Storage battery unit

Abstract

The invention relates to a storage battery unit (10) which has: an electrode separator unit (12) which is configured to store, receive and / or discharge electrical energy; a housing element (14) which is configured to support the electrode separator unit (12) in an electrolyte; and a first spacer element (16) which is at least partially arranged between an inner side (18) of the housing element (14) and the electrode separator unit (12), wherein the first spacer element (16) is configured to set a predefined distance (20) between the inner side (18) of the housing element (14) and the electrode separator unit (12).

Description

[0001] Battery unit

[0002] Description

[0003] The present invention relates to a battery unit or an electrochemical cell, a method for manufacturing a first spacer element, and a vehicle and / or a stationary storage device.

[0004] Currently, a wide variety of solutions exist for positioning battery units in battery systems. Due to the increasing number of application scenarios and the rising performance and quality requirements of battery systems, the demand for innovative and robust battery units is constantly growing.

[0005] The continuous increase in efficiency in vehicle technology, as well as increasing competition, is causing cost pressure, resulting in a greater demand for cheaper, more efficient and reliable vehicle components.

[0006] Disclosure of the invention

[0007] The embodiments of the invention advantageously provide an improved battery unit. The invention is defined in the independent claims. Advantageous further developments of the invention are described in the dependent claims and the following description.

[0008] An advantage of the battery unit with the features of claim 1 is that the first spacer element allows the electrode separator unit to be spaced away from an inner wall of the housing element, thus enabling a variety of functions, such as the venting of gas within the battery unit in the event of thermal runaway. A further advantage is that the first spacer element allows the electrode separator unit to be held in a predetermined position, ensuring that even if the electrolyte is consumed, for example, due to aging processes in the housing element, the entire electrode separator unit remains covered with electrolyte. This allows the battery unit to store a similar or only slightly lower energy capacity, particularly during extended operation, compared to when the battery unit was first in operation. Consequently, the battery unit exhibits reduced capacity loss over its service life.Preferably, the first spacer element can provide a rapid transport of the gas towards a bursting disc, so that in the event of overpressure in the battery unit, this can be quickly and specifically discharged from the battery unit via the bursting disc without the cell bursting uncontrollably.

[0009] According to the invention, this is achieved by the battery unit having an electrode separator unit which is configured to store, absorb and / or release electrical energy, wherein the battery unit has a housing element which is configured to store the electrode separator unit in an electrolyte, wherein the battery unit has a first spacer element which is arranged at least partially between an inner side of the housing element and the electrode separator unit, wherein the first spacer element is configured to set a predetermined distance between the inner side of the housing element and the electrode separator unit.

[0010] In other words, the predetermined distance between the inside of the housing element and the electrode separator unit can be selected such that it simplifies and accelerates the removal of any gas generated in the battery unit. More preferably, the predetermined distance can be selected such that the electrode separator unit is completely covered with electrolyte throughout the entire operating time of the battery unit, thus preferably preventing reduced aging or similar effects.

[0011] The dependent claims describe preferred embodiments of the invention.

[0012] Preferably, the housing element has at least one contacting element which is configured to conduct electrical energy from the inside to an outside of the housing element, wherein the first spacer element is arranged on a wall of the inside of the housing element which is free of the contacting element.

[0013] An advantage of this embodiment is that the design of the housing element does not need to be adapted, and thus, in particular, no adjustment of a production line to the first spacer element is required. Therefore, only the electrode separator unit and the first spacer element need to be adapted. For example, the housing element can have a rectangular cross-section, with the contacting element arranged on one side of the rectangle and the first spacer element arranged on one and / or all other sides of the rectangle.

[0014] Preferably, the first spacing element has an extension height and / or a spacing element which is configured to set the predetermined distance.

[0015] An advantage of this embodiment is that either the spacer element itself can form the predetermined distance, for example by means of a fold or similar feature, or a spacer element, such as a molded part or similar, is attached to the first spacer element to adjust the predetermined distance. Thus, the first spacer element can be adapted to the predetermined distance, particularly depending on the specific application scenario.

[0016] Preferably, the predetermined distance is chosen such that, after a certain operating period of the battery unit, the first spacer element can at least partially absorb the gas released during the aging process, thereby displacing the electrolyte in this area. Preferably, the first spacer element can be arranged opposite a venting element, particularly at the top of the battery unit. An advantage of this embodiment is that a gas chamber or similar structure can be formed above the electrode separator unit, so that, in the event of electrolyte degradation over the operating period of the battery unit and the resulting gas release, the electrode separator unit remains essentially completely covered by the electrolyte and thus does not "run dry." This can ultimately lead to a lower capacity loss.

[0017] The slightly lower initial capacity resulting from the space required by the spacer element, for example due to a smaller electrode separator unit, can be offset by the advantages described above in various application scenarios, such as in industrial cells. Furthermore, a smaller electrode separator unit can also result in a reduced use of active materials.

[0018] Preferably, a plurality of spacer elements is arranged on an inner side of the housing element, wherein the first spacer element of the plurality of spacer elements and a second spacer element of the plurality of spacer elements are arranged essentially opposite each other on the electrode separator unit.

[0019] An advantage of this embodiment is that a channel or channels for discharging gas generated in the battery unit can be formed on both a first and a second side of the electrode separator unit when two spacer elements are located in the battery unit. "Essentially opposite each other" in this context can particularly mean that the spacer elements are arranged on two opposite sides of the electrode separator unit, whereby these may have a slight offset, particularly due to manufacturing tolerances. Furthermore, synergistic effects can be generated, such as both the discharging of any gas that may be generated in the battery unit in the event of venting or thermal runaway, and – during normal cell operation – maintaining a constant electrolyte level in the housing element.Preferably, the first spacer element has at least one recess, wherein the recess is designed to drain gas generated in the electrode separator unit.

[0020] One advantage of this embodiment is that the gas produced can be directed into a specifically arranged fluid flow via the recess, in order to achieve the best possible gas removal result.

[0021] Preferably the first spacer element has at least one channel element and / or forms one, wherein the recess is arranged in the channel element, wherein the channel element is configured to receive and / or discharge gas generated in the electrode separator unit through the recess so that gas transport is provided substantially parallel or along the housing element (14).

[0022] An advantage of this embodiment is that a fluid channel can be provided by means of the channel element and the recess, enabling the targeted discharge of gas generated in the electrode separator unit. The gas can then enter the fluid channel laterally from the layers of the electrode separator unit.

[0023] Preferably, the housing element has a venting element which is configured to close an opening of the housing element during normal operation of the battery unit and to release the opening in the event of gas evolution in the electrode separator unit, wherein the opening of the housing element and the recess of the first spacer element are configured to allow gas generated during gas evolution to escape from the battery unit.

[0024] An advantage of this embodiment is that, should gas develop within or on the electrode separator unit, it can be selectively vented via the recess and then guided through the opening of the housing element, thus providing a targeted channel for removing both heat and gas or particle streams from the battery unit. The venting element can preferably be a rupture disc or similar device. The rapid transport of the gas to the rupture disc ensures that any build-up of overpressure in the battery unit can be quickly and selectively released from the battery unit or cell via the rupture disc, preventing the battery unit from bursting uncontrollably.

[0025] Preferably, the channel element is configured to receive the gas generated in the electrode separator unit through the recess and discharge it via the opening. An advantage of this embodiment is that a fluid channel can be formed to allow the gas to be directed out of the battery unit.

[0026] Preferably, the first spacer element is designed to electrically isolate the electrode separator unit from the housing element.

[0027] An advantage of this embodiment is that no loss currents occur at the housing element, or these are reduced, in particular by attaching the first spacer element as well as by setting the predetermined distance.

[0028] Preferably, the first spacer element comprises at least a portion of a polymeric material and / or a ceramic material.

[0029] One advantage of this embodiment is that a spacer element made of the aforementioned materials can exhibit both good long-term stability and an electrically insulating effect.

[0030] Preferably, the first spacer element comprises at least a portion of a thermoplastic, a thermoset and / or an elastomer.

[0031] One advantage of this embodiment is that the materials mentioned can be processed so well and produced in large quantities, so that the manufacturing costs of the battery unit can be further reduced.

[0032] Thermosets and elastomers have the advantage over thermoplastics that they do not melt under short-term high temperature stress and thus cannot clog the fluid channel. Preferred elastomers are EPDM or FKM, as both exhibit good resistance to battery electrolytes.

[0033] Spacers made of ceramic materials such as aluminum oxide or zirconium oxide possess particularly high thermal stability and abrasion resistance.

[0034] Metal spacers are also conceivable, which are coated with a polymer or ceramic layer for electrical insulation.

[0035] It is conceivable to design the spacer element as a molded part with a smooth surface into which channels are incorporated.

[0036] A spacer element with a channel structure is also conceivable, where the channels are covered by a thin layer – e.g., a film or nonwoven fabric. This layer preferably ensures that a force is applied to the electrode separator unit that is as homogeneous as possible, while exhibiting only low flow resistance for the released gas. Spacers made of gas-permeable materials – for example, open-pore nonwovens – are also conceivable. Suitable porosities can be higher than 30% by volume (preferably higher than 50% by volume). Such spacers can, on the one hand, ensure a homogeneous force during normal operation and, on the other hand, can guide the hot gases through their structure.The existing porosity also ensures that even when such a spacer element melts, sufficient free cross-sectional area remains (the free cross-sectional area after melting corresponds approximately to the free porosity of the original spacer element), allowing for reliable gas transport. Nonwovens made of polyolefin-based or polyester-based fibers are conceivable for this purpose.

[0037] It is further preferred that the opening of the housing element is positioned in such a way that the gas produced is directed away from a vehicle when the battery unit is installed in the vehicle.

[0038] One advantage of this embodiment is that, with the help of the opening and the recess and the resulting fluid channel, the hot gas flows or a particle flow can be directed away from the vehicle.

[0039] Preferably, the venting element has a predetermined thickness designed to break upon gas evolution, and / or a defined melting point designed to liquefy the venting element upon gas evolution, and / or a resistance designed to stabilize the venting element under short-term stress.

[0040] One advantage of this embodiment is that during normal operation of a vehicle in which the battery unit is located, the opening is not released and is only released in the event of gas development or similar occurrences.

[0041] Preferably, the first spacer element is designed to dampen the electrode separator unit within the housing element. For this purpose, the spacer element can be reversibly compressible or deformable.

[0042] One advantage of this embodiment is that, if the battery unit is located in a vehicle or similar, any shock loads are not directly transferred to the electrode separator unit, and that the first spacer element has a damping effect in order to increase the longevity of the electrode separator unit.

[0043] Preferably, a sheath element is arranged between the electrode separator unit and the housing element, wherein the first spacer element is arranged on the sheath element to simplify the assembly of the first spacer element in the housing element.

[0044] One advantage of this embodiment is that the sheathing element can align a large number of spacer elements to each other, thus simplifying the assembly of the spacer element.

[0045] Preferably, the sheath element has at least one opening, wherein the opening of the sheath element and the recess of the first spacer element overlap at least partially in order to dissipate the gas produced.

[0046] One advantage of this embodiment is that the opening in the casing element allows for the targeted fluid channel to be formed for the removal of the gas produced as well as thermal energy in the battery unit.

[0047] Another embodiment can consist of a sheath element made of a fiber-based material – e.g., a nonwoven fabric – and an integrated spacer element, which also comprises a fiber-based material – e.g., a nonwoven fabric. The spacer element can have a different thickness or porosity than the sheath element. Preferably, the sheath element can cover at least parts of the outer surfaces of the electrode separator unit and / or at least parts of the inner surface of the housing element.

[0048] Another aspect of the invention relates to a method for manufacturing a first spacer element for a battery unit, as described above and below, which comprises the following steps:

[0049] - Providing a blank,

[0050] - Making at least one recess in the blank,

[0051] - Setting the height of the blank with the recess to form the first spacer element.

[0052] One advantage of this embodiment is that the respective first spacing element can be specifically adapted to a particular application scenario, especially with regard to an extension height or similar.

[0053] Preferably the method further comprises the following steps:

[0054] - Providing a coat blank,

[0055] - Creating an opening in the shell blank to form the shell element, positioning the first spacer element on the shell element so that the opening and the recess overlap at least partially.

[0056] One advantage of this embodiment is that the discharge effect of the first spacer element can be improved with the sheath element in order to more easily dissipate any gas that forms in the battery unit.

[0057] Another aspect of the invention relates to a vehicle and / or a stationary storage device which has a battery unit as described above and below and / or an energy storage device which was manufactured using the method as described above and below.

[0058] Furthermore, it should be noted that the term "unit" is to be understood broadly in this context and includes both single-part and multi-part training of the respective units, whereby the respective sub-units do not necessarily have to be located in one position in the vehicle, but can also be distributed around the plant.

[0059] All disclosures described above and below with regard to one aspect of the invention shall apply equally to all other aspects of the invention.

[0060] Exemplary embodiments of the invention are described in detail below with reference to the accompanying drawings. The drawing shows:

[0061] Figures 1 to 6B show a battery unit according to one embodiment,

[0062] Figures 7 and 8 show a flowchart illustrating steps of the procedure according to one embodiment, and

[0063] Figure 9 shows a vehicle according to one embodiment.

[0064] Embodiments of the invention

[0065] The figures are schematic only and not to scale. Identical, equivalent, or similar elements with the same reference symbols may be used within the figures.

[0066] Figure 1 shows a battery unit 10 according to one embodiment. The battery unit 10 comprises an electrode separator unit 12, which is configured to store, absorb, and / or release electrical energy. Furthermore, the battery unit 10 comprises a housing element 14, which is configured to immerse the electrode separator unit 12 in an electrolyte. The battery unit 10 also comprises a first spacer element 16, which is arranged at least partially between an inner surface 18 of the housing element 14 and the electrode separator unit 12, wherein the first spacer element 16 is configured to establish a predetermined distance 20 between the inner surface 18 of the housing element 14 and the electrode separator unit 12. More preferably, the battery unit 10 comprises a casing element 36, on which, in particular, the first spacer element 16 can be arranged.Preferably, the housing element 14 has a venting element 30 which closes an opening 32 of the housing element 14 or releases it in the event of gas evolution.

[0067] Figure 2a shows a battery unit 10 according to one embodiment. The battery unit 10 comprises a housing element 14. The housing element 14 has a contact element 22 for conducting electrical energy from the electrode separator unit 12, which is arranged in the housing element 14, to an outer surface 24 of the housing element. Preferably, a first spacer element 16 is arranged between the electrode separator unit 12 and the inner surface 18 of the housing element 14 such that it can establish a predetermined distance 20. As shown in Figure 2a, the battery unit 10 has contact elements 22 on both sides, with the first spacer element 16 being arranged on an inner surface 18 of the housing element 14 that is free of the contact elements 22.Preferably, the housing element 14 has a venting element 30 which closes and releases an opening 32 of the housing element 14 during normal operation when gas is generated in the electrode separator unit 12 or on the inside 18 of the housing element 14.

[0068] Figure 2b shows a battery unit 10 according to one embodiment. The battery unit 10 has a similar structure to the battery unit 10 in Figure 2a. As shown in Figure 2b, a first spacer element 16 and a second spacer element 26 are arranged in the battery unit 10 on both a first side and a second side, respectively. Preferably, the housing element 14 also has a vent element 30 on both sides, which closes an opening 32 located on both sides. Preferably, both the first spacer element 16 and the second spacer element 26 can adjust the predetermined distance 20.

[0069] Figure 3a shows a battery unit 10 according to one embodiment. The battery unit 10 has a similar structure to the battery unit 10 in Figures 2a and 2b. Preferably, the first spacer element 16 is arranged between the electrode separator unit 12 and the vent element 30, for example on a bottom side of the electrode separator unit, in order to space the electrode separator unit 12 away from a vent element 30 or an opening 32, in particular by the predetermined distance 20. Preferably, the housing element 14 can have an outer surface 24, wherein the contact elements 22 are configured to conduct electrical energy from the inner surface 18 to the outer surface 24 of the housing element 14.Further preferably, the venting element 30 has a predetermined thickness 34 which is designed to break upon gas evolution, has a defined melting point which is designed to liquefy the venting element 30 upon gas evolution and / or has a resistance which is designed to stabilize the venting element 30 under short-term stress.

[0070] Figure 3b shows a battery unit according to one embodiment. As can be seen in Figure 3b, it has a similar structure to the battery unit 10 of Figure 3a. Figure 3b shows a fluid flow 39, which illustrates how gas generated during venting or thermal runaway in the electrode separator unit 12 can be discharged via the opening 32. The venting element 30 can be dislodged or removed, for example, by the pressure or temperature increase. The gas can then flow in the areas of the spacer element 16 and thus reliably reach the opening 32.

[0071] Figure 4a shows a battery unit 10 according to one embodiment. As shown in Figure 4a, the first spacer element 16 is arranged on an inner surface 18 of the housing element 14 to space the electrode separator unit 12 away from the housing element 14 by a predetermined distance 20. Preferably, the housing element 14 can have contact elements 22 to conduct electrical energy from the inner surface 18 to the outer surface 24.

[0072] Figure 4b shows a battery unit 10 according to one embodiment. The battery unit 10 has a similar structure to the battery unit 10 in Figure 4a. Figure 4b shows a fluid flow 39, which is intended to illustrate a gas generated in the battery unit 10 or electrode separator unit 12, which is led out of the battery unit, in particular through the opening 32.

[0073] Figure 5a shows a battery unit 10 according to one embodiment. The battery unit 10 preferably comprises a casing element 36 on which a first spacer element 16 is arranged. Preferably, the first spacer element 16 has a plurality of recesses 28. Preferably, the casing element 36 has at least one opening 38, wherein, in particular, the recess 28 of the first spacer element 16 overlaps with the opening 38. Preferably, the first spacer element 16 can thus have or form a channel element 29 in order to be able to discharge the gas that may form in the electrode separator unit 12 by means of the recess 28, the opening 38, and the opening 32. Preferably, a second spacer element 26 is arranged on the casing element 36, which has a plurality of recesses 28.The second spacer element 26 may preferably have a channel element 29 in order to be able to discharge a gas generated in the electrode separator unit 12 by means of a breakthrough 38 of the recess 28 and the opening 32.

[0074] Figure 5b shows a battery unit 10 according to one embodiment. As shown in Figure 5b, the electrode separator unit 12 can be enclosed by a sheath element 36. In particular, an opening 38 in the sheath element 36 can be directed towards an opening 28 in the first spacer element 16. Preferably, the first spacer element 16 can form a channel element 29 to receive any gas generated in the electrode separator unit 12 through the recess 28 and discharge it via the opening 32. Figure 5b shows a fluid flow 39, which is guided through both the opening 38 and the recess 28 by means of the channel element 29.

[0075] Figure 5c shows a battery unit 10 according to one embodiment. The battery unit 10 has a similar configuration to the battery unit 10 in Figure 5b. The electrode separator unit 12, together with the sheath element 36 and the first spacer element 16, is inserted into the housing element 14. This allows, in particular, the opening 38 and the recess 28 to be aligned with the opening 32 and the venting element 30, respectively. As shown in Figure 5c, the fluid flow 39 can exit through the opening 32.

[0076] Figure 6a shows a battery unit 10 according to one embodiment. The battery unit 10 has a contacting element 22 on the electrode separator unit 12, which is arranged on one side of the electrode separator unit 12. More preferably, the battery unit 10 has a casing element 36 on which a first spacer element 16 and a second spacer element 26 are arranged. Preferably, both the first spacer element 16 and the second spacer element 26 can have a channel element 29 to allow the gas generated in the electrode separator unit 12 to be discharged by means of the recesses 28.

[0077] Figure 6b shows a battery unit 10 according to one embodiment. The battery unit 10 has a similar structure to the battery unit 10 of Figure 6a. Preferably, the electrode separator unit 12 with the sheath element 36 can be inserted into the housing element 14. In particular, a first spacer element 16 can be arranged on the longitudinal sides to space the electrode separator unit 12 from the housing element 14 to an inner surface 18 of the housing element 14, in particular to set a predetermined distance 20. Figure 7 shows a flowchart illustrating steps of the method 200 according to one embodiment. The method 200 for manufacturing a first spacer element 16 for a battery unit 10, as described above and below, comprises the following steps:

[0078] - Providing S1 of a blank, - Creating S2 of at least one recess 28 in the blank,

[0079] - Setting S3 to a height of the blank with the recess 28 to form the first spacer element 16.

[0080] Figure 8 shows a flowchart illustrating the steps of method 200 according to one embodiment. Method 200 preferably comprises the same steps S1 to S3 as those already described with reference to Figure 7. More preferably, the

[0081] The method further comprises the steps of providing S4 of a shell blank, introducing S5 of an opening 38 into the shell blank to form the shell element 36, and positioning S6 of the first spacer element 16 on the shell element 36 such that the opening 38 and the recess 28 at least partially overlap. Figure 9 shows a vehicle 100 according to one embodiment. The vehicle 100 and / or the stationary storage unit comprise a battery unit 10, as described above and below, and / or an energy storage device, which was manufactured using the method 200, as described above and below.

Claims

Claims 1. Battery unit (10) comprising: - an electrode separator unit (12) which is configured to store, absorb and / or release electrical energy, - a housing element (14) which is designed to store the electrode separator unit (12) in an electrolyte, - a first spacer element (16) which is arranged at least partially between an inner side (18) of the housing element (14) and the electrode separator unit (12), wherein the first spacer element (16) is configured to set a predetermined distance (20) between the inner side (18) of the housing element (14) and the electrode separator unit (12).

2. Battery unit (10) according to claim 1, wherein the housing element (14) has at least one contacting element (22) which is configured to conduct electrical energy from the inside (18) to an outside (24) of the housing element (14), wherein the first spacer element (16) is arranged on a wall of the inside (18) of the housing element (14) which is free of the contacting element (22).

3. Battery unit (10) according to one of the preceding claims, wherein the first spacer element (16) has an extension height and / or a spacer element which is configured to set the predetermined distance (20).

4. Battery unit (10) according to one of the preceding claims, wherein a plurality of spacer elements is arranged on the inside (18) of the housing element (14), wherein the first spacer element (16) of the plurality of spacer elements and a second spacer element (26) of the plurality of spacer elements are arranged substantially opposite each other on the electrode separator unit (12).

5. Battery unit (10) according to one of the preceding claims, wherein the first spacer element (16) has at least one recess (28), wherein the recess (28) is configured to discharge gas generated in the electrode separator unit (12).

6. Battery unit (10) according to claim 5, wherein the first spacer element (16) has and / or forms at least one channel element (29), wherein the recess (28) is arranged in the channel element (29), wherein the channel element (29) is configured to receive and / or discharge the gas generated in the electrode separator unit (12) through the recess (28), so that gas transport is provided substantially parallel or along the housing element (14).

7. Battery unit (10) according to one of claims 5 to 6, wherein the housing element (14) has a venting element (30) which is configured to close an opening (32) of the housing element (14) during normal operation of the battery unit (10) and to release the opening (32) in the event of gas evolution in the electrode separator unit (12), wherein the opening (32) of the housing element (14) and the recess (28) of the first spacer element (16) are configured to discharge the gas generated during gas evolution from the battery unit (10).

8. Battery unit (10) according to claims 6 and 7, wherein the channel element (29) is configured to receive gas generated in the electrode separator unit (12) through the recess (28) and to discharge it via the opening (32).

9. Battery unit (10) according to one of the preceding claims, wherein the first spacer element (16) is configured to electrically isolate the electrode separator unit (12) from the housing element (14).

10. Battery unit (10) according to one of the preceding claims, wherein the first spacer element (16) comprises at least partially a polymeric material and / or a ceramic material.

11. Battery unit (10) according to one of the preceding claims, wherein the first spacer element (16) comprises at least partially a thermoplastic, a thermoset and / or an elastomer.

12. Battery unit (10) according to one of the preceding claims, wherein a sheath element (36) is arranged between the electrode separator unit (12) and the housing element (14), wherein the first spacer element (16) is arranged on the sheath element (36) to simplify the assembly of the first spacer element (16) in the housing element (14).

13. Battery unit (10) according to claim 5 and claim 12, wherein the casing element (36) has at least one opening (38), wherein the opening (38) of the casing element (36) and the recess (18) of the first spacer element (16) at least partially overlap in order to vent the gas produced.

14. Method (200) for manufacturing a first spacer element (16) for a battery unit (10) according to any of the preceding claims, comprising the steps: - Providing (S1) a blank, - Making (S2) at least one recess (28) into the blank, - Setting (S3) a height of the blank with the recess (28) to form the first spacer element (16).

15. Vehicle (100) and / or stationary storage device comprising a battery unit (10) according to any one of claims 1 to 13 and / or an energy storage device manufactured by the method (200) according to claim 14.

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