Enclosure for battery including degradable materials

Abstract

Disclosed herein is a battery assembly comprising a housing comprising plurality of walls (120) defining a space configured for positioning a battery cell (10) therein, wherein one of the walls comprises an inlet (300) for receiving a degradable coating composition (7), and wherein one of the walls comprises an outlet (400) for discharge of a degraded coating.

Description

ENCLOSURE FOR BATTERY INCLUDING DEGRADABLE MATERIALSGOVERNMENT CONTRACT

[0001] This disclosure was made with Government support under GovernmentContract No. NCMS FY2021 Adhesive Perf. Improvements Phase 2142120 awarded by the GVSC. The United States Government may have certain rights the subject matter disclosed herein.CROSS-REFERENCE TO RELATED APPLICATION

[0002] This application claims the benefit of U.S. Provisional Patent Application SerialNo. 63 / 692,315 filed on September 9, 2024, entitled “Enclosure for Battery IncludingDegradable Materials,” incorporated herein by reference in its entirety.FIELD

[0003] Enclosures for a battery including a degradable material are disclosed.SUMMARY

[0004] Disclosed herein are battery assemblies comprising: a housing comprising a plurality of walls defining a space configured for positioning a battery cell therein; wherein one of the walls comprises an inlet for receiving a degradable coating composition; and wherein one of the walls comprises an outlet for receiving a discharge of a degraded coating.

[0005] Also disclosed are vehicles comprising any of the battery assemblies disclosed herein.

[0006] Also disclosed arc systems comprising any of the battery assemblies disclosed herein; and a degradable coating composition for forming the degradable coating.

[0007] Also disclosed are kits comprising any of the battery assemblies disclosed herein; and a degradable coating composition for forming the degradable coating.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a schematic of a top-down view of cylindrical battery cells.

[0009] FIG. 2 is a schematic of an exploded isometric view of an array of prismatic battery cells.

[0010] FIG. 3 is a schematic of a front view of an array of pouch battery cells.

[0011] FIG. 4 is a schematic of an isometric view of cylindrical cells positioned in a battery module including an inlet and an outlet.

[0012] FIG. 5 is a schematic of an exploded perspective view of a battery pack comprising multiple battery cells.

[0013] FIG. 6 is a schematic of an isometric view of (A) a battery cell, (B) a battery module, and (C) a battery pack.

[0014] FIG. 7 is a schematic of a perspective view of a battery pack.

[0015] FIG. 8 is a schematic of a cell to battery pack configuration.

[0016] FIG. 9 is a schematic of an isometric cut-out view of a cell to chassis battery assembly.DETAILED DESCRIPTION

[0017] For purposes of this detailed description, it is to be understood that the disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0018] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0019] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recitedmaximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0020] As used herein, “including,” “containing” and like terms are understood in the context of this application to be synonymous with “comprising” and are therefore open-ended and do not exclude the presence of additional undescribed or unrecited elements, materials, ingredients or method steps. As used herein, “consisting of” is understood in the context of this application to exclude the presence of any unspecified element, ingredient, or method step. As used herein, “consisting essentially of’ is understood in the context of this application to include the specified elements, materials, or ingredients or method steps “and those that do not materially affect the basic and novel characteristic(s)” of what is being described. As used herein, open- ended terms include closed terms such as consisting essentially of and consisting of.

[0021] In this application, the use of the singular includes the plural, and the plural encompasses the singular, unless specifically stated otherwise. For example, although reference is made herein to “an” amine-containing compound or “a” furan-containing compound, a combination (i.e., a plurality) of these components may be used.

[0022] In addition, in this application, the use of “or” means “and / or” unless specifically stated otherwise, even though “and / or” may be explicitly used in certain instances.

[0023] As used herein, the terms “on,” “onto,” “applied on,” “applied onto,” “formed on,” “deposited on,” “deposited onto,” and the like mean formed, overlaid, deposited, or provided on, but not necessarily in contact with, a substrate surface. For example, a composition “applied onto” a substrate surface does not preclude the presence of one or more other intervening coatings of the same or different composition located between the composition and the substrate surface.

[0024] As used herein, a “coating composition” refers to a composition, e.g., a solution, mixture, or a dispersion that is capable of producing a coating on a surface of a substrate.

[0025] As used herein, “coating” refers to a cured coating composition.

[0026] As used herein, an “adhesive composition” refers to a coating composition that, in a cured state, produces an adhesive.

[0027] As used herein, “adhesive” refers to a coating or a free-standing film that forms a load-bearing joint, such as a load-bearing joint having a lap shear strength of at least 0.5 MPaand less than 5 MPa, as determined according to ASTM DI 002- 10 using an Instron 5567 machine in tensile mode with a pull rate of 1.3 mm per minute.

[0028] As used herein, a “structural adhesive” refers to a coating composition that, in a cured state, produces a structural adhesive.

[0029] As used herein, “structural adhesive” refers to a coating or a free-standing film that forms a load bearing joint having a lap shear strength of at least 5 MPa, as determined according to ASTM D1002-10 using an Instron 5567 machine in tensile mode with a pull rate of 1.3 mm per minute.

[0030] As used herein, a “gap filler composition” refers to a curable composition that, when cured, forms a gap filler.

[0031] As used herein, a “gap filler” refers to a coating that fills a gap.

[0032] As used herein, a “pottant composition” refers to a curable composition that, when cured, forms a pottant.

[0033] As used herein, a “pottant” refers to an encapsulant.

[0034] As used herein, a “pre-preg” refers to a composition pre-impregnating reinforcement fiber prior to cure.

[0035] As used herein, a “liquid shim composition” refers to a curable composition that, when cured, forms a liquid shim.

[0036] As used herein, a “liquid shim” refers to a coating that eliminates gaps between substrate surfaces.

[0037] As further defined herein, ambient conditions generally refer to room temperature (e.g., 23°C) and humidity conditions or temperature and humidity conditions that are typically found in the area in which the composition is applied to a substrate, e.g., at 10°C to 40°C and 5% to 80% relative humidity, while slightly thermal conditions are temperatures that are slightly above ambient temperature, but are generally below the curing temperature for the composition (i.e., in other words, at temperatures and humidity conditions below which the reactive components will readily react and cure, e.g., > 40°C and less than 220°C at 20% to 80% relative humidity).

[0038] As used herein, the terms “cure,” “cured,” “curing,” or the like, means that the components that form the composition are crosslinked (i.e., interact and / or react) to form a coating or a bond. In the case of a 2K composition, the composition begins to cure when thecomponents of the composition are mixed resulting in the reaction of the reactive functional groups of the components of the composition.

[0039] The term “curable,” as used, for example, in connection with a coating composition, means that the composition is able to be cured under ambient or slightly thermal conditions.

[0040] As used herein, “solvent-assisted degradable,” “solvent-assisted degradability,” and the like refer to a substance, such as a coating, that degrades upon exposure to a solvent or a blend of solvents capable of cleaving a disulfide bond, such as a reducing agent.

[0041] As used herein, “reducing agent” refers to a compound that donates electrons.

[0042] As used herein, “thermally conductive,” when used with respect to a coating, refers to a coating having a thermal conductivity of at least 0.5 W / nrK as measured using a Modified Transient Plane Source (MTPS) method (conformed to ASTM D7984) with a TCi thermal conductivity analyzer from C-Therm Technologies Ltd.

[0043] As used herein, “dielectric,” when used with respect to a coating, refers to a coating comprising a dielectric strength of at least 10 kV / mm measured using a Sefelec Dielectric Strength Tester (RMG12AC-DC; voltage limit 12.0 kV, Imax Limit 0.1 mA, 19 sec ramp, 20 sec dwell, 2 sec fall) according to ASTM D 149-09, such as at least 12 kV / mm, such as at least 15 kV / mm.

[0044] The present disclosure is directed to a battery assembly and may include a housing such as a module 100 or the like, comprising a plurality of walls defining a space configured for positioning a battery cell therein; wherein one of the walls comprises an inlet 300 for receiving a degradable coating composition; and wherein one of the walls comprises an outlet 400 for discharge of a degraded coating. See FIG. 4.

[0045] FIGS. 1 to 9 illustrate non-limiting examples of battery assembly components and constructions as well as non-limiting applications or use of compositions as disclosed herein in said battery assemblies. Although FIGS. 1 to 9 illustrate specific examples of cell shapes and cell arrangements, cells may be arranged in any configuration known to those skilled in the art.

[0046] Additionally, the battery assemblies may include a degradable coating, such as a solvent-assisted degradable coating. The degradable coating may be in the form of a film, a pad, an adhesive, a structural adhesive, a seal, a pottant, a gap filler, a pre-preg, an embeddant, an encapsulant, or the like. The degradable coating may be thermally conductive. That is, thedegradable may be formulated to provide thermal protection between battery cells, within battery modules and / or within battery packs. These materials may be used on any surface or in any space within such battery assemblies. For example, compositions disclosed herein also may be useful in battery assemblies including, but not limited to, cell to module (FIGS. 3, 4, 6B), module to pack (FIGS. 6C, 7), cell to pack (FIGS. 8), and cell to chassis battery assemblies (FIG. 9). Such battery assemblies may be used in, but not limited to, any aforementioned application.

[0047] FIG.4 illustrates an isometric view of cylindrical cells 10 in a battery module 100. Each cell may comprise a top 11, a bottom 12, and walls 13 positioned between the top and bottom and each having a surface. The top 11 and the bottom 12 may be oppositely charged terminals with one being a positive terminal 1 and the other being a negative terminal (not shown). The battery cells may be connected at their terminals by interconnectors such as wires 5 and the like to enable an electric current to flow between the electric cells. The module 100 or module walls 120 may form a space having a volume. One of the module walls 120 may have an inlet 300 and one of the module walls 120 may have an outlet 400. The inlet 300 and the outlet 400 may be configured for receiving a degradable coating composition and for discharge of a degraded coating, respectively.

[0048] The cells 10 may be positioned within the space to consume a portion of the volume. The coating 7 formed from the coating compositions disclosed herein may be positioned within the space to consume a portion of the volume such that the coating is adjacent to a surface of a cell wall 13 and / or an interior surface of one or more of the walls 120 of the module 100.

[0049] Battery assemblies may be any combination of one or more battery cells, the interconnects which provide electrical conductivity between them, as well as ancillary components such as, in non-limiting examples, control electronics and components that ensure the necessary structural, mechanical, and environmental requirements for the operation of a specific battery (for example, without limitation, cell interconnectors such as wires, battery pack enclosures including trays and lids, module enclosures, module frames and frame plates, module racking, cooling and heating components including cooling plates, cooling fins, and cooling tubes, electrical busbars, battery management systems, battery thermal management systems, chargers, inverters and converters).

[0050] Battery cells 10 are generally single unit energy storage containers that may be connected in series or in parallel. Battery cells may be any suitable size or shape known to those skilled in the art, such as but not limited to, cylindrical (FIGS. 1, 4 and 9), prismatic (FIGS. 2, 5- 8) and / or pouch (FIG. 3). Battery cells 10 are enclosed to provide desired mechanical protection and environmental isolation of the cell. For example, cylindrical and prismatic cells may be encased in metal cans, cases, and lids, while pouch cells may be enclosed in multilayer laminate foils. Battery terminals 1 connect the electrodes inside the battery cell to the electrical circuit outside the battery cell, with one being a positive terminal and the other being a negative terminal. As illustrated in FIG. 4, battery cells 10 may be connected by interconnector wires 5 with other battery cells 10 in series or in parallel to enable an electric current to flow between cells 10.

[0051] As illustrated in FIGS. 3 and 4, battery cells 10 may be arranged in modules 100 comprising multiple cells 10 connected in series or in parallel. The modules 100 may include an enclosure of the arranged cells 10. Ancillary components, such as those aforementioned, may be included. Spaces of any dimensions may be located between the plurality of cells, ancillary components, base, and / or any interior surface of the module wall or other enclosure 120.

[0052] FIG. 1 illustrates a top-down view of cylindrical battery cells 10 having terminals 1. As shown, the cells are arranged in rows with either cooling tubes 3 or dielectric insulation paper (e-paper) 4 between them. As shown, coatings 7 optionally formed from the compositions disclosed herein in a cured state, may be positioned between the cells 10, cooling tubes 3 and / or e-paper 4.

[0053] FIG. 2 illustrates an exploded isometric view of an array of prismatic battery cells 10. As shown, each prismatic cell 10 may comprise a top 11, a bottom, and walls 13 positioned between the top and bottom and each having a surface. As shown, materials, such as pads 8 formed from the compositions disclosed herein in a cured state, may be positioned between surfaces of cell walls 13 of adjacent cells 10.

[0054] FIG. 3 illustrates a cut-out front view of an array of pouch battery cells 10 in a module 100. The module walls 120 partially or fully encase the cells 10. As shown, materials, such as pads 8 formed from the compositions disclosed herein in a cured state, may be positioned between surfaces of cells 10.

[0055] FIG.5 illustrates an exploded perspective view of a battery module 100 comprised of one or more arrays of battery cells 10, a cooling fin 230, and a cooling plate 240. Materials, such as pads 8 formed from the compositions disclosed herein in a cured state, may be positioned between cells 10. Additional pads 8 may be positioned between the cells 10, the cooling fin 230, the cooling plate 240, and / or an interior surface of walls 120. Other pads 8 may be positioned adjacent to an exterior surface of the walls 120.

[0056] FIG. 6 illustrates an isometric view of a battery cell 10 (FIG.6A) to battery module 100 (FIG.6B) to battery pack 200 (FIG.6C) battery assembly. The battery module 100 comprises a plurality of battery cells 10 and the battery pack 200 comprises a plurality of battery modules 100.

[0057] FIG. 7 illustrates a perspective view of a battery pack 200 cutout. The battery pack includes a plurality of battery modules 100 and cells 10 within each module 100. The base of the battery pack 200 comprises a cooling plate 240. Materials, such as adhesives, 9 formed from the compositions disclosed herein in a cured state, may be positioned between the cooling plate 240 and interior surface of a wall of the battery pack 200. Materials, such as pads 8 formed from the compositions disclosed herein in a cured state, may be positioned between cells 10 within modules 100.

[0058] FIG.8 illustrates an isometric view of a cell 10 to pack battery 200 assembly.Cells 10 are arranged within the pack 200 (without being in separate modules).

[0059] In other cases, the battery cells may be arranged on or within an article such as, but not limited to, a cell to chassis battery assembly, as illustrated in FIG. 9, wherein one or more cells is used to construct the battery assembly without prior assembly of the cells into modules and / or packs. FIG. 9 illustrates an isometric cut-out view of a cell to chassis battery assembly 300. Cells 10 are arranged on a base comprising the undercarriage 55 and supported by the vehicle frame 45 and under the vehicle interior floor 35.

[0060] Any battery assembly may further comprise a thermal management system comprising air or fluid circuits which may be liquid based (for example glycol solutions) or direct refrigerant based.

[0061] Also disclosed herein are systems comprising any of the battery assemblies described above and a degradable coating composition for forming the degradable coating. Thesystem may further comprise a solvent for degrading, such as chemically degrading, the coating and / or may further comprise a dielectric coating composition for forming the dielectric coating.

[0062] Also disclosed are kits comprising any of the battery assemblies described above, and a degradable coating composition for forming the degradable coating. The kit may further comprise a solvent for degrading, such as chemically degrading, the coating. The kit may further comprise a dielectric coating composition for forming the dielectric coating. The kit may further comprise instructions for inputting the degradable coating composition through the inlet, curing the coating composition, degrading the coating, and / or removing the degraded coating through the outlet. The kit may further comprise instructions for curing the dielectric coating composition.

[0063] Suitable solvents include but are not limited to DMF, TEP, acetone, caprolactone, ethanol, isopropanol, or combinations thereof.

[0064] The battery assemblies disclosed herein are not limited and may be particularly suitable for use in various vehicles. As used herein, “vehicle” or variations thereof includes, but is not limited to, civilian and military vehicles, such as automobiles, motorcycles, and / or trucks, light and heavy commercial vehicles, and / or civilian and military aircraft.

[0065] Whereas specific aspects of the disclosure have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosure which is to be given the full breadth of the claims appended and any and all equivalents thereof.

Claims

We claim:

1. A battery assembly comprising: a housing comprising plurality of walls defining a space configured for positioning a battery cell therein; wherein one of the walls comprises an inlet for receiving a degradable coating composition; and wherein one of the walls comprises an outlet for discharge of a degraded coating.

2. The battery assembly of claim 1, further comprising the battery cell.

3. The battery assembly of claim 1 or claim 2, further comprising a battery component.

4. The battery assembly of any of the preceding claims, adjacent to a vehicle chassis.

5. The battery assembly of any of the preceding claims, wherein the degradable coating composition comprises a film-forming composition, an adhesive composition, a structural adhesive composition, a sealing composition, a pottant composition, a gap filler composition, a pre-preg composition, an embedding composition, an encapsulating composition, a foam composition, or the like.

6. The battery assembly of claim 5, wherein the coating composition, in a cured state, forms a coating positioned within the space adjacent to a surface of a cell wall of the battery cell and / or adjacent to an interior surface of one of the plurality of walls.

7. The battery assembly of any of the preceding claims, wherein the coating comprises a film, an adhesive, a structural adhesive, a seal, a pottant, a gap filler, a pre-preg, an embeddant, an encapsulant, a foam, or the like.

8. The battery assembly of any of the preceding claims, wherein the coating is a thermally conductive coating and / or a dielectric coating.

9. A vehicle comprising the battery assembly of any of the preceding claims.

10. The vehicle of claim 9, wherein the vehicle comprises a land vehicle or an aircraft.

11. A system comprising: the battery assembly of any of claims 1 to 8; and the degradable coating composition for forming the degradable coating.

12. The system of claim 11, further comprising a solvent for degrading the coating and / or a dielectric coating composition for forming the dielectric coating.

13. The system of claim 11 or claim 12, wherein the solvent comprises DMF, TEP, acetone, caprolactone, ethanol, and / or isopropanol.

14. A kit comprising: the battery assembly of any of claims 1 to 8; and the degradable coating composition for forming the degradable coating.

15. The kit of claim 14, further comprising a solvent for degrading the coating.

16. The kit of claim 14 or claim 15, wherein the solvent comprises DMF, TEP, acetone, caprolactone, ethanol, and / or isopropanol17. The kit of any of claims 14 to 16, further comprising a dielectric coating composition for forming the dielectric coating.

18. The kit of any of claims 14 to 17, further comprising instructions for inputting the degradable coating composition through the inlet, curing the degradable coating composition, degrading the coating, and / or removing the degraded coating through the outlet.

19. The kit of any of claims 14 to 18, further comprising instructions for curing the dielectric coating composition.

Images