. [Figure 12] A photograph of the battery cell of FIG. 7 in a state where the insertion state into the jig assembly of FIG. 9 has advanced more than the insertion state shown in FIG. 11. [Figure 13] A photograph showing the state in which the battery cell of FIG. 7 is completely inserted into the jig assembly of FIG. 9. [Figure 14] A photograph showing the state of removing excess thermally conductive adhesive from the battery cell of FIG. 7 after insertion into the jig assembly of FIG. 9. [Figure 15] A photograph of the battery cell of FIG. 7 in the jig assembly of FIG. 9 during curing of the thermally conductive adhesive. [Figure 16] A photograph of the jig assembly of FIG. 9 while five individuals of the battery cell of FIG. 7 are being cured. [Figure 17] A simplified schematic diagram of a method for forming a thermally conductive side wall of a battery cell, according to various embodiments.
Mode for Carrying Out the Invention
[0023] In the description of this specification, various embodiments are described. For the purpose of explanation, specific configurations and details are described so that the embodiments can be fully understood. However, it is also clear to those skilled in the art that the embodiments can be implemented without specific details. Also, well-known features may be omitted or simplified so that the description of the embodiments is not unclear.
[0024] Next, referring to the drawings, in various drawings, similar reference numbers refer to similar features in each drawing. Figure 1 shows a photograph of a battery cell 10 having thermally conductive sidewalls 12 according to various embodiments. Figure 2 shows a cross-sectional view of the battery cell 10 through the thermally conductive sidewalls 12. Figure 3 shows an enlarged cross-sectional view through one of the thermally conductive sidewalls 12. The battery cell 10 includes a thermally conductive shell 14 surrounding the energy storage section 16 of the battery cell 10. The thermally conductive shell 14 includes a thermally conductive base membrane 18 and a thermally conductive cover membrane 20, which are bonded along the periphery of the thermally conductive shell 14. In many embodiments, a thermally conductive adhesive 22 is applied to the sides of the periphery of the thermally conductive shell 14, and each side is bent and bonded to the sidewall of the thermally conductive shell 14 via the thermally conductive adhesive 22 to form one of the thermally conductive sidewalls 12.
[0025] Figure 4 shows the internal components of a battery module 30, which includes a plurality of battery cells 10, a plurality of first-side thermal conductive members 23, and a plurality of second-side thermal conductive members 34. The thermal conductive sidewall 12 is thermally coupled to the first-side thermal conductive members 32 and the second-side thermal conductive members 34, which are configured to transfer heat from the thermal conductive sidewall 12 to the outside of the battery module 30. As described herein, each of the plurality of battery cells 10 includes a thermal conductive shell 14 surrounding the energy storage section 16 of the battery cell 10. Heat from the energy storage section 16 is transferred to the thermal conductive shell 14. The thermal conductive shell 14 transfers some of the heat to the thermal conductive sidewall 12. One of the thermal conductive sidewalls 12 is thermally coupled to the first-side thermal conductive member 32. The other thermal conductive sidewall 12 is thermally coupled to the second-side thermal conductive member 34. To improve heat transfer, a heat-conductive paste can be placed between the heat-conductive members 32 and 34 and the heat-conductive side wall 12. The first heat-conductive member 32 and the second heat-conductive member 34 may be configured with a plurality of cooling fins to improve heat transfer from the heat-conductive members 32 and 34 to the ambient air.
[0026] Figures 5 and 6 show photographs of the application of thermal conductive adhesive 22 to the lateral periphery of the thermal conductive shell 14 during the formation of the thermal conductive sidewall 12. Any suitable thermal conductive adhesive can be used as the thermal conductive adhesive 22. In some embodiments, the thermal conductive adhesive contains a suitable thermal conductive metal component suspended in a suitable adhesive matrix. Examples of suitable thermal conductive adhesives include CoolTherm® TC-2002 from Parker Hannifin and BT-301-50M from Wakefield Solutions. Figure 7 shows a photograph of the battery cell from Figures 5 and 6 with the thermal conductive adhesive 22 applied to the lateral periphery of the thermal conductive shell 14. Figure 8 shows a cross-sectional view through the battery cell 10 to which the thermal conductive adhesive 22 has been applied.
[0027] Figure 9 shows a partially exploded view of a manufacturing jig 50 for forming the thermally conductive sidewalls of a battery cell according to various embodiments. The manufacturing jig 50 includes a base plate member 52 and a second side support wall assembly 54. The base plate member 52 includes a first side battery cell support surface 56, a first side support wall 58, and a second side recess 60 extending along the first side battery cell support surface 56. The second side support wall assembly 54 includes a second side support base member 62 and a second side support wall member 64 slidably attached to the second side support base member 62 via a protruding pin 66 and a spring 68. The second side support base member 62 is detachably attached to the base plate member 52 by bolts 69 to support the second side support wall member 64 spaced apart from the first side support wall 58. The second side support wall member 64 includes a second side battery cell support surface 70 and a second side support wall 72. The second side support wall member 64 is spring-biased by a spring 68 in a direction away from the second side support base member 62. The bottoms of the second side support base member 62 and the second side support wall member 64 are housed in the second side recess 60. The second side recess 60 is configured to allow relative movement between the second side support wall member 64 and the second side support base member 62. The first side battery cell support surface 56 and the second side battery cell support surface 70 are on the same plane. The first side support wall 58 and the second side support wall 72 each include curved portions 74, 76 shaped to bend the respective side edges of the periphery of the thermal conductive shell in the battery cell and engage with the respective side walls of the thermal conductive shell as the battery cell is advanced into the manufacturing jig 50 between the first side support wall 58 and the second side support wall 72 while in contact with the first side battery cell support surface 56 and the second side battery cell support surface 70. The first side support wall 58 and the second side support wall 72 include parallel sidewall surfaces for holding the folded peripheral side portions in a folded shape during the curing of the conductive adhesive used to bond the folded peripheral side portions to the sidewalls of the thermal conductive shell to form the thermal conductive sidewalls of the battery cell. In the illustrated embodiment, the manufacturing jig 50 is configured to process five individual battery cells 10. Figure 10 shows an enlarged view of the curved portion 74 of the base plate member 52 and the curved portion 76 of the second side support wall member 64.The curved portions 74 and 76 are shaped so that the side edges of the battery cell 10 are bent when the battery cell 10 is inserted into the jig assembly 50. The spring 68 presses the second side support wall member 64 against one side of the battery cell 10 to maintain appropriate lateral force against the bent side edges of the battery cell 10 during the curing of the thermal conductive adhesive 22. Figure 11 shows a photograph of the battery cell 10 being inserted into the jig assembly 50. Figure 12 shows a photograph of the battery cell 10 further inserted into the jig assembly 10 than the initial insertion state shown in Figure 11. Figure 13 shows a photograph of the battery cell 10 fully inserted into the jig assembly 50. Figure 14 shows a photograph of the removal of excess thermal conductive adhesive from the battery cell 10 after insertion into the jig assembly 50. Figure 15 shows a photograph of the battery cell 10 inside the jig assembly 50 during the curing of the thermal conductive adhesive. Figure 16 shows a photograph of the jig assembly 50 in the process of curing five individual battery cells 10.
[0028] Figure 17 shows a simplified schematic diagram of Method 100 for forming a thermally conductive sidewall of a battery cell according to various embodiments. Method 100 can be used to form a thermally conductive sidewall of any suitable battery cell, such as battery cell 10. Method 100 can also be carried out using any suitable manufacturing fixture, such as manufacturing fixture 50. Method 100 includes receiving a battery cell comprising an energy storage section and a thermally conductive shell surrounding the energy storage section (step 102). The thermally conductive shell includes a base membrane and a cover membrane. The thermally conductive shell includes an outer periphery, which includes the outer periphery of the cover membrane attached to the outer periphery of the base membrane. Method 100 further includes applying a thermal conductive adhesive to the outer edge portion of a thermal conductive shell extending along the side of a battery cell (step 104), bending the outer edge portion of the thermal conductive shell to which the thermal conductive adhesive is attached relative to the side wall of the thermal conductive shell (step 106), and curing the thermal conductive adhesive to bond the outer edge portion of the thermal conductive shell to the side wall of the thermal conductive shell to form a thermal conductive side wall (step 108).
[0029] Examples of non-restrictive cases
[0030] Example 1 is a battery cell comprising an energy storage section, a thermally conductive shell, and a thermally conductive adhesive layer. The thermally conductive shell surrounds the energy storage section. The thermally conductive shell includes a base membrane and a cover membrane. The thermally conductive shell includes a first outer periphery, which includes a first outer periphery of the cover membrane attached to the first outer periphery of the base membrane. The folded portion of the first outer periphery of the thermally conductive shell is joined to a first side surface of the thermally conductive shell via a thermally conductive adhesive layer to form a first thermally conductive sidewall of the battery cell.
[0031] Example 2 is a battery cell following the battery cell of Example 1, wherein the thermal conductive shell includes a second outer periphery, which includes a second outer periphery of a cover membrane attached to the second outer periphery of a base membrane. The battery cell of Example 2 further includes a second thermal conductive adhesive layer, where the folded portion of the second outer periphery of the thermal conductive shell is bonded to the second side surface of the thermal conductive shell via the second thermal conductive adhesive layer to form a second thermal conductive sidewall of the battery cell. Example 3 is a battery cell following the battery cell of Example 2, wherein the second thermal conductive sidewall is located on the opposite side of the battery cell from the first thermal conductive sidewall. Example 4 is a battery cell following the battery cell of Example 3, wherein the second thermal conductive sidewall is parallel to the first thermal conductive sidewall. Example 5 is a battery cell following the battery cell of Example 2, wherein each of the first and second thermally conductive adhesive layers contains a thermally conductive adhesive comprising a thermally conductive metal component suspended in an adhesive matrix.
[0032] Example 6 is a battery module comprising a plurality of battery cells and a first thermal conductive member. Each of the plurality of battery cells in the battery module of Example 6 corresponds to one of the battery cells from the battery module of Example 1, Example 2, Example 3, Example 4, and Example 5. The first thermal conductive member is thermally bonded to the first thermal conductive sidewall of each of the plurality of battery cells. The first thermal conductive member is configured to transfer heat collected from the plurality of battery cells through the first thermal conductive sidewall to the outside of the battery module. Example 7 is a battery module corresponding to the battery module of Example 6, in which a thermal conductive paste thermally bonds the first thermal conductive member and the first thermal conductive sidewall. Example 8 is a battery module corresponding to the battery module of Example 6, in which the first thermal conductive member includes a plurality of cooling fins.
[0033] Example 9 is a battery module including a battery, a first thermal conductive member, and a second thermal conductive member. Each of the plurality of battery cells in the battery module of Example 9 corresponds to one of the battery cells from Example 2, Example 3, Example 4, and Example 5. The first thermal conductive member of the battery module of Example 9 is thermally coupled to the first thermal conductive sidewall of each of the plurality of battery cells. The first thermal conductive member is configured to transfer heat collected from the battery cells via the first thermal conductive sidewall to the outside of the battery module of Example 9. The second thermal conductive member of the battery module of Example 9 is thermally coupled to the second thermal conductive sidewall of each of the plurality of battery cells. The second thermal conductive member is configured to transfer heat collected from the battery cells via the second thermal conductive sidewall to the outside of the battery module of Example 9. Example 10 is a battery module following the battery module of Example 9, wherein a thermally conductive paste (a) thermally bonds a first thermally conductive member to a first thermally conductive sidewall, and (b) thermally bonds a second thermally conductive member to a second thermally conductive sidewall. Example 11 is a battery module following the battery module of Example 9, wherein each of the first and second thermally conductive members includes a plurality of cooling fins.
[0034] Example 12 is a method for forming a first thermally conductive sidewall of a battery cell. The method of Example 12 includes (a) receiving a battery cell comprising an energy storage section and a thermally conductive shell surrounding the energy storage section, wherein the thermally conductive shell comprises a base membrane and a cover membrane, and the thermally conductive shell comprises a first outer periphery, the first outer periphery comprising a first outer periphery of a cover membrane attached to the first outer periphery of the base membrane; (b) applying a thermally conductive adhesive to the first outer periphery of the thermally conductive shell; (c) bending the first outer periphery of the thermally conductive shell to which the thermally conductive adhesive is attached relative to a first sidewall of the thermally conductive shell; and (d) curing the thermally conductive adhesive to bond the first outer periphery of the thermally conductive shell to the first sidewall of the thermally conductive shell, thereby forming a first thermally conductive sidewall of the battery cell.
[0035] Example 13 is a method following the method of Example 12, wherein the thermal conductive shell includes a second outer periphery, the second outer periphery includes a second outer periphery of a cover membrane attached to the second outer periphery of a base membrane, and the first and second outer peripheries are located on opposite sides of the battery cell. The method of Example 13 further includes (a) applying a thermal conductive adhesive to the second outer periphery of the thermal conductive shell, (b) bending the second outer periphery of the thermal conductive shell with the thermal conductive adhesive attached relative to the second sidewall of the thermal conductive shell, and (c) curing the thermal conductive adhesive to bond the second outer periphery of the thermal conductive shell to the second sidewall of the thermal conductive shell, thereby forming a second thermal conductive sidewall of the battery cell. Example 14 is a method following the method of Example 13, wherein the second thermal conductive sidewall is located on the opposite side of the battery cell from the first thermal conductive sidewall. Example 15 is a method following the method of Example 14, in which the second thermally conductive sidewall is parallel to the first thermally conductive sidewall. Example 16 is a method following any one of the methods of Example 12, Example 13, Example 14, and Example 15, in which the thermally conductive adhesive comprises a thermally conductive metal component suspended in the adhesive matrix.
[0036] Example 17 is a manufacturing jig including a base member and a lateral support assembly. The base member includes a bottom surface, a first side battery cell support surface, and a first side support wall. The second side support assembly includes a second side support base member and a second side support wall member slidably mounted to the second side support base member. The second side support wall member is spaced apart from the first side support wall. The second side support wall member includes a second side battery cell support surface and a second side support wall. The second side support wall member is spring-biased away from the second side support base member. The first side battery cell support surface and the second side battery cell support surface are coplanar. The first side support wall and the second side support wall include parallel side wall surfaces configured to hold the folded side portions of the peripheral edges of the thermal conductive shell engaged with the respective side walls of the thermal conductive shell during the curing of a conductive adhesive used to bond the folded side portions of the peripheral edges of the thermal conductive shell to the respective side walls of the thermal conductive shell. Example 18 is a manufacturing jig following the manufacturing jig of Example 17, wherein (a) the base member includes a second recess extending along the first battery cell support surface, (b) the bottom of the second support wall member is housed in the second recess, and (c) the second recess is configured to allow relative movement between the second support wall member and the second support base member. Example 19 is a manufacturing jig following the manufacturing jig of Example 18, wherein the second support base member is detachably attached to the base member to support the second support wall member spaced apart from the first support wall. Example 20 is a manufacturing jig that follows the manufacturing jig of Example 19, wherein each of the first and second support walls includes a curved portion shaped to bend the respective side edges of the peripheral portion of the thermal conductive shell of the battery cell and engage with the respective side walls of the thermal conductive shell as the battery cell is advanced into the manufacturing jig between the first and second support walls while in contact with the first and second battery cell support surfaces.
[0037] Other modifications are also within the scope of the present invention. Therefore, various modifications and alternative configurations are possible in the present invention, and specific exemplary embodiments have been shown in the drawings and described in detail above. However, there is no intention to limit the present invention to the specific (multiple) disclosed forms, and rather the present invention encompasses all modifications, alternative configurations, and equivalents that fall within the spirit and scope of the present invention as defined in the appended claims.
[0038] In the context describing the present invention (particularly in the context of the following claims), the use of words such as “a,” “an,” and “the,” as well as similar reference terms, should be interpreted as encompassing both singular and plural, unless otherwise specifically stated herein or clearly contradicted by the context. The words “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended expressions (i.e., “including, but not limited to,”) unless otherwise specifically stated herein. The word “connected” should be interpreted as encompassing a state in which something is partially or completely contained inside, attached, or combined, even if any intervening material is present. Unless otherwise specifically stated herein, the descriptions of value ranges are intended as a simplified way of referring individually to the individual values contained within that range, and each individual value is incorporated herein as if it were described individually. All methods described herein may be performed in any order, unless otherwise specifically stated herein or clearly contradicted by the context. The use of any examples or illustrative language (e.g., "etc.") provided herein is intended solely to clarify embodiments of the invention and does not limit the scope of the invention unless otherwise stated in the claims. Nothing in this specification should be construed as indicating that elements not described in the claims are essential for carrying out the invention.
[0039] This specification describes preferred embodiments of the Invention, including the best mode for carrying out the Invention as known to the inventors. Variations of these preferred embodiments may be obvious to those skilled in the art by reading the above description. The inventors anticipate that those skilled in the art will appropriately adopt these variations, and they also intend that the Invention may be carried out in forms other than those specifically described herein. Accordingly, the Invention encompasses all modifications and equivalents of the subject matter described in the appended claims, to the extent permitted by applicable law. Furthermore, unless otherwise specifically stated herein or clearly contradicted by context, any combination of any possible variations of the above elements is also encompassed in the Invention.
[0040] All documents cited herein, including publications, patent applications, and patents, are individually and specifically indicated so as to be incorporated by reference, and are incorporated herein by reference to the same extent as if they were described in their entirety herein.
Claims
1. A battery cell, wherein the battery cell is Energy storage unit, A thermally conductive shell surrounding the energy storage unit, wherein the thermally conductive shell includes a base membrane and a cover membrane, the thermally conductive shell includes a first outer periphery, and the first outer periphery includes a first outer periphery of the cover membrane attached to the first outer periphery of the base membrane, A first thermally conductive adhesive layer, wherein the folded portion of the first outer periphery of the thermally conductive shell is joined to the first side surface of the thermally conductive shell via the first thermally conductive adhesive layer to form the first thermally conductive side wall of the battery cell. A battery cell equipped with the following features.
2. The battery cell according to claim 1, wherein the thermally conductive shell includes a second outer periphery, the second outer periphery includes a second outer periphery of the cover membrane attached to the second outer periphery of the base membrane, and further includes a second thermally conductive adhesive layer, the folded portion of the second outer periphery of the thermally conductive shell is joined to a second side surface of the thermally conductive shell via the second thermally conductive adhesive layer to form a second thermally conductive side wall of the battery cell.
3. The battery cell according to claim 2, wherein the second thermally conductive sidewall is located on the opposite side of the battery cell from the first thermally conductive sidewall.
4. The battery cell according to claim 3, wherein the second thermally conductive sidewall is parallel to the first thermally conductive sidewall.
5. The battery cell according to claim 2, wherein each of the first thermally conductive adhesive layer and the second thermally conductive adhesive layer comprises a thermally conductive adhesive containing a thermally conductive metal component suspended in an adhesive matrix.
6. A battery module, wherein the battery module is A plurality of battery cells, each of which is a battery cell according to any one of claims 1 to 5, A first thermal conductive member, which is thermally coupled to the first thermal conductive sidewall in each of the plurality of battery cells, and configured to transfer heat collected from the battery cells to the outside of the battery module via the first thermal conductive sidewall, and A battery module equipped with the following features.
7. The battery module according to claim 6, wherein a thermally conductive paste thermally bonds the first thermally conductive member and the first thermally conductive side wall.
8. The battery module according to claim 6, wherein the first heat-conducting member includes a plurality of cooling fins.
9. A battery module, wherein the battery module is A plurality of battery cells, each of which is a battery cell according to any one of claims 2 to 5, A first thermal conductive member, which is thermally coupled to the first thermal conductive sidewall in each of the plurality of battery cells and configured to transfer heat collected from the battery cells to the outside of the battery module via the first thermal conductive sidewall, A second thermal conductive member, which is thermally coupled to the second thermal conductive sidewall in each of the plurality of battery cells and configured to transfer heat collected from the battery cells to the outside of the battery module via the second thermal conductive sidewall, and A battery module equipped with the following features.
10. The battery module according to claim 9, wherein a thermally conductive paste thermally bonds the first thermally conductive member and the first thermally conductive sidewall, and thermally bonds the second thermally conductive member and the second thermally conductive sidewall.
11. The battery module according to claim 9, wherein each of the first thermal conductive member and the second thermal conductive member includes a plurality of cooling fins.
12. To receive a battery cell comprising an energy storage unit and a thermally conductive shell surrounding the energy storage unit, wherein the thermally conductive shell comprises a base membrane and a cover membrane, the thermally conductive shell comprises a first outer periphery, and the first outer periphery comprises a first outer periphery of the cover membrane attached to the first outer periphery of the base membrane, Applying a thermally conductive adhesive to the first outer periphery of the thermally conductive shell, The first outer periphery of the thermal conductive shell to which the thermal conductive adhesive is attached is bent relative to the first side wall of the thermal conductive shell, The thermal conductive adhesive is cured to bond the first outer periphery of the thermal conductive shell to the first side wall of the thermal conductive shell, thereby forming the first thermal conductive side wall of the battery cell. Methods that include...
13. The thermally conductive shell includes a second outer periphery, the second outer periphery includes a second outer periphery of the cover membrane attached to the second outer periphery of the base membrane, the first outer periphery and the second outer periphery are arranged on opposite sides of the battery cell, and the method further, The thermal conductive adhesive is applied to the second outer periphery of the thermal conductive shell, The second outer periphery of the thermal conductive shell to which the thermal conductive adhesive is attached is bent relative to the second side wall of the thermal conductive shell, The thermally conductive adhesive is cured to bond the second outer periphery of the thermally conductive shell to the second side wall of the thermally conductive shell, thereby forming the second thermally conductive side wall of the battery cell. The method according to claim 12, including the method described in claim 12.
14. The method according to claim 13, wherein the second thermally conductive sidewall is located on the opposite side of the battery cell from the first thermally conductive sidewall.
15. The method according to claim 14, wherein the second thermally conductive sidewall is parallel to the first thermally conductive sidewall.
16. The method according to any one of claims 12 to 15, wherein the thermally conductive adhesive comprises a thermally conductive metal component suspended in an adhesive matrix.
17. A manufacturing jig, wherein the manufacturing jig is A base member including the bottom surface, the first side battery cell support surface, and the first side support wall, A second side support assembly including a second side support base member and a second side support wall member slidably attached to the second side support base member. Equipped with, The second side support wall member is spaced apart from the first side support wall. The second side support wall member includes the second side battery cell support surface and the second side support wall, The second side support wall member is spring-biased in a direction away from the second side support base member. The first battery cell support surface and the second battery cell support surface are on the same plane, A manufacturing jig comprising a first side support wall and a second side support wall, each including parallel side wall surfaces configured to hold the folded side portion of the peripheral edge of the thermal conductive shell in the battery shell engaged with the respective side walls of the thermal conductive shell during the curing of a conductive adhesive used to bond the folded side portion of the peripheral edge of the thermal conductive shell to the respective side walls of the thermal conductive shell.
18. The base member includes a second recess extending along the first battery cell support surface, The bottom of the second side support wall member is housed in the second side recess, The manufacturing jig according to claim 17, wherein the second recess is configured to allow relative movement between the second support wall member and the second support base member.
19. The manufacturing jig according to claim 18, wherein the second side support base member is detachably attached to the base member so as to support the second side support wall member spaced apart from the first side support wall.
20. The manufacturing jig according to claim 19, wherein each of the first side support wall and the second side support wall includes a curved portion shaped to bend each side portion of the peripheral edge of the thermal conductive shell of the battery cell and engage with each side wall of the thermal conductive shell as the battery cell is advanced into the manufacturing jig between the first side support wall and the second side support wall while in contact with the first side battery cell support surface and the second side battery cell support surface.