Battery pack for BEV with inter-cell thermal barriers
The battery pack design with spacers addresses thermal barrier challenges in electric vehicle cells, ensuring effective thermal management and scalability through cost-effective, compressible and insulating spacers with optional cooling channels.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- SABIC GLOBAL TECHNOLOGIES BV
- Filing Date
- 2025-12-11
- Publication Date
- 2026-07-02
AI Technical Summary
Existing battery packs for electric vehicles face challenges with inter-cell thermal barriers, particularly in prismatic or pouch cells, where current solutions are costly and complex, making them incompatible with large-scale production requirements.
A battery pack design featuring spacers with a fire-retardant center layer sandwiched between compressible layers, configured with variable or constant thickness and optionally including cooling channels, to manage thermal expansion and prevent thermal runaway.
The spacer design effectively limits thermal runaway propagation, accommodates cell swelling, and is cost-effective for high-volume production, while maintaining electrical insulation and enabling coolant circulation.
Smart Images
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Abstract
Description
24POLY0037-WO-ORD1BATTERY PACK FOR BEV WITH INTER-CELL THERMAL BARRIERSBACKGROUND
[0001] The disclosure is directed to battery packs and more specifically to a battery pack for a battery electronic vehicle (BEV) with inter-cell thermal barriers.
[0002] With increased safety requirements of battery packs for electric powered vehicles (EVs) and the continuous energy densification of cells, there are challenges with respect to intercell (prismatic or pouch) thermal barriers. Some technical solutions may combine the use of relatively expensive and complex components, which may not be compatible with an up-scaling of production requirements.BRIEF SUMMARY
[0003] This disclosure provides a battery pack for a battery electronic vehicle (BEV), the battery pack including: a housing; battery cells within the housing, arranged adjacent to one another, the battery cells extending between first and second cell ends that are longitudinally spaced apart from each other, wherein the battery cells define cell mate faces that face one another in the battery pack, wherein the cell mate faces extend between the first and second cell ends; a spacer disposed between the cell mate faces to separate adjacent ones of the battery cells, the spacer extends between first and second spacer ends that are aligned with the first and second cell ends; wherein the spacer is formed of a spacer center layer that is a fire retardant, and the spacer center layer is sandwiched between first and second spacer compressible layers such that the first and second spacer compressible layers defines ones of first and second spacer sidewalls that24POLY0037-WO-ORD2face ones of the cell mate faces; and wherein the spacer is configured with a variable thickness between the first and second spacer ends.
[0004] This disclosure also provides another embodiment of the battery pack for a battery electronic vehicle (BEV), the battery pack including: a housing; battery cells within the housing, arranged adjacent to one another, the battery cells extending between first and second cell ends that are longitudinally spaced apart from each other, wherein the battery cells define cell mate faces that face one another in the battery pack, wherein the cell mate faces extend between the first and second cell ends; a spacer disposed between the cell mate faces to separate adjacent ones of the battery cells, wherein the spacer extends between first and second spacer ends that are aligned with the first and second cell ends; wherein the spacer is formed of a spacer center layer that is a compressible, and the spacer center layer is sandwiched between first and second spacer fire retardant layers such that the first and second spacer fire retardant layers defines ones of first and second spacer sidewalls that face one of the cell mate faces; and wherein one of the first and second spacer sidewalls defines one or more spacer cooling channels; and a coolant is configured to flow through the one or more spacer cooling channels.BRIEF DESCRIPTION OF THE DRAWINGS24POLY0037-WO-ORD3
[0005] The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements.
[0006] FIG. 1 shows a battery pack for a battery electronic vehicle (BEV), according to an embodiment;
[0007] FIG. 2 shows a part view of the battery pack, including battery cells and a spacer between the battery cells, where the spacer has a center fire retardant layer and first and second outer foam layers, according to an embodiment;
[0008] FIG. 3 shows an embodiment of the spacer with a convex cross section, according to an embodiment;
[0009] FIG. 4 shows the battery pack as deformed from thermal expansion at a center region and utilizing the spacer of FIG. 3, according to an embodiment;
[0010] FIG. 5 shows an embodiment of the spacer with a concave cross section, according to an embodiment;
[0011] FIG. 6 shows the battery pack as deformed from thermal expansion at a center region, utilizing the spacer of FIG. 5, according to an embodiment;
[0012] FIG. 7 shows an embodiment of the spacer with a constant outer cross section thickness and a center layer with a convex cross section;
[0013] FIG. 8 shows an embodiment of the spacer with a constant outer cross section thickness and a center layer with a concave cross section;24POLY0037-WO-ORD4
[0014] FIG. 9 shows a batery pack for a batery electronic vehicle (BEV), where the batery pack has coolant ports, according to an embodiment;
[0015] FIG. 10 shows a side view of an embodiment of the batery pack including batery cells and a spacer between the batery cells, where the spacer has a center foam layer and first and second outer fire retardant layers, where the first and second outer fire retardant layers are against sidewalls of the batery cells and define coolant channels; and
[0016] FIG. 11 shows an end view of the embodiment of FIG. 10.DETAILED DESCRIPTION
[0017] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0018] Turning to FIG. 1, disclosed is a batery pack 100 for a batery electronic vehicle (BEV) 110. The batery pack 100 has a housing 120.
[0019] As shown in greater detail in FIG. 2, the housing 120 (FIG. 1) contains first and second batery cells 130A, 130B (generally referred to as batery cells 130). The batery cells 130 may be prismatic cells that are stacked as a row of cells. That is, the batery cells 130 are arranged adjacent to one another. The batery cells 130 are configured similarly to each other so that reference to features of the first batery cell 130A apply to the second batery cell 130B. The batery cells 130 extend between first and second cell ends 140A, 140B (generally referred to as cell ends 140). The cell ends 140 are longitudinally spaced apart from each other, e.g., along a longitudinal direction 150A.24POLY0037-WO-ORD5
[0020] The batery cells 130, at the cell ends 140, each define first and second cell end walls 142A, 142B (generally referred to as cell end walls 142). Along a depthwise direction 15 OB, the batery cells 130 each define first and second cell peripheral walls 144A, 144B (generally referred to as cell peripheral walls 144). Along a transverse direction 150C, the batery cells 130 each define first and second cell sidewalls 146A, 146B (generally referred to as cell sidewalls 146). It is to be appreciated that the use of “end wall,” “peripheral wall” and “sidewall” are for convenience only.
[0021] The cell sidewalls 146 that face each other respectively define first and second cell mate faces 160A, 160B (generally referred to as cell mate faces 160). That is, the cell mate faces 160 face one another in the batery pack 100. The cell mate faces 160 extend longitudinally and depthwise between the cell ends 140 and the peripheral walls 144 of the batery cells 130.
[0022] A spacer 170 is disposed between the cell mate faces 160 to separate adjacent ones of the batery cells 130. The spacer 170 extends longitudinally between first and second spacer ends 172A, 172B (generally referred to as spacer ends 172). Along the depthwise direction 150B, the spacer 170 defines first and second spacer peripheral walls 174A, 174B (generally referred to as spacer peripheral walls 174). Along the transverse direction 150C, the spacer 170 defines first and second sidewalls 176A, 176B (generally referred to as spacer sidewalls 176). The spacer sidewalls 176 face ones of the cell mate faces 160 of the batery cells 130. The spacer ends 172 are longitudinally aligned with the cell ends 140. The spacer peripheral walls 174 are depthwise aligned with the cell peripheral walls 144. That is, the spacer 170 and batery cells 130 have a same height H and depth D as each other.24POLY0037-WO-ORD6
[0023] The spacer 170 is formed of a spacer center layer 180 that is a fire retardant, e.g., an intumescent material. The spacer center layer 180 is sandwiched between first and second spacer compressible layers 190A, 190B (generally referred to as spacer compressible layers 190). The spacer compressible layers 190 may be made of foam. More specifically, the spacer compressible layers 190 may be formed of the same foam as each other, though they may be formed of different foams. The spacer compressible layers 190 respectively define the spacer sidewalls 176.
[0024] According to one or more of the embodiments, the spacer 170 is configured with a variable thickness T1 between the spacer sidewalls 176. That is, the thickness T1 is along the transverse direction 150C. The thickness T1 changes depending on a longitudinal position of the spacer 170, i.e., between the spacer ends 172.
[0025] Tuning to FIG. 3, the spacer 170 is configured such that the first and second spacer sidewalls 176A, 176B together define a convex shape so that the thickness T1 of the spacer 170 is largest at its longitudinal center. The spacer center layer 180 has a constant thickness T2 between the first and second spacer ends 172A, 172B, i.e., the first and second cell ends 140A, 140B of the battery cell 130 (FIG. 4). FIG. 4 shows the resulting shape of the spacer 170 when pressed with pressure Pl between the cells 130 of the battery pack 110, e.g., due to warpage or thermal expansion of the cells 130. The spacer compressible layers 190 are pressed into a flat shape, reducing strain and reactive forces on the cells 130.
[0026] Tuning to FIG. 5, the spacer 170 is configured such that the first and second spacer side walls 176 A, 176B together define a concave shape, so that the thickness T1 of the spacer 170 is smallest at its longitudinal center. The spacer center layer 180 has a constant24POLY0037-WO-ORD7thickness T2 between the first and second spacer ends 172A, 172B, i.e., the first and second cell ends 140A, 140B of the battery cell 130 (FIG. 6). FIG. 6 shows the resulting shape of the spacer 170 when pressed with pressure Pl between the cells 130 of the battery pack 110, e.g., due to warpage or thermal expansion of the cells 130. The battery pack 110 is able to expand into areas defined by the concave shape of the first and second spacer sidewalls 176A, 176B, reducing strain and reactive forces on the cells 130. In this embodiment, the spacer compressible layers 190, when compressed, may maintain a concave shape.
[0027] Turning to FIG. 7 an alternative configuration of the spacer 170 is shown. The spacer 170 defines a constant thickness T1 between the first and second spacer ends 172 A, 172B. The spacer center layer 180 defines a convex profile between the first and second spacer endsl72A, 172B. The first and second compressible layers 190A, 190B are shaped to conform to the spacer center layer 180. This configuration would help reduce stress in battery cells 130 that may expand at the first and second cell end walls 142A,142B (FIG. 2) of the battery cells 130.
[0028] Turning to FIG. 8, an alternative configuration of the spacer 170 is shown. The spacer 170 is, overall, define a constant thickness T1 between the first and second spacer ends 172A, 172B. The spacer center layer 180 defines a concave profile between the first and second spacer ends 172A, 172B. The first and second spacer compressible layers 190A, 190B are shaped to conform to the spacer center layer 180. This configuration would help reduce stress in the battery cells 130 that may expand at the longitudinal center, e.g., midway between the first and second cell end walls 142A, 142B (FIG. 2) of the battery cells 130.
[0029] Turning to FIG. 9, disclosed is a battery pack 100 for a battery electronic vehicle (BEV) 110. The battery pack 100 has a housing 120. The housing has first and second ports24POLY0037-WO-ORD8122A, 122B (generally referred to as ports 122). The ports 122 are utilized for a coolant inlet and outlet flow.
[0030] As shown in greater detail in FIGs. 10 and 11, the housing 120 (FIG. 9) contains first and second battery cells 130A, 130B (generally referred to as battery cells 130). The battery cells 130 may be prismatic cells that are stacked as a row of cells. That is, the battery cells 130 are arranged adjacent to one another. The battery cells 130 are configured similarly to each other so that reference to features of the first battery cell 130A apply to the second battery cell 130B. The battery cells 130 extend between first and second cell ends 140A, MOB (generally referred to as cell ends 140). The cell ends 140 are longitudinally spaced apart from each other, e.g., along a longitudinal direction 150A.
[0031] The battery cells 130, at the cell ends 140, each define first and second cell end walls 142A, 142B (the first and second cell end walls 142A, 142B are generally referred to as cell end walls 142). Along a depthwise direction 150B, the battery cells 130 each define first and second cell peripheral walls 144A, 144B (generally referred to as cell peripheral walls 144). Along a transverse direction 150C, the battery cells 130 each define first and second cell sidewalls 146A, 146B (generally referred to as cell sidewalls 146). It is to be appreciated that the use of “end wall,” “peripheral wall” and “sidewall” are for convenience only.
[0032] The cell sidewalls 146 that face each other respectively define first and second cell mate faces 160A, 160B (generally referred to as cell mate faces 160). That is, the cell mate faces 160 face one another in the battery pack 100. The cell mate faces 160 extend longitudinally between the cell ends 140 of the battery cells 130.24POLY0037-WO-ORD9
[0033] A spacer 170 is disposed between the cell mate faces 160 to separate adjacent ones of the battery cells 130. The spacer 170 extends longitudinally between first and second spacer ends 172A, 172B (generally referred to as spacer ends 172). Along a depthwise direction 150B, the spacer 170 defines first and second spacer peripheral walls 174A, 174B (generally referred to as spacer peripheral walls 174). Along a transverse direction 150C, the spacer 170 defines first and second spacer sidewalls 176A, 176B (generally referred to as spacer sidewalls 176). The spacer 170 may define a constant thickness T1 between the spacer sidewalls 176. The spacer ends 172 are longitudinally with the cell ends 140 of the battery cell 130. The spacer peripheral walls 174 are depthwise aligned with the cell peripheral walls 144. That is, the spacer 170 and battery cell 130 have a same height H and depth D as each other.
[0034] The spacer 170 is formed of a spacer center layer 200 that is a compressible, and in one embodiment made of foam. The spacer center layer 200 is sandwiched between first and second spacer fire retardant layers 210A, 210B (generally referred to as spacer fire retardant layers 210). The spacer fire retardant layers 210 may be made of the same material as each other, though they may be made of different materials. In an embodiment spacer fire retardant layers 210 may be made of an intumescent material. The first spacer fire retardant layer 210A defines the first spacer sidewall 176Athat faces one of the cell mate faces 160 of the battery cells 130. The second spacer fire retardant layer 210B defines the second spacer sidewall 176B that faces another one of the cell mate faces 160 of the battery cells 130.
[0035] At least one of the spacer sidewalls 176 defines one or more spacer cooling channels 220, though alternatively and as shown in FIG. 10, both of the spacer sidewalls 176 defines the one or more spacer cooling channels 220. The spacer cooling channels 220 may extend in the longitudinal direction 150A. A coolant 230 is configured to flow through the one or24POLY0037-WO-ORD10more spacer cooling channels 220. The coolant 230 may be a dielectric fluid. The one or more spacer cooling channels 220 are shown as six cooling channels distributed along the depthwise direction 150B. This configuration is not intended on limiting the scope of the embodiment.
[0036] According to the embodiments, prismatic or pouch cells may require certain amounts of pre-compression to obtain optimal performance. In addition, the cells (during the charging and discharging cycle) may swell and contract. The swelling (or contracting) may increase during use. According to the embodiments, the cells are configured with thermal barriers, or spacers, disclosed above, between groups of cells to limit the thermal runaway propagation if a cell undergoes a thermal event. The spacers disclosed herein enable stopping of propagation of thermal runaway in electric battery modules or packs that utilize prismatic or pouch cells and are shaped to provide an initial reaction force that provides relatively optimal use conditions. The spacer configurations enable breathing and swelling of cells, and are manufactured at a cost position compatible with high production volume to serve EV (electric vehicle) and stationary storage batteries. The materials used for the spacer are also electrically insulating. Different spacer shapes are provided to provide different loads to better fit the needs of prismatic cells.
[0037] With the embodiments, the layered sandwich thermal barrier, i.e., the spacer, has layers of compressible foam that allows swelling or breathing. The spacer has layer(s) of STAMAX FR PPLGF that limits cell to cell thermal runway propagation. The foam layer thickness can be designed to provide desired average pressure throughout the cell wall and also can be contoured to keep the pressure as uniform as possible. The thermal barrier in the spacer can have variable thickness of one or both of the layers to obtain the desired average and peak pressure profile on the cell walls during the operation of the cells. The embodiments include utilization of a compressible material which may be polyolefin-based foam. PP and PE based24POLY0037-WO-ORD11foams may be more sensitive to an excessive compression, hence the embodiments include, in a solid part, a compression limiter, such as a rigid intumescent layer.
[0038] The designed spacers in the foam-solid-foam sandwich prevent the foam from being crushed over the whole surface and therefore prevents the cell from unevenly expanding and cracking a typical sidewall coating. The configuration of the embodiments can be adjusted to fulfill the need of immersion cooling technologies, allowing the circulation of dielectric fluid in contact with cell surface.
[0039] The polymeric material is chosen based upon the desired properties, such as thermal stability. Examples of polymeric materials include, but are not limited to, polyesters, polycarbonates, polystyrenes (e.g., copolymers of polycarbonate and styrene, polyphenylene ether-polystyrene blends), polyimides (e.g., polyetherimides), acrylonitrile-styrene-butadiene (ABS), polyarylates, polyalkylmethacrylates (e.g., polymethylmethacrylates (PMMA)), polyolefins (e.g., polypropylenes (PP) and polyethylenes, high density polyethylenes (HDPE), low density polyethylenes (LDPE), linear low density polyethylenes (LLDPE)), polyamides (e.g., polyamideimides), polyarylates, polysulfones (e.g., polyarylsulfones, polysulfonamides), polyphenylene sulfides, polytetrafluoroethylenes, polyethers (e.g., polyether ketones (PEK), polyether etherketones (PEEK), polyethersulfones (PES)), polyacrylics, polyacetals, polybenzoxazoles (e.g., polybenzothiazinophenothiazines, polybenzothiazoles), polyoxadiazoles, polypyrazinoquinoxalines, polypyromellitimides, polyquinoxalines, polybenzimidazoles, polyoxindoles, polyoxoisoindolines (e.g., polydioxoisoindolines), polytriazines, polypyridazines, polypiperazines, polypyridines, polypiperidines, polytriazoles, polypyrazoles, polypyrrolidones, polycarboranes, polyoxabicyclononanes, polydibenzofurans, polyphthalamide, polyacetals, polyanhydrides, polyvinyls (e.g., polyvinyl ethers, polyvinyl thioethers, polyvinyl alcohols,24POLY0037-WO-ORD12polyvinyl ketones, polyvinyl halides, polyvinyl nitriles, polyvinyl esters, polyvinylchlorides), polysulfonates, polysulfides, polyureas, polyphosphazenes, polysilazanes, poly siloxanes, fluoropolymers (e.g., polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), fluorinated ethylene-propylene (FEP), polyethylene tetrafluoroethylene (ETFE)), polycarbonate -siloxane block copolymer (such as LEXAN™ EXL Resin), terephthalate ester of resorcinol (ITR) (such as LEXAN™ SLX Resin), N-phenylphenol phthaleinylbisphenol (PPPBP) (such as LEXAN™ XHT Resin), or a combination comprising at least one of the foregoing.
[0040] The part can comprise a polyester. Polyesters include those derived from an aliphatic, cycloaliphatic, or aromatic diol, or mixtures thereof, containing from 2 to about 10 carbon atoms and an aliphatic, cycloaliphatic, or aromatic dicarboxylic acid, and have repeating units of the following general formula:
[0042] wherein n is an integer of from 2 to 6, and R1and R2are each independently a divalent C1-C20 aliphatic radical, a C2-C12 cycloaliphatic alkyl radical, or a C6-C24 aromatic radical. The polyesters can be formed from terephthalic acid and a combination of ethylene glycol and cyclohexadimethanol, for example, formed from terephthalic acid and a combination of ethylene glycol, diethylene glycol and cyclohexadimethanol. Examples of polyesters include at least one of polyethylene terephthalate), spiroglycol modified polyethylene terephthalate, polycyclohexylenedimethylene terephthalate glycol, poly(l,4-cyclohexylenedimethylene 1,4-cyclohexanedicarboxylate), and polyethyelene naphthalate, poly-cyclohexylenedimethylene-terephthalate-glycol, polycyclohexylenedimethylene terephthalate, or polyethylene terephthalate24POLY0037-WO-ORD13with diethylene glycol. The polyester can comprises polyethylene terephthalate) ("PET"), e.g., unmodified PET. The polyester can comprise spiroglycol modified amorphous PET.
[0043] The system disclosed herein include(s) at least one of the following aspects:
[0044] According to a first aspect of the disclosure, disclosed is a battery pack for a battery electronic vehicle (BEV), the battery pack including: a housing; battery cells within the housing, arranged adjacent to one another, the battery cells extending between first and second cell ends that are longitudinally spaced apart from each other, wherein the battery cells define cell mate faces that face one another in the battery pack, wherein the cell mate faces extend between the first and second cell ends; a spacer disposed between the cell mate faces to separate adjacent ones of the battery cells, the spacer extends between first and second spacer ends that are aligned with the first and second cell ends; wherein the spacer is formed of a spacer center layer that is a fire retardant, and the spacer center layer is sandwiched between first and second spacer compressible layers such that the first and second spacer compressible layers defines ones of first and second spacer sidewalls that face ones of the cell mate faces; and wherein the spacer is configured with a variable thickness between the first and second spacer ends.
[0045] According to a second aspect of the disclosure directed to the battery pack, the spacer is configured such that the first and second spacer sidewalls define a convex shape, and the spacer center layer has a constant thickness between the first and second spacer ends.24POLY0037-WO-ORD14
[0046] According to a third aspect of the disclosure directed to the battery pack, the spacer is configured such that the first and second spacer sidewalls define a concave shape, and the spacer center layer has a constant thickness between the first and second spacer ends.
[0047] According to a fourth aspect of the disclosure directed to the battery pack, the spacer defines a constant thickness between the first and second spacer ends; and the spacer center layer defines a convex profile between the first and second spacer ends, and the first and second spacer compressible layers are shaped to conform to the spacer center layer.
[0048] According to a fifth aspect of the disclosure directed to the battery pack, the spacer defines a constant thickness between the first and second spacer ends; and the spacer center layer defines a concave profile between the first and second spacer ends, and the first and second spacer compressible layers are shaped to conform to the spacer center layer.
[0049] According to a sixth aspect of the disclosure directed to the battery pack, the spacer center layer is formed of an intumescent material.
[0050] According to a seventh aspect of the disclosure directed to the battery pack, the first spacer compressible layer is foam.
[0051] According to an eighth aspect of the disclosure directed to the battery pack, the first and second spacer compressible layers are the same material as each other.24POLY0037-WO-ORD15
[0052] According to a ninth aspect of the disclosure directed to the battery pack, the battery cells are prismatic cells that are stacked as a row of cells.
[0053] According to a tenth aspect of the disclosure directed to the battery pack, the battery cells include: first and second cell end walls that are longitudinally spaced apart from each other; first and second cell peripheral walls that are depthwise spaced apart from each other; and first and second cell sidewalls that extend transversely spaced apart from each other, and wherein the first and second cell sidewalls define the cell mate faces between adjacent ones of the battery cells.
[0054] According to an eleventh aspect of the disclosure directed to another embodiment of the battery pack for a battery electronic vehicle (BEV), the battery pack includes a housing; battery cells within the housing, arranged adjacent to one another, the battery cells extending between first and second cell ends that are longitudinally spaced apart from each other, wherein the battery cells define cell mate faces that face one another in the battery pack, wherein the cell mate faces extend between the first and second cell ends; a spacer disposed between the cell mate faces to separate adjacent ones of the battery cells, wherein the spacer extends between first and second spacer ends that are aligned with the first and second cell ends; wherein the spacer is formed of a spacer center layer that is a compressible, and the spacer center layer is sandwiched between first and second spacer fire retardant layers such that the first and second spacer fire retardant layers defines ones of first and second spacer sidewalls that face one of the cell mate faces; and wherein one of the first and second spacer sidewalls defines one or more24POLY0037-WO-ORD16spacer cooling channels; and a coolant is configured to flow through the one or more spacer cooling channels.
[0055] According to a twelfth aspect of the disclosure directed to another embodiment of the battery pack, the coolant is a dielectric fluid.
[0056] According to a thirteenth aspect of the disclosure directed to another embodiment of the battery pack, the one or more spacer cooling channels includes a plurality of the spacer colling channels, distributed depthwise along the spacer.
[0057] According to a fourteenth aspect of the disclosure directed to another embodiment of the battery pack, both of the first and second spacer sidewalls defines the one or more spacer cooling channels.
[0058] According to a fifteenth aspect of the disclosure directed to another embodiment of the battery pack, the spacer defines a constant thickness between the first and second spacer ends.
[0059] According to a sixteenth aspect of the disclosure directed to another embodiment of the battery pack, the spacer center compressible layer is foam.
[0060] According to a seventeenth aspect of the disclosure directed to another embodiment of the battery pack, the first spacer fire retardant layer is formed of an intumescent material.24POLY0037-WO-ORD17
[0061] According to an eighteenth aspect of the disclosure directed to another embodiment of the battery pack, the second spacer fire retardant layer is the same material as the first spacer fire retardant layer.
[0062] According to a nineteenth aspect of the disclosure directed to another embodiment of the battery pack, the battery cells are prismatic cells that are stacked as a row of cells.
[0063] According to a twentieth aspect of the disclosure directed to another embodiment of the battery pack, the battery cells include: first and second cell end walls that are longitudinally spaced apart from each other; first and second cell peripheral walls that are depthwise spaced apart from each other; and first and second cell sidewalls that are transversely spaced apart from each other, and wherein the first and second cell sidewalls define the cell mate faces between adjacent ones of the battery cells.
[0064] In general, the invention may alternately comprise, consist of, or consist essentially of, any appropriate components herein disclosed. The invention may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any components, materials, ingredients, adjuvants or species used in the prior art compositions or that are otherwise not necessary to the achievement of the function and / or objectives of the present invention. The endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., ranges of “less than or equal to 25 wt%, or 5 wt% to 20 wt%,” is inclusive of the endpoints and all intermediate values of the ranges of “5 wt% to 25 wt%,” etc.). Disclosure of a narrower range or more specific group in addition to a broader range is not a24POLY0037-WO-ORD18disclaimer of the broader range or larger group. “Combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. Furthermore, the terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to denote one element from another. The terms “a” and “an” and “the” herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and / or.” The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the film(s) includes one or more films). Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure, and / or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.
[0065] The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). The notation “+ 10%” means that the indicated measurement can be from an amount that is minus 10% to an amount that is plus 10% of the stated value. The terms “front”, “back”, “bottom”, and / or “top” are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation. “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which24POLY0037-WO-ORD19this invention belongs. A “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.
[0066] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
[0067] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
Claims
24POLY0037-WO-ORD20We claim:1) A battery pack for a battery electronic vehicle (BEV), the battery pack comprising:a housing;battery cells within the housing, arranged adjacent to one another, the battery cells extending between first and second cell ends that are longitudinally spaced apart from each other,wherein the battery cells define cell mate faces that face one another in the battery pack, wherein the cell mate faces extend between the first and second cell ends;a spacer disposed between the cell mate faces to separate adjacent ones of the battery cells, the spacer extends between first and second spacer ends that are aligned with the first and second cell ends,wherein the spacer is formed of a spacer center layer that is a fire retardant, and the spacer center layer is sandwiched between first and second spacer compressible layers such that the first and second spacer compressible layers define ones of first and second spacer sidewalls that face ones of the cell mate faces, andwherein the spacer is configured with a variable thickness between the first and second spacer ends.2) The battery pack of claim 1, wherein:24POLY0037-WO-ORD21the spacer is configured such that the first and second spacer sidewalls define a convex shape; andthe spacer center layer has a constant thickness between the first and second spacer ends.3) The battery pack of claim 1 or 2, wherein:the spacer is configured such that the first and second spacer sidewalls define a concave shape; andthe spacer center layer has a constant thickness between the first and second spacer ends.4) The battery pack of any of claims 1-3, wherein:the spacer defines a constant thickness between the first and second spacer ends; andthe spacer center layer defines a convex profile between the first and second spacer ends, and the first and second spacer compressible layers are shaped to conform to the spacer center layer.5) The battery pack of any of claims 1-4, wherein:the spacer defines constant thickness between the first and second spacer ends; and24POLY0037-WO-ORD22the spacer center layer defines a concave profile between the first and second spacer ends, and the first and second spacer compressible layers are shaped to conform to the spacer center layer.6) The battery pack of any of claims 1-5, wherein:the spacer center layer is formed of an intumescent material; andthe spacer compressible layers are formed of foam.7) The battery pack of any of claims 1-6, wherein the battery cells include:first and second cell end walls that are longitudinally spaced apart from each other;first and second cell peripheral walls that are depthwise spaced apart from each other; andfirst and second cell sidewalls that extend transversely spaced apart from each other,wherein the first and second cell sidewalls define the cell mate faces between adjacent ones of the battery cells.8) A battery pack for a battery electronic vehicle (BEV), the battery pack comprising:a housing;24POLY0037-WO-ORD23battery cells within the housing, arranged adjacent to one another, the battery cells extending between first and second cell ends that are longitudinally spaced apart from each other,wherein the battery cells define cell mate faces that face one another in the battery pack, wherein the cell mate faces extend between the first and second cell ends;a spacer disposed between the cell mate faces to separate adjacent ones of the battery cells, wherein the spacer extends between first and second spacer ends that are aligned with the first and second cell ends,wherein the spacer is formed of a spacer center layer that is compressible, and the spacer center layer is sandwiched between first and second spacer fire retardant layers such that the first and second spacer fire retardant layers define ones of first and second spacer sidewalls that face one of the cell mate faces; andwherein one or both of the first and second spacer sidewalls defines one or more spacer cooling channels; anda coolant is configured to flow through the one or more spacer cooling channels.9) The battery pack of claim 8, wherein the coolant is a dielectric fluid.10) The battery pack of claim 8 or 9, wherein the one or more spacer cooling channels includes a plurality of the spacer colling channels, distributed depthwise along the spacer.24POLY0037-WO-ORD2411) The battery pack of any of claims 8-10, wherein both of the first and second spacer sidewalls defines the one or more spacer cooling channels.12) The battery pack of any of claims 8-11, wherein the spacer defines a constant thickness between the first and second spacer ends.13) The battery pack of any of claims 8-12, wherein the spacer center layer is foam.14) The battery pack of any of claims 8-13, wherein the first spacer fire retardant layer is formed of an intumescent material.15) The battery pack of any of claims 8-14, wherein the battery cells include:first and second cell end walls that are longitudinally spaced apart from each other;first and second cell peripheral walls that are depthwise spaced apart from each other; andfirst and second cell sidewalls that are transversely spaced apart from each other,wherein the first and second cell sidewalls define the cell mate faces between adjacent ones of the battery cells.