Battery housing and solid-state battery assembly comprising same

Abstract

Disclosed is a weight-efficient battery housing comprising multiple cavities for accommodating a cell member. In one aspect, the battery housing comprises an exterior wall and an internal wall, wherein the exterior wall defines an interior space, and the internal wall divides the interior space into multiple cavities to accommodate a cell or a cell member. In some embodiments, one or more channels are further formed to accommodate wiring(s), sensor(s), and / or pathway(s) for coolant or heating fluid.

Description

BATTERY HOUSING AND SOLID-STATE BATTERY ASSEMBLY COMPRISING SAME CROSS-REFERENCE

[0001] The present application claims the benefit of US Serial No.63 / 608,955, filed December 12, 2023, the entire content of which is incorporated herein by reference into this application. FIELD

[0002] Disclosed is a battery housing comprising multiple cavities each of which accommodate a cell. Also disclosed is a solid-state battery assembly comprising the housing. BACKGROUND

[0003] Lithium metal batteries are highly promising as lithium metal anode exhibits a high capacity in comparison to conventional anode materials such as graphite. Due to the volume expansion and contraction of lithium metal anode during charge and discharge, lithium metal battery requires an operation pressure of at least 0.5MPa. It is much higher than that of traditional lithium-ion battery (LIB), which usually requires a pressure of less than 0.1MPa. Such operation under pressure requires a structure / mechanism with a higher mechanical strength. Such structure / mechanism usually sacrifices the volumetric and gravimetric energy density. Thus, it creates challenges for the structural designs in balancing mechanical performance, weight efficiency, and form factors (such as pouch cells with a jig, prismatic cells with a hard casing or housing). Those challenges become even more critical when capacities and sizes of the battery exceed a certain level, for example a battery with an energy capacity of 10 Ah or higher. Thus, there remains a need for a new battery housing. SUMMARY

[0004] In one aspect, the present disclosure provides a weight-efficient battery housing comprising multiple cavities for accommodating a cell member. In one aspect, the present disclosure provides a weight-efficient battery housing comprising an exterior wall and an internal wall. The exterior wall defines an interior space, and the internal wall divides theinterior space into multiple cavities to accommodate a cell member. In some embodiments, the internal wall is constructed in a way that it bridges between two parts of the exterior wall, thus reinforcing the mechanical strength and stability of the housing. In some embodiments, the internal wall, optionally with the exterior wall, forms one or more channels to accommodate wiring, sensor, and / or pathway for coolant or heating fluid. BRIEF DESCRIPTION OF THE FIGURES

[0005] Non-limiting embodiments of the present disclosure will be described by way of example with reference to the accompanying figures, which are schematic and are not intended to be drawn to scale. In the figures, each identical or nearly identical component illustrated is typically represented by a single numeral. For purposes of clarity, not every component is labeled in every figure, nor is every component of each embodiment of the disclosure shown where illustration is not necessary to allow those of ordinary skill in the art to understand the disclosure.

[0006] Fig.1 shows a perspective view of a battery housing according to one embodiment of the present disclosure.

[0007] Fig. 2A shows a top view of a cross-section of a battery housing according to one embodiment of the present disclosure.

[0008] Fig.2B shows a front view of a cross-section along A-A’ in Fig.2A according to one embodiment of the present disclosure.

[0009] Fig. 2C shows a front view of a cross-section along A-A’ in Fig. 2A according to another embodiment of the present disclosure.

[0010] Figs. 2D to 2F show an overview of a battery housing with multiple internal walls according to some embodiments of the present disclosure.

[0011] Fig. 3A shows a top view of a cross-section of a battery housing according to one embodiment of the present disclosure. Figs. 3B to 3D show a front view of a cross-section along B-B’ in Fig.3A according to some embodiments of the present disclosure.

[0012] Fig.4 shows a top view of a cross-section view of a battery housing according to one embodiment of the present disclosure.

[0013] Fig. 5 shows a top view of a cross-section of a battery housing according to one embodiment of the present disclosure.

[0014] Fig. 6 shows a top view of a cross-section of a battery housing according to another embodiment of the present disclosure.

[0015] Fig. 7 shows a top view of a cross-section of a battery housing according to one embodiment of the present disclosure.

[0016] Fig. 8 shows a front view of a cross-section along B-B’ in Fig. 3A according to one embodiment of the present disclosure.

[0017] Fig.9A shows an overview of a battery housing according to one embodiment of the present disclosure. Figs. 9B, 9C and 9D show a deflection profile of an exterior wall in a housing with no internal wall, one internal wall and two internal walls, respectively, according to some embodiments of the present disclosure.

[0018] Figs.10A, 10B and 10C show a bending stress profile of an exterior wall in a housing with no internal wall, one internal wall and two internal walls, respectively, according to some embodiments of the present disclosure.

[0019] Figs. 11A, 11B and 11C show a shear stress profile of an exterior wall in a housing with no internal wall, one internal wall and two internal walls, respectively, according to some embodiments of the present disclosure.

[0020] Fig. 12A shows a deformation mapping of the exterior wall of a housing with two internal walls according to one embodiment of the present disclosure. Fig.12B shows a finite element analysis (FEA) stress profile of the exterior wall of a housing with four vertical internal walls and one horizontal internal wall according to one embodiment of the present disclosure. Fig.12C shows an FEA stress profile of the exterior wall of a housing with four vertical internal walls and two horizontal internal walls according to one embodiment of the present disclosure.

[0021] Fig.13A shows a side view of a deformed housing with no internal wall and the FEA stress profile of the exterior wall according to one embodiment of the present disclosure. Fig. 13B shows a side view of a deformed housing with one horizontal internal wall and the FEA stress profile of the exterior wall according to one embodiment of the present disclosure.

[0022] Fig.13C shows a top view of a deformed housing with no internal wall and the FEA stress profile of the exterior wall according to one embodiment of the present disclosure.

[0023] Fig.13D shows a top view of a deformed housing with four vertical internal walls and the FEA stress profile of the exterior wall according to one embodiment of the present disclosure.

[0024] Fig.14 shows a front view of a cross-section of a housing according to one embodiment of the present disclosure. DETAILED DESCRIPTION

[0025] In one aspect, the present disclosure provides a weight-efficient battery housing comprising multiple cavities configured to accommodate a cell member. In one aspect, the present disclosure provides a weight-efficient battery housing comprising an exterior wall and an internal wall. The exterior wall defines an interior space, and the internal wall divides the interior space into multiple cavities to accommodate a cell member. In some embodiments, the internal wall is constructed in a way that it bridges between two parts of the exterior wall, thus reinforcing the mechanical strength and stability of the housing so that the housing can withstand an operating pressure equal to or higher than 0.5 MPa. This design is an alternative to relying on the thickness of the exterior wall to withstand the operating pressure without buckling or otherwise deforming. In some embodiments, the internal wall, optionally with the exterior wall, forms one or more channels to accommodate wiring, sensor(s), and / or pathway(s) for coolant or heating fluid.

[0026] Fig. 1 shows the exterior of a representative battery housing (10) according to one embodiment of the present disclosure. Battery housing (10) can have one or more exteriorwalls and at least one cap or cover. For example, battery (10) can have a single, integral exterior wall (19) defining an interior space and a cap or cover (16) that encloses the interior space after cells or cell members are placed in the interior space. In other embodiments, the battery housing (10) may have multiple exterior walls that define an interior space as shown for example in Figs.2A and 2B.

[0027] As shown in Figs. 2A and 2B and according to one embodiment of the present disclosure, the battery housing includes a plurality of exterior walls joined together such as a first exterior wall (11), a second exterior wall (12) opposing the first exterior wall, a third exterior wall (13) connecting the first and second exterior walls (11 and 12), a fourth exterior wall (14) opposing the third exterior wall (13) and connecting the first and second exterior walls (11 and 12), a fifth exterior wall (15) connecting the third and fourth exterior walls (13 and 14), a sixth exterior wall (16) opposing the fifth exterior wall (15) and connecting the third and fourth exterior walls (13 and 14), and at least one internal wall (30), wherein the first through sixth walls (11, 12, 13, 14, 15 and 16) define an interior space of the battery housing, the at least one internal wall (30) divides the interior space into multiple cavities (50), and the multiple cavities are sized to accommodate a cell or cell member. In some embodiments, the sixth exterior wall (16) is a cover or cap attached to the other exterior walls or otherwise configured to enclose the interior space after cell members are placed in the interior space. In some embodiments, both the fifth and sixth exterior walls (15 and 16) are a cover or cap enclosing the interior space after cell members are placed in the interior space. The number and arrangement of exterior walls shown in Figs. 2A and 2B are merely exemplary. In some embodiments, the exterior walls and / or internal walls are made by extrusion, welding, casting, machining, and combination thereof.

[0028] In some embodiments, the internal wall (30) bridges two opposing exterior walls such as the first and second exterior walls (11 and 12) as shown in Fig. 2A and decreases the deformation of these two opposing exterior walls when the cell member in the cavitiesundergoes a volume expansion or contraction during charge and discharge of the battery. In some embodiments, the housing comprises a first terminal (21) and a second terminal (22) as exemplarily shown in Fig.2B. In some embodiments, either terminal or both terminals can be placed on any side of the exterior wall. In some embodiments, either or both terminals are placed on a cap or cover of the housing.

[0029] In some embodiments, the at least one internal wall (30) includes a first internal wall (31) and a second internal wall (32), wherein the first and second internal walls are substantially perpendicular to each other as exemplarily shown in Figs.2C and 2D (note that Fig.2D does not show the thickness of the exterior walls or the internal walls). In some embodiments, the first internal wall (31) is vertical while the second internal wall (32) is horizontal. As shown in Fig.2D, the first internal wall (31) and the second internal wall (32) divide the interior space into four cavities. In some embodiments, each of the internal walls may have multiple internal walls configured in parallel. For example, the housing may comprise two first internal walls (31) as shown in Fig.2E. These two first internal walls (31) and one second internal wall (32) divide the interior space of the housing into six cavities. In some embodiments and as exemplarily shown in Fig. 2F, the internal wall (30) comprises a first internal wall (31), a second internal wall (32) and a third internal wall (33), wherein they are substantially perpendicular to each other. The first, second and third internal walls (31, 32, and 33) divide the interior space into six cavities. The number and arrangement of internal walls in Figs.2C- 2F are merely exemplary.

[0030] As shown in Figs. 3A and 3B and according to some embodiments of the present disclosure, the battery housing includes a first exterior wall (11), a second exterior wall (12) opposing the first exterior wall, a third exterior wall (13) connecting the first and second exterior walls (11 and 12) from one end, a fourth exterior wall (14) opposing the third exterior wall (13) and connecting the first and second exterior walls (11 and 12) from the other end, a fifth exterior wall (15) connecting the third and fourth exterior walls (13 and 14) which maybe a cap or cover, a sixth exterior wall (16) opposing the fifth exterior wall and connecting the third and fourth exterior walls (13 and 14) which may be a cap or cover, and multiple internal walls (30) (four internal walls in this particular case), wherein the first through sixth walls (11, 12, 13, 14, 15 and 16) define an interior space of the battery housing, the internal walls (30) divide the interior space into multiple cavities (50) and one or more channels (60). Each of the cavities (50) is sized to accommodate a cell member while the channels (60) are configured to accommodate wiring(s), sensor(s), and / or pathway(s) for coolant or heating fluid. In some embodiments, the number of channels may be one, two, three or more. Fig. 3A shows three channels (60) as an example. The number and arrangement of exterior walls shown in Figs.3A and 3B is merely exemplary.

[0031] In some embodiments, the internal walls (30) comprise a first internal wall (31) and a second internal wall (32). In some embodiments, the first internal wall (31) bridges a pair of opposing exterior walls such as the first and second exterior walls (11 and 12) as shown in Fig. 3A. In some embodiments, the second internal wall (32) as typically shown in Fig. 3C may also bridge the first and second exterior walls (11 and 12) (the first and second exterior walls are shown in Fig.3A and not shown in Fig.3C). In some embodiments and as shown in Fig. 3C, the second internal wall (32) has no direct connection with the third and fourth exterior walls (13 and 14) but has direct connections to the first internal wall (31). In some embodiments, as shown in Fig.3D, the second internal wall (32) has direct connections to the third and fourth exterior walls (13 and 14). In some embodiments, the extended connections between the first internal wall (31) and the third or fourth exterior wall (13 or 14) further improve the mechanical strength and the dimensional stability. In some embodiments, the first internal wall is vertical while the second internal wall is horizontal. In some embodiments, the first and second internal walls are substantially perpendicular to each other. In some embodiments, the multiple cavities for accommodating cells or cell members are arranged in one row as shown in Fig. 3B or arranged in two rows as shown in Figs.3C and 3D.

[0032] In some embodiments, the battery housing may comprise no channels. In some embodiments, the battery housing may comprise one or more channels. In some embodiments, the channel may be close to one side in the housing or between two adjacent cavities. In some embodiments, the battery housing comprises one channel (60) defined by two internal walls (30) as shown in Fig.4. In some embodiments, the battery housing comprises one channel (60) close to an exterior wall and located at one side the housing as shown in Fig. 5. In some embodiments, the battery housing comprises two channels (60) each located at one side of the cell housing as shown in Fig. 6. In some embodiments, the battery housing comprises three channels (60), wherein two are located at both ends and the third one is located between two adjacent cavities as shown in Fig.3A. In Figs 2A-6, the battery housing is depicted as having pointed corners, however this is merely exemplary and in some embodiments, the battery housing comprises one or more curved or rounded corners as shown in Fig.7.

[0033] In some embodiments, the cell member is a single cell or a stack of single cells. In some embodiments, a single cell is an assembly or stack of one or more cathode layers, one or more anode layers, and one or more electrolyte layers, wherein each electrolyte layer is sandwiched between a cathode layer and an anode layer. In some embodiments, a single cell comprises an electrode with one or more sections stacked along a stacking direction. In some embodiments, the volume expansion or contraction of the cell member occurs mainly along the stacking direction.

[0034] In some embodiments, the stacking direction can be in the first (x-axis), second (y-axis) or third (z-axis) direction. In some embodiments, the stacking direction is a direction along which the cavity has a minimum dimension and the dimension change is kept to a minimum extent. In some embodiments, the stacking direction is along a direction which would cause a minimum deformation against the channels to protect the components therein such as wiring(s) and / or sensor(s). In some embodiments, the electrode of a cell member in each cavity is stacked by sheet-stacking, Z-stacking, prismatic winding (flat jelly roll) or a combination thereof.

[0035] In some embodiments, the housing may comprise no channels as exemplarily shown in Figs.2A to 2C. In some embodiments, the housing may comprise a first channel perpendicular to the fifth and sixth exterior walls (15 and 16) as shown in Figs. 3A to 3C. In some embodiments, the housing may comprise multiple channels with different configurations. In some embodiments and as shown in Fig.8, the battery housing comprises a first channel (61) and a second channel (62), wherein the second channel (62) is perpendicular to the third and fourth exterior walls (13 and 14). In some embodiments, the housing also comprises a third channel (not shown in the drawing), which is perpendicular to the first and second channels (61 and 62). In some embodiments, the first, second and / or third channels are connected to each other via an opening in the internal wall(s). In some embodiments, the channel(s) are configured to accommodate wiring(s), sensor(s), and / or pathway(s) for coolant or heating fluid.

[0036] In some embodiments, the sensor is selected from the group consisting of thermometer, stress sensor and moisture sensor. In some embodiments, the sensor is connected to an external battery monitoring system. In some embodiments, the one or more channels comprise an opening in one of the one or more internal walls. In some embodiments, the opening accommodates an electrical connection between the cell members and an external circuit. In some embodiments, one or more channels accommodate an acting element. In some embodiments, the acting element is to generate heat, or to activate or deactivate an electrical connection between one of the cell members and an external circuit. In some embodiments, the opening accommodates a pathway for decreasing or increasing temperature of the multiple cell members.

[0037] In some embodiments and as exemplarily illustrated in Fig.9A, the housing has a first dimension (L0) along a first direction (x-axis), a second dimension (y0) along a second direction (y-axis), and a third dimension (H0) along a third direction (z-axis). The first, second and third directions define a three-dimensional space. In some embodiments, the first, second and third directions are perpendicular to each other. In some embodiments, the dimension along onedirection is equal to or shorter than the other two directions. In some embodiments, the second dimension is equal to or shorter than the first and third dimensions. In some embodiments, the first dimension is equal to or greater than the second and third dimensions. In some embodiments, the ratio of the first dimension to the second dimension is in a range from 5 to 15, from 5 to 12.5, from 5 to 10, from 7.5 to 15, from 7.5 to 12.5, from 7.5 to 10, or all and any ranges and subranges therebetween.

[0038] As the cell member(s) undergo a volume change, for example during charging, the dimensions of the housing are changed. In some embodiments, the deformations along different directions are different. In some embodiments, the deformation rate along the first direction (D1) is calculated by D1= ∆L / L0^ 100%, wherein L0is the original first dimension and the first dimension change (∆L) is the difference between the original first dimension (L0) and the one after the volume expansion (L1), i.e., ∆L = L1- L0. When the housing receives a load toward the interior space and subject to contraction, the deformation rate along the first direction (D1) is calculated by ∆L / L0^ 100%, wherein L0is the original first dimension and the first dimension change (∆L) is the difference between the original first dimension (L0) and the one after contraction (L2), i.e., ∆L = L0– L2.

[0039] In some embodiments, the deformation rate along the second direction (D2) is calculated by D2= ∆y / y0^100%, wherein y0is the original second dimension and ∆y is the difference between the original second dimension (y0) and the one after the volume expansion (y1), i.e., ∆y = y1- y0. When the housing is subject to contraction, the deformation rate along the second direction (D2) is calculated by D2= ∆y / y0^100%, wherein y0is the original second dimension and the second dimension change (∆y) is the difference between the original second dimension (y0) and the one after contraction (y2), i.e., ∆y = y0– y2.

[0040] In some embodiments, the deformation rate along the third direction (D3) is calculated by D3= ∆H / H0^ 100%, wherein H0is the original third dimension and the third dimension change (∆H) is the difference between the original third dimension (H0) and the one after thevolume expansion (H1), i.e., ∆H = H1– H0When the housing is subject to a contraction, the deformation rate along the third direction (D3) is calculated by ∆H / H0^100%, wherein H0is the original third dimension and the third dimension change (∆H) is the difference between the original third dimension (H0) and the one after contraction (H2), i.e., ∆H = H0– H2.

[0041] In some embodiments, the deformation rate also depends on the stacking direction of the electrode in the cell member(s), the original dimensions of the housing, the existence of the internal wall(s), and the configuration of the internal wall(s). In some embodiments, the deformation rate along the stacking direction is higher than the other directions. In some embodiments, the deformation rate along the second direction is higher than the first and third directions. In some embodiments, as the deformation at different locations of an exterior wall varies, a maximum deflection (∆ymax) is used to characterize the deformability of the exterior wall. In some embodiments, the maximum deflection (∆ymax) is located at a position with the least support from the exterior wall(s) and / or internal wall(s) as illustrated in Figs.9B, 9C and 9D, wherein the dashed square indicates an area of focus for profiling the deflection upon a load is applied on the exterior wall.

[0042] Fig.9B shows a representative way to calculate the maximum deflection along a second direction for a housing with no internal wall. In some embodiments, the maximum deflection (∆ymax) for a housing with no internal wall is calculated according to the equation below:wherein: L is the total length of the exterior wall along a direction as exemplarily shown in Fig. 9B; w is a loading on the exterior wall in N / mm and calculated by operational pressure*b, b is the dimension normal to both the length and loading w in mm , E is the elastic modulus of the material of the exterior wall in N / mm2, I is moment of inertia of the wall in mm4and is calculated by (b*h3) / 12, andh is the thickness in mm of the exterior wall.

[0043] In some embodiments, the loading may have a direction either facing inward or outward of the housing.

[0044] Figs.9C and 9D show an exemplary way to calculate the maximum deflection along a second direction for a housing with one and two internal walls by following , respectively.

[0045] Thus, in some embodiments, the housings described herein having at least one internal wall may have a maximum deflection less than or equal to w^(L / 2)4 / (185^E^I) or less than or equal to (0.0069^w^(L / 3)4) / (E^I).

[0046] In some embodiments, assuming that all other conditions are the same and the internal wall has the same thickness as the external wall(s), the incorporation of one and two internal walls can reduce the maximum deflection by 97.0% and 99.3%, respectively, in comparison to the one without any internal wall. In some embodiments, the housings described herein having at least one internal wall may have a maximum deflection that is 97.0% less than or 99.3% less than the maximum deflection of an identical housing without the at least one internal wall.

[0047] In some embodiments, the incorporation of an internal wall also reduces the bending stress and / or shear stress of the exterior wall(s). In some embodiments, the maximum bending stress (Mmax) is located at a position with the least support from the exterior wall(s) and / or internal wall(s) as illustrated in Figs.10A, 10B and 10C, wherein the dashed square indicates an area of focus for profiling the bending stress upon a load is applied on the exterior wall.

[0048] Fig.10A shows a representative way to calculate the maximum bending stress (Mmax) of an exterior wall in a housing with no internal wall. In some embodiments, the maximum bending stress (Mmax) for a housing with no internal wall may be calculated according to the equation below: Mmax =w^L2 / 8,wherein w is a loading on the exterior wall, and L is the total length of the exterior wall.

[0049] Figs.10B and 10C show a profile of the bending stress of an exterior wall in a housing with one and two internal walls, respectively. In some embodiments, as exemplarily shown in Figs.10B and 10C, the maximum bending stress (∆Mmax) for a housing with one internal wall and two internal walls can be calculated by following Mmax =w^(L / 2)2 / 8 and Mmax =w^(L / 3)2 / 10, respectively, wherein w is a loading on the exterior wall , and L is the total length of the exterior wall. Thus, in some embodiments, the housings described herein having at least one internal wall may have a maximum bending stress of less than or equal w^(L / 2)2 / 8 or less than or equal to w^(L / 3)2 / 10.

[0050] In some embodiments, assuming that all other conditions are the same and the internal wall has a thickness the same as that of the external wall(s), the incorporation of one and two internal walls can reduce the maximum bending stress by 75.0% and 91.0%, respectively, in comparison to that without any internal wall. Thus in some embodiments, the housings described herein having at least one internal wall may have a maximum bending stress that is 75.0% less than or 91.0% less than the maximum bending stress of an identical housing without the at least one internal wall.

[0051] In some embodiments, the maximum shear stress (Vmax) is located at a position with the most support and least deformation as illustrated in Figs. 11A, 11B and 11C, wherein the dashed square indicates an area of focus for profiling the shear stress upon a load is applied on the exterior wall. Fig. 11A shows an exemplary way to calculate the maximum shear stress (Vmax) of an exterior wall in a housing with no internal wall. In some embodiments, the maximum shear stress (Vmax) for a housing with no internal wall is calculated by following Vmax =w^L / 2, wherein w is a loading on the exterior wall, and L is the total length of the exterior wall along a direction.

[0052] Figs.11B and 11C show a profile of shear stress of an exterior wall in a housing with one and two internal walls, respectively. In some embodiments, as exemplarily shown in Figs.11B and 11C, the maximum shear stress (Vmax) for a housing with one internal wall and two internal walls can be calculated by following Vmax =5^w^(L / 2) / 8 and Vmax =0.6^w^L / 3, respectively, wherein w is a loading on the exterior wall, and L is the total length of the exterior wall. Thus, in some embodiments, the housings described herein having at least one internal wall may have a maximum shear stress of less than or equal 5^w^(L / 2) / 8 or less than or equal to 0.6^w^L / 3.

[0053] In some embodiments, assuming that all other conditions are the same and the internal wall has a thickness the same as that of the external wall(s), the incorporation of one and two internal walls can reduce the maximum shear stress by 37.5% and 60.0%, respectively, in comparison to that without any internal wall. Thus in some embodiments, the housings described herein having at least one internal wall may have a maximum shear stress that is 37.5% less than or 60.0% less than the maximum shear stress of an identical housing without the at least one internal wall.

[0054] In some embodiments, the housings described herein may exhibit one or more of the following: (i) a maximum deflection less than or equal to w^(L / 2)4 / (185^E^I); (ii) a maximum deflection less than or equal to (0.0069^w^(L / 3)4) / (E^I); (iii) a maximum bending stress of less than or equal w^(L / 2)2 / 8; (iv) a maximum bending stress less than or equal to w^(L / 3)2 / 10; (v) a maximum shear stress of less than or equal 5^w^(L / 2) / 8; and / or (vi) a maximum bending stress less than or equal to 0.6^w^L / 3. In some embodiments, the housings described herein having at least one internal wall may have a maximum deflection that is 97.0% less than or 99.3% less than the maximum deflection of an identical housing without the at least one internal wall; a maximum bending stress that is 75.0% less than or 91.0% less than the maximum bending stress of an identical housing without the at least one internal wall; and / or a maximum shear stress that is 37.5% less than or 60.0% less than the maximum shear stress of an identical housing without the at least one internal wall.

[0055] In some embodiments, the internal wall(s) increase the mechanical strength of the housing and decreases the deformation. In some embodiments, the housing with an internal wall is less deformed in comparison to the one without any internal wall. Fig. 12A shows resultant displacement (URES) of the exterior wall of a housing with one vertical internal wall and one horizontal internal wall. In some embodiments, the displacement (deformation or deflection) along the second direction (y-axis) is higher than the first and third directions (x- and z-axis).

[0056] In some embodiments, the internal wall decreases the maximum stress. In some embodiments, a finite element analysis (FEA) was conducted to further investigate the internal wall’s influence on the mechanical properties and dimensional stability based on the following conditions / assumptions: the operation pressure is normal to the face aligned with the stacking direction of the electrode, the exterior wall is made of AISI 316 stainless steel, and the internal wall if any has the same thickness as the exterior wall. In some embodiments, Fig.12B shows the FEA von Mises stress profile of a housing with four vertical internal walls and one horizontal internal wall, wherein the exterior wall and internal walls define four cavities and three channels. Fig.12C shows the FEA von Mises stress profile of a housing with four vertical internal walls and two horizontal internal walls, wherein the exterior wall and internal walls define six cavities and three channels. The arrows in Figs.12B and 12C indicate a yield strength of 172 MPa. As shown in Figs.12B and 12C, the incorporation of internal walls significantly reduces the maximum stress on the exterior wall and improves the dimensional stability.

[0057] Figs.13A-13D show FEA von Mises stress profiles under various configurations. Fig. 13A is a side view of a cross-section of a housing with no internal wall and a stress profile of the exterior wall while Fig.13C is a top view of a cross-section of a housing with no internal wall and the stress profile of the exterior wall. As for a housing with at least one wall, Figs. 13B and 13D show a side view and a top view of a cross-section of the housing and the stress profile of the exterior wall. As shown in Figs.13A-13D, the internal wall significantly reducesthe deformation rate of the exterior wall and decreases the maximum stress on the exterior wall. The housing with an internal wall exhibits a smaller deformation (deflection) in comparison with that with no internal wall.

[0058] In some embodiments and as shown in Fig. 14, the channels are configured to accommodate a first wire (71) and a second wire (72). The first wire is electrically connected to a first terminal (21) and the second wire (72) is electrically connected to a second terminal (22), wherein the first and second terminals (21 and 22) are electrically insulated from each other.

[0059] In one aspect, the present disclosure provides a battery housing comprising: 1) at least one exterior wall defining an interior space of the housing; and 2) one or more internal walls dividing the interior space into multiple cavities, wherein the cavities are sized to accommodate one or more cell members.

[0060] In some embodiments, the housing exhibits a decreased or minimum deformation in comparison with one without any internal wall when the battery therein undergoes a volume expansion or contraction during charge and discharge. In some embodiments, the housing can provide a pressure including a component perpendicular to the stacking direction of electrode in the cell member(s) in a range from 0.25 MPa to 5.00 MPa during charge and discharge of the battery.

[0061] In some embodiments, the housing exhibits a maximum deflection of less than or equal to w^(L / 2)4 / (185^E^I), wherein w is a loading on the exterior wall (N / mm), L is the total length of the exterior wall (mm) along a direction, E is the elastic modulus of the exterior wall (N / mm2), and I is moment of inertia (mm4) of the exterior wall. In some embodiments, the maximum deflection of the housing is at least 97% lower than a maximum deflection of an identical housing without internal wall(s).

[0062] In some embodiments, housing exhibits a maximum bending stress of less than or equal to w^(L / 2)2 / 8, wherein w is a loading on the exterior wall (N / mm), and L is the total length ofthe exterior wall (mm) along a direction. In some embodiments, the maximum bending stress of the housing is at least 75% lower than a maximum bending stress of an identical housing with no internal wall(s).

[0063] In some embodiments, the housing exhibits a maximum shear stress is less than or equal to 5^w^(L / 2) / 8, wherein w is a loading on the exterior wall (N / mm) and L is the total length of the exterior wall (mm) along a direction. In some embodiments, the housing exhibits the maximum shear stress of the housing is at least 37.5% lower than a maximum shear stress of an identical housing without the internal wall(s).

[0064] In some embodiments, the exterior wall comprises a first exterior wall, a second exterior wall opposing the first exterior wall, a third exterior wall connecting the first and second exterior walls, a fourth exterior wall connecting the first and second exterior walls and opposing the third exterior wall. In some embodiments, the exterior wall further comprises a fifth exterior wall and a sixth exterior wall opposing the fifth exterior wall and connecting the first through fourth exterior walls, wherein the first through sixth exterior walls define the interior space.

[0065] In some embodiments, the one or more internal walls divide the interior space into the multiple cavities and one or more channels, wherein the cavities are sized to accommodate one or more cell members while the one or more channels are configurated to accommodate at least one selected from the group consisting of wiring, sensor, pathway for cooling or heating fluid and combinations thereof.

[0066] In some embodiments, the multiple cavities are arranged in one row or column, multiple rows, multiple columns, or combinations thereof. In some embodiments, the multiple cavities are arranged as an array comprising multiple rows and multiple columns, such as 2x2 array, 2x3 array, 2x4 array, 2x5 array, 3x3 array, 3x4 array and 3x5 array.

[0067] In some embodiments, the housing comprises one or more first internal walls and one or more second internal walls, which divide the interior space into multiple cavities and optionally one or more channels. In some embodiments, the housing comprises one or morefirst internal walls, one or more second internal walls, and one or more third internal walls, which divide the interior space into multiple cavities and optionally one or more channels.

[0068] In some embodiments, when there are multiple channels, the channels may exhibit the same or different configurations. In some embodiments, there are two types of channels which are substantially normal to each other. In some embodiments, there are three types of channels which are substantially normal to each other. In some embodiments, those channels are connected to each other via an opening in the internal walls.

[0069] In some embodiments, the housing is configured with at least one curved or rounded corner. In some embodiments, the housing comprises an engineered surface at the corner and / or any other locations such as terminals.

[0070] In some embodiments, the housing has a first dimension, a second dimension and a third dimension along a first direction, a second direction and a third direction, respectively, wherein each direction is perpendicular to the other two directions.

[0071] In some embodiments, the second dimension is equal to or less than the first and third dimensions. In some embodiments, the first dimension is in a range from 50 mm to 200 mm. In some embodiments, the second dimension is in a range from 20 mm to 50 mm. In some embodiments, the third dimension is in a range from 20 mm to 80 mm.

[0072] In some embodiments, the exterior walls are made of a material selected from the group consisting of aluminum, steels, Ti-based materials, carbon fiber reinforced plastics (CFRPs), and combinations thereof. In some embodiments, the internal walls are made of a material same as or different from the exterior walls. In some embodiments, the internal walls are made of a material selected from the group consisting of aluminum, steels, Ti-based materials, CFRP, and combinations thereof.

[0073] In some embodiments, the first through sixth exterior walls and the internal wall(s) may have the same or different thickness. In some embodiments, the first through sixth exterior walls and the internal wall(s) independently have a thickness equal to or less than 5.00 mm,4.80 mm, 4.60 mm, 4.40 mm, 4.20 mm, 4.00 mm, 3.80 mm, 3.60 mm, 3.40 mm, 3.20 mm, 3.00 mm, 2.80 mm, 2.60 mm, 2.40 mm, 2.20 mm, 2.00 mm, 1.80 mm, 1,60 mm, 1.40 mm, 1.20 mm, 1.00 mm, 0.85 mm, 0.60 mm, or 0.50 mm. In some embodiments, they have a thickness in a range from 0.5 mm to 5.0 mm, from 1.00 mm to 5.0 mm, from 1.5 mm to 5.0 mm, from 2.0 mm to 5.0 mm, from 2.5 mm to 5.0 mm, from 3.0 mm to 5.0 mm, from 3.5 mm to 5.0 mm, or any and all subrange and ranges therebetween. In some embodiments, the housing is capable of providing a desired pressure with a minimum weight and / or volume of the exterior walls and the internal walls so as to ensure a desirable gravimetric and / or volumetric energy density.

[0074] In some embodiments, the housing provides a pressure (operational pressure) on the cell members along one of the directions. In some embodiments, the pressure is no less than 0.25 MPa, 0.50 MPa, 0.75 MPa, 1.00 MPa, 1.25 MPa, 1.50 MPa, 1.75 MPa, or 2.00 MPa along the first, second and / or third direction. In some embodiments, the pressure comprises a vector or component along the second direction which is no less than 0.25 MPa, 0.50 MPa, 0.75 MPa, 1.00 MPa, 1.25 MPa, 1.50 MPa, 1.75 MPa, or 2.00 MPa. In some embodiments, the pressure comprises a vector or component along the second direction which is no higher than 5.00 MPa, 4.75 MPa, 4.50 MPa, 4.25 MPa, 4.00 MPa, 3.75 MPa, 3.50 MPa, 3.25 MPa, 3.00 MPa, 2.75 MPa, 2.50 MPa, 2.25 MPa, 2.00 MPa, 1.75 MPa, 1.50 MPa, 1.25 MPa, or 1.00 MPa. In some embodiments, the pressure comprises a vector or component along the second direction in a range from 0.25MPa to 5.0 MPa. In some embodiments, the second direction is the stacking direction of the electrode in the cell member(s).

[0075] In some embodiments, to achieve a fixed deformation and / or maximum stress, the present disclosure provides a housing with an exterior wall having a thinner thickness in comparison with that of an identical housing with no internal walls. Thus, the housing of the present disclosure exhibits a higher weight efficiency. In some embodiments, the housing with at least one internal wall has a thickness of at least 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80% thinner in comparison with an identical housing with no internal walls.

[0076] In one aspect, the present disclosure provides an assembly or module of an electrochemical device comprising the housing as disclosed herein and one or more cell members therein. In some embodiments, the cell member comprises a package. In some embodiments, the package is made of a flexible material such as polymer / aluminum laminate materials.

[0077] In some embodiments, the one or more cell members comprise one or more electrodes undergoing a volume change during charge and discharge of the battery. In some embodiments, the electrochemical device is a lithium ion battery, lithium metal battery, a semi-solid-state battery, a quasi-solid state battery, a polymer solid state battery, or an all solid state battery.

[0078] In some embodiments, the volume change during charge and discharge of the battery occurs mainly along stacking direction of electrode in the one or more cell members.

[0079] In some embodiments, at least one of the multiple cavities comprises an elastic member to compensate for the volume change of cell members therein. In some embodiments, the elastic member is a polymeric foam. In some embodiments, the elastic member is a polymeric foam. In some embodiments, the polymeric foam is made of a base material comprising at least one selected from the group consisting of urethane elastomer, polyester, natural rubber, silicone rubber, ethylene propylene diene monomer (EPDM), styrene-butadiene rubber (SBR), butyl rubber (BR) and mixtures thereof.

[0080] In some embodiments, the elastic member has a porosity in a range from 20% to 70%.

[0081] In some embodiments, the elastic member has a thickness in a range from 1.5 mm to 12.7 mm.

[0082] In some embodiments, at least one of one or more electrolyte layers is a solid electrolyte. In some embodiments, the solid electrolyte is a quasi-solid electrolyte (polymer solid electrolyte), an inorganic solid electrolyte, or mixtures thereof. In some embodiments, the inorganic solid electrolyte comprises an oxide-based solid electrolyte, a sulfide-based solid electrolyte, or both. In some embodiments, the battery is a solid-state battery. In someembodiments, the battery is an all-solid-state battery. In some embodiments, the oxide-based solid electrolyte is at least one selected from the group consisting of Li1+x+yAlxTi2−xSiyP3−yO12(0<x<2, 0≤y<3), BaTiO3, Pb(ZrxTi1−x)O3(PZT, 0≤a≤1), Pb1−xLaxZr1−yTiyO3(PLZT) (0≤x<1, 0≤y<1), Pb(Mg1 / 3Nb2 / 3) O3—PbTiO3(PMN-PT), HfO2, SrTiO3, SnO2, CeO2, Na2O, MgO, NiO, CaO, BaO, ZnO, ZrO2, Y2O3, Al2O3, TiO2, SiO2, Li3PO4, LixTiy(PO4)3(0<x<2, 0<y<3), LixAlyTiz(PO4)3(0<x<2, 0<y<1, 0<z<3), Li1+x+y(AlaGa1−a)x(TibGe1−b)2−xSiyP3−yO12(0≤x≤1,0≤y≤1, 0≤a≤1, and 0≤b≤1), LixLayTiO3(0<x<2, 0<y<3), Li2O, LiOH, Li2CO3, LiAlO2, Li2O—Al2O3—SiO2—P2O5— TiO2—GeO2, Li3+xLa3M2O12(M is at least one selected from the group consisting of Te, Nb, and Zr, x is an integer of 1 to 10), and Li3+xLa3Zr2−aMaO12, wherein M is at least one selected from Ga, W, Nb, Ta, and Al, 0<a<2, x is an integer of 1 to 10.

[0083] In some embodiments, the sulfide-based solid electrolyte is at least one selected from P2S5, Li2S—P2S5—LiX (where X is a halogen element), Li2S—P2S5—Li2O, Li2S—P2S5— Li2O—LiI, Li2S—SiS2, Li2S—SiS2—LiI, Li2S—SiS2—LiBr, Li2S—SiS2—LiCl, Li2S— SiS2—B2S3—LiI, Li2S—SiS2—P2S5—LiI, Li2S—B2S3, Li2S—P2S5—ZmSn(where m and n are each a positive number, and Z is one selected from Ge, Zn and Ga), Li2S—GeS2, Li2S—SiS2— Li3PO4, Li2S—SiS2—LipMOq(where p and q are each a positive number, and M is one selected from P, Si, Ge, B, Al, Ga, and In), Li7−xPS6−xClx(0≤x≤2), Li7−xPS6−xBrx(0≤x≤2), and Li7−xPS6−xIx(0≤x≤2).

[0084] In some embodiments, the cathode comprises at least one selected from the group consisting of LiFePO4, LixMO2, LixNi1-y-zCoyM1zO2and LixNi1-y-zMnyM2zO2, wherein M is at least one selected from the group consisting of Ni, Co, Mn, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr, V, Nb, Ta, Cr, Mo, W, Rh, Pd, Cu, Zn, Cd, Ga, In, Sn, and rare earth elements, wherein M1 is at least one selected from the group consisting of Mn, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr, V, Nb, Ta, Cr, Mo, W, Rh, Pd, Cu, Zn, Cd, Ga, In, Sn, and rare earth elements, wherein M2 is at least one selected from the group consisting of Co, Al, B, Fe, Mg, Ca, Sr, Sc, Y, Ti, Zr, V,Nb, Ta, Cr, Mo, W, Rh, Pd, Cu, Zn, Cd, Ga, In, Sn, and rare earth elements, and wherein 0.95 ≤ x ≤ 1.1, 1-y-z>0, 0< y ≤ 0.5, 0 ≤ z ≤ 0.5.

[0085] In some embodiments, the anode comprises an anode active material layer and an anode current collector. In some embodiments, the anode active material is lithium metal or lithium alloy. In some embodiments, the lithium alloy is an allow of lithium metal with at least one element selected from the group consisting of C, Si, Sn, Ge, B, Al, In, Bi, Sb, Na, Mg, Zn, Au, and Ag.

[0086] In some embodiments, the elastic member has a porosity in a range from 20% to 70%. In some embodiments, the elastic member has a thickness in a range from 1.5 mm to 12.7 mm.

[0087] In some embodiments, the one or more cell members have an energy capacity equal to or higher than 5 Ah, 10 Ah, 20 Ah, 30 Ah, 40 Ah, 50 Ah, 60 Ah, 70 Ah, 80 Ah, 85 Ah, 90 Ah, 95 Ah, or 100 Ah.

[0088] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and / or,” should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified.

[0089] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “oneor the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

[0090] All transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

[0091] The phrases such as “first,” “second,” “third,” and the like are to be understood to describe various elements, these elements should not be limited by these phrases. These phrases are only used to distinguish one element from another. Thus, a first element in some embodiments could be termed a second element in other embodiments without departing from the teachings of the present disclosure.

[0092] Various embodiments of the features of this disclosure are described herein. However, it should be understood that such embodiments are provided merely by way of example, and numerous variations, changes, and substitutions can occur to those skilled in the art without departing from the scope of this disclosure. It should also be understood that various alternative to the specific embodiments described herein are also within the scope of this disclosure.

Claims

What is claimed is:

1. A housing for a battery, comprising: a) at least one exterior wall defining an interior space of the housing; and b) one or more internal walls dividing the interior space into multiple cavities, wherein the cavities are sized to accommodate one or more cell members, wherein the housing exhibits a maximum deflection less than or equal to w^(L / 2)4 / (185^E^I), wherein w is a loading on the exterior wall, L is the total length of the exterior wall along a direction, E is the elastic modulus of the exterior wall, and I is moment of inertia of the exterior wall.

2. The housing of claim 1, wherein the maximum deflection of the housing is at least 97% lower than a maximum deflection of an identical housing without the one or more internal walls.

3. The housing of claim 1, wherein the housing exhibits a maximum bending stress of less than or equal to w^(L / 2)2 / 8, wherein w is the loading in N / mm, and L is the total length of the exterior wall in mm.

4. The housing of claim 3, wherein the maximum bending stress of the housing is at least 75% lower than a maximum bending stress of an identical housing without the one or more internal walls.

5. The housing of claim 1, wherein the housing exhibits a maximum shear stress less than or equal to 5^w^(L / 2) / 8, wherein w is the loading on the exterior wall in N / mm and L is the total length of the exterior wall in mm.

6. The housing of claim 5, wherein the maximum shear stress of the housing is at least 37.5% lower than a maximum shear stress of an identical housing without the one or more internal walls.

7. The housing of claim 1, wherein the multiple cavities are arranged in one row or column, multiple rows, columns, or combinations thereof.

8. The housing of claim 1, wherein the multiple cavities are arranged as an array comprising multiple rows and multiple columns.

9. The housing of claim 1, wherein the at least one exterior wall has a thickness of at least 30% thinner than that of an identical housing with no internal walls.

10. The housing of claim 1, wherein the at least one exterior wall is made of a material selected from the group consisting of aluminum, steels, Ti-based materials, carbon fiber reinforced plastics (CFRPs), and combinations thereof.

11. The housing of any preceding claim, wherein the one or more internal walls divide the interior space into the multiple cavities and one or more channels, and wherein the one or more channels are sized to accommodate at least one selected from the group consisting of wiring, sensor, pathway for cooling or heating fluid and combinations thereof.

12. The housing of claim 11, wherein the sensor is selected from the group consisting of thermometer, stress sensor, moisture sensor and combinations thereof.

13. An assembly of an electrochemical device comprising the housing of any preceding claim and one or more cell members positioned in each of the multiple cavities of the housing.

14. The assembly of claim 13, wherein the one or more cell members comprise one or more electrodes undergoing a volume change during charge and discharge of the electrochemical device, wherein the volume change occurs mainly along stacking direction of the one or more electrodes in the one or more cell members, and each of the multiple cavities in the housing provides a pressure with a component perpendicular to the stacking direction in a range from 0.25MPa to 5.0 MPa.

15. The assembly of claim 13, wherein at least one of the multiple cavities comprises an elastic member to compensate for the volume change of the one or more cell members therein.

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