DE102010004828A1 - battery pack - Google Patents

Abstract

The invention relates to a high-performance battery, in particular for operating an electric motor vehicle drive motor, with a plurality of electrical, preferably in series, interconnected battery packs (1) each having a battery (2), which is sheathed with a battery casing (3), wherein the battery casing ( 3) comprises at least one battery pack (1), preferably each battery pack (1), a laminate film (4) or consists of this, which comprises: • a metal foil (8), • one on the side facing away from the battery (2) Metal foil (8) arranged base film (12) made of plastic, • at least one on the metal foil (8) applied protective layer (7) on the battery (2) facing side of the metal foil (8), • an inner layer (5) made of plastic, An adhesive layer (6) arranged between the protective layer (7) and the inner layer (5), wherein the adhesive layer (6) comprises or is a thermosetting adhesive layer.

Description

The invention relates to a high-performance battery, in particular for operating a drive motor of an electric motor vehicle. Furthermore, the invention relates to a system comprising an electrical (large) consumer and such a high-performance battery.

Low-power batteries for small electrical appliances, such as mobile phones, are well known. Low-power batteries usually consist of a sheathed battery pack and are characterized by a comparatively low electrical capacity of usually less than 5,000 mAh, a low voltage of about 4.2 V, compared to high-performance batteries, for example for operating electric drive motors of motor vehicles. a low maximum power output as well as by a low weight of usually less than 150 g.

The EP 1 884 353 A1 describes a plastic composite film for a battery pack of a low-power battery, wherein the plastic composite film comprises a base film made of plastic, a metal foil and a functional plastic layer. On the metal foil is a metal protective layer to protect the metal foil from aggressive battery components, the battery formed as a lithium-polymer battery.

The EP 1 209 094 B1 describes an alternative composite foil for small batteries wherein the foil laminate comprises a liquid paraffin layer.

The WO 2002101849 A1 also describes a foil material for a small battery pack, wherein spacers formed of polymer material are arranged between the battery and the foil laminate.

The EP 1 102 336 B1 describes another alternative laminate film for a miniature battery having on a protective layer (barrier layer) an unsaturated carboxylic acid graft polyolefin resin layer.

The EP 1 359 631 B1 describes a laminate for a battery casing whose protective layer comprises a laminated phenolic polymer.

The EP 1 422 767 A1 describes a foil laminate for a small battery in which the protective layer provided on the metal foil formed as aluminum foil comprises a zirconium compound.

The EP 0 975 031 B1 describes a battery pack for a low-power battery in which an adhesive layer is provided between an inner polyolefin resin layer and a metal layer, wherein the adhesive layer comprises an acid-denatured polyolefin resin having an acid content ranging from 0.01 to 10% by weight.

From the EP 1 884 353 A1 A plastic composite film for producing a battery pack for a low-power battery is known, wherein a denatured polyolefin layer is provided as a bonding layer between a protective layer and an innermost polyolefin layer.

All of the aforementioned laminate films are designed for sheathing comparatively low-power battery packs for small appliances such as mobile telephones.

The known in the non-technical technical field of low-power batteries laminates are not suitable for the sheathing of compared to low power battery packages large-volume battery packs to build a high-performance battery, such as is needed in motor vehicles for supplying electrical power to a drive motor. Such high-performance batteries or battery sheaths for high-performance batteries consisting of a plurality of battery packs connected in series, in particular, must meet much stricter requirements. Since the life cycle of such high power battery packs is significantly higher than that of small package battery packs, the delamination stability must be substantially improved. In addition, cold workability should be improved because high capacity battery packs are larger in volume than low power battery packs. Furthermore, the mechanical stiffness of the shell laminate used should be improved to avoid the risk of damage in the event of an accident.

Such damage can lead to a sudden release of large amounts of energy, which brings a significant risk of fire. Furthermore, the heat stability of the laminate used should be improved in comparison with the known laminates, since the heat development in high-performance batteries compared to the known small battery packs (eg mobile phone batteries) is much larger.

Since the known in the technical field of low-power batteries battery packs, more specifically their shells, do not meet the above requirements, the invention has the object to provide a high-performance battery, or their battery packs at least one of the above requirements, preferably several or all of the above requirements , is sufficient / sufficient. Furthermore, the object is a system comprising a electrical consumers and at least one such high-performance battery to specify.

This object is solved with the features of claim 1, in particular in that in a battery pack for a high-performance battery, the adhesive layer between the protective layer and the inner layer comprises or is a thermoset adhesive layer. With regard to the system, the object is achieved by the combination of an electrical load, in particular an electric drive motor of a motor vehicle and at least one battery pack designed as described above and / or an arrangement of a plurality of battery packs as described above.

Advantageous developments of the invention are specified in the subclaims. All combinations of at least two features disclosed in the description, the claims and / or the figures fall within the scope of the invention. In order to avoid repetition, features disclosed according to the device should be regarded as disclosed according to the method and be able to be claimed. Likewise, according to the method disclosed features should be considered as device disclosed and claimed claimable.

In order to meet the requirements for increased delamination stability for high-performance batteries, it is proposed that the batteries interconnected to form the high-power battery and having at least two or more interconnected electrodes be arranged between one of the battery-facing, preferably a polyolefin film, for example a polypropylene film Inner layer and a likewise facing the battery, provided on the metal foil, preferably an aluminum foil, provided protective layer designed as a thermosetting adhesive layer adhesive layer. Duroplast material, such as polyurethane or epoxy resin is characterized by improved stability against delamination processes. In addition, the heat resistance to the acid-denatured polyolefin resin used in the art in mobile phone battery packs as the adhesive layer is substantially improved. The improved delamination resistance of the adhesive layer ensures a long life cycle of the high-performance battery packs.

With regard to the concrete formation of the thermosetting adhesive layer, there are different possibilities. The thermosetting adhesive layer may consist of a single layer or be composed of partial adhesive layers. Preferably, the thermosetting adhesive layer comprises or consists of a polyurethane layer or an epoxy resin layer. In general, it should be noted that the layers or films used can be formed from a single layer or a single film or from a layer or film arrangement comprising at least two partial layers or films.

In battery packs for small electrical applications, where the low-power battery is usually formed by a single sheathed battery pack, the aluminum foil used as the metal foil in practice has a maximum thickness of 40 microns. To minimize the risk of destruction of the battery casing in battery packs for high-performance batteries is provided in a further development of the invention advantageously that the thickness of the metal foil, which is preferably formed as aluminum foil is at least 50 microns. Most preferably, the thickness is 60 microns. In addition to an increased mechanical rigidity, a (substantially) improved cold formability is thereby achieved, whereby the film laminate used can be deformed in an improved thermoforming process in order to be able to absorb the battery, preferably a lithium-polymer battery, after deformation. The reason for the improved cold workability is due to the crystal grain structure of the metal layer preferably formed as aluminum layer - the thicker the metal layer, in particular the aluminum layer, the more crystal grain layers are available, which are sheared, flow or slide on the action of corresponding forces, in particular shear forces can occur without tearing or so-called pinholes.

Very particular preference is given to using an aluminum foil as the metal foil, it also being possible for its alloys to be used in addition to pure aluminum. For example, metal foils of the following materials can be used: Al 99.0, Al 99-5 or alloys of the types AA 8 xxx, the materials AA 8006, AA 8014, AA 8021 and AA 8079 being particularly suitable. As already mentioned above, the minimum thickness is preferably 60 μm.

It is very particularly preferred if the thickness of the base film is adapted to the thickness of the metal foil, the thickness of the base film preferably being at least 10 μm, very particularly preferably at least approximately 25 μm.

The plastic base film may contain one or more layers. For example, it may be a polyester film, for. Example, a polyethylene terephthalate (PET), a polyamide film, most preferably an oriented polyamide film (oPA), a polyolefin film, for example a oriented polypropylene film (oPP) or the base film may comprise at least one of the aforementioned films. If the base film contains several layers, these may be two or more, in each case adhesive-laminated, extrusion-laminated and / or hot-calendered layers, or films. Adhesive-laminated layers or films can be processed with aqueous, solvent-based and / or solvent-free adhesives. It is very particularly preferred if the base film is a biaxially oriented polyamide film or the base film comprises such a polyamide film.

As indicated at the outset, there are also different possibilities with regard to the formation of the inner layer. It is very particularly preferred if the inner layer is a sealable layer. The inner layer may be composed of several layers, for example, each other adhesive-coated, painted, extrusion-laminated, hot-calendered and / or applied by curtain coating layers or films, respectively. More particularly, the inner layer contains or consists of a polyolefin layer, for example polypropylene, oriented polypropylene (oPP) or polyethylene, polyesters such as polyethylene terephthalate (PET). The total thickness of the inner layer, which in particular forms the innermost layer of the laminate, is preferably between approximately 5 μm and 100 μm.

To further improve the delamination stability of the laminate film used, it is advantageously provided in a further development that two adhesive layers are provided between the (outer) base layer and the metal foil, namely a base film-side adhesive layer of duroplastic material and a metal foil-side primer layer. It is very particularly preferred if the primer layer does not directly adjoin the metal foil, but rather on an (additional) base film-side protective layer applied to the metal foil, which is preferably a protective layer identical to the battery-side protective layer of the metal foil. The adhesive layer of thermoset material is very particularly preferably a polyurethane layer which very particularly preferably has less free isocyanate groups than the primer layer, in order thus to be able to form an improved adhesive bond to the base layer, in particular as an oriented polyamide layer. The primer layer is preferably designed to adhere to the (outer) protective layer of the metal foil described above.

Also with regard to the formation of the at least one protective layer, there are different possibilities, preferably it is a chromate layer. Additionally or alternatively, it is possible that the protective layer comprises at least one of the following substances and / or at least one oxide of one of the following substances: chromium, fluorine, tungsten, titanium, silicon.

The protective layer is very particularly preferably applied to the metal foil, preferably the aluminum foil, by wet-chemical means, preferably in which the metal foil, in particular an aluminum foil, is passed or sprayed through a corresponding immersion bath. In this application method, a protective layer is formed on both sides of the metal foil. The protective layer should preferably be designed in such a way that it protects the metal foil, in particular the aluminum foil, from aggressive battery constituents, in particular from hydrofluoric acid.

Preferably, the thickness of the metal protective layer is between about 0.1 and 1000 nm.

It is very particularly preferred if at least one battery of the high-performance battery forming, interconnected battery packs is designed as a lithium-polymer battery. Preferably, the batteries of all the battery packs are designed as lithium-polymer battery. The battery capacity of at least one of the battery packs is preferably at least 30,000 mAh, preferably at least 50,000 mAh, very particularly preferably at least 90,000 mAh. It is particularly expedient if the batteries of all battery packs which form the high-performance battery by interconnection have one of the aforementioned minimum capacities. In a development of the invention, it is advantageously provided that an electrical voltage of at least 3 V, even more preferably of at least 4 V, is even more preferred on the battery of at least one of the battery packs, preferably on the batteries of all the battery packs considered in the charged state of at least 10 V, preferably of at least 20 V, most preferably of at least 30 V, is present.

If the battery packs are connected in series, the voltages add up. Preferably, at the contacts of the high-power battery in the charged state, an electrical voltage of at least 100 V, more preferably of at least 200 V, even more preferably of at least 300 V, even more preferably of at least 400 V, even more preferably of about 410 V. , Advantageously, the applied voltage is less than 2,000 V, even more preferably less than 1,000 V.

It is particularly expedient if the volume of at least one of the battery packs is 50 cm ³ , preferably at least 100 cm ³ . It is particularly expedient if the volume of all battery packs each at least 50 cm ³ , still more preferably at least 100 cm ³ . It is particularly expedient if the high-performance battery is formed from a multiplicity of, very particularly preferably at least 10, in particular at least 20, identical, preferably electrically series-connected, battery packs, the battery packs preferably being arranged in a surrounding housing, a so-called high-performance battery housing, are arranged, wherein preferably each battery pack is encased according to the invention as described above.

It is particularly expedient if the high-performance battery (including housing) has a volume of at least 1 dm ³ , very particularly preferably of at least 5 dm ³ . Most preferably, the volume is more than 100 dm ³ , more preferably more than 200 dm ³ , most preferably about 300 dm ³ or more.

It is particularly preferred if the high-performance battery can permanently deliver at least 10 kW, preferably at least 20 kW, very particularly preferably at least 30 kW, even more preferably at least 75 kW, during operation. Alternatively, the aforementioned power values may be maximum values, i. H. to trade at peak power output values.

For example, if the high-power battery is formed of one hundred battery packs in series, each comprising a jacketed lithium polymer battery having a capacity of 90,000 mAh, each battery pack having a voltage of 3 V, 300 V can be tapped on the high-power battery. In theory, without taking losses into account and assuming that the battery of the battery packs are completely emptied, a power of 27 kW could be tapped for one hour in such a high-performance battery.

Furthermore, the invention relates to a system, for example a motor vehicle, comprising an electrical load, which most preferably by a maximum power consumption or continuous power consumption of at least 5 kW, preferably at least 10 kW, preferably at least 20 kW, more preferably at least 30 kW, even more preferably of at least 40 kW, even more preferably 75 kW distinguished. In particular, the electrical consumer is an electric drive motor. The system comprises, in addition to the electrical load designed as described above, at least one high-performance battery configured as described above, which is formed by a plurality of battery packs, preferably each connected in series, each comprising a sheath.

Preferably, the sheathed and electrically interconnected battery packs are arranged in a high-performance battery housing.

Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawing. This shows in:

1 the schematic structure of a possible embodiment of a battery pack with battery casing, and

2 a schematic representation of one of several battery packs according to 1 built-up high-performance battery.

In 1 is a cut, incomplete representation of a particularly preferred embodiment of a (high-performance) battery pack 1 , in particular for motor vehicle applications, wherein a high-performance battery consists of a plurality of such electrically, preferably in series, interconnected battery packs. The battery pack 1 includes a designed as a lithium-polymer battery (high-performance) battery 2 that with a battery casing 3 is sheathed. The battery casing 3 is made of a laminate foil four the innermost, the battery 2 facing inner layer 5 comprises a polypropylene film. The inner layer 5 has a thickness of 50 μm. Immediately to the, here of a single film, alternatively formed of several films inner layer 5 borders an adhesive layer on the outside 6 at. The inner layer 5 is formed by a thermosetting adhesive layer - in the embodiment shown a polyurethane layer. The adhesive layer 6 which in the embodiment shown has a thickness of 4 microns, borders on that of the inner layer 5 facing away from a protective layer 7 in which it is a coating of a metal foil 8th is. At the metal foil 8th In the exemplary embodiment shown, this is an aluminum foil having a thickness of 60 μm. The protective layer is a chromate layer. The metal foil 8th not only points to the battery 2 facing side, but also on the from the battery 2 opposite side a metal protective coating 9 (Protective layer), which is formed identically as the protective layer 7 , Immediately outside the metal protective layer 9 that like the protective layer 7 has a thickness of 100 nm, adjacent to a primer layer 10 with a thickness of 1.6 microns. The primer layer 10 is made of polyurethane material. Immediately outside the primer layer 10 borders an adhesive layer 11 made of thermoset material, here of polyurethane, which has a thickness of 3.5 microns in the embodiment shown. The adhesive layer 11 provides a permanent connection to a single or multilayer base film 12 for sure, the outermost layer of the laminate film four forms. In the embodiment shown, the base film has 12 a thickness of 25 microns and is formed by a film of oriented polyamide (oPA).

In 2 is schematically a high performance battery 13 shown. This includes a high performance battery housing 14 , within which only schematically illustrated, interconnected in series, identical battery packs 1 are arranged. Every battery pack 1 includes a battery casing and one of the battery casing 3 sheathed battery. Preferred is each battery pack 1 as in 1 shown formed.

By way of example only, the high performance battery includes 13 a total of fifteen battery packs 1 , each having a capacity of 100,000 mAh and each having a voltage of 30 V. At the contacts 15 . 16 the high-performance battery 13 Consequently, theoretically a voltage of 450 V is applied. So it could be tapped for two hours a power of 22.5 kW and, for example, a 45 kW engine for two hours at half power to be operated.

LIST OF REFERENCE NUMBERS

1

battery pack

2

battery

3

battery enclosure

4

laminate film

5

inner layer

6

adhesive layer

7

protective layer

8th

metal foil

9

Metal protective layer

10

primer layer

11

adhesive layer

12

base film

13

High-capacity battery

14

High-performance battery case

15

Contact

16

Contact

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1884353 A1 [0003, 0010]
• EP 1209094 B1 [0004]
• WO 2002101849 A1 [0005]
• EP 1102336 B1 [0006]
• EP 1359631 B1 [0007]
• EP 1422767 A1 [0008]
• EP 0975031 B1 [0009]

Claims (15)

High-performance battery, in particular for operating an electric motor vehicle drive motor, with a plurality of electrical, preferably in series, interconnected battery packs ( 1 ) each with a battery ( 2 ) fitted with a battery casing ( 3 ), wherein the battery casing ( 3 ) at least one battery pack ( 1 ), preferably each battery pack ( 1 ), a laminate film ( four ), which comprises: a metal foil ( 8th ), • one on the battery ( 2 ) facing away from the metal foil ( 8th ) arranged base film ( 12 ) made of plastic, • at least one on the metal foil ( 8th ) applied protective layer ( 7 ) on the battery ( 2 ) facing side of the metal foil ( 8th ), • an inner layer ( 5 ) made of plastic, • one between the protective layer ( 7 ) and the inner layer ( 5 ) adhesive layer ( 6 ), the adhesive layer ( 6 ) comprises or is a thermosetting adhesive layer. High-performance battery according to claim 1, characterized in that the thermosetting adhesive layer comprises at least one of the following substances or a mixture thereof or consists of the following substances or a mixture thereof: polyurethane, epoxy resin. High-power battery according to one of claims 1 or 2, characterized in that the metal foil ( 8th ) has a thickness of at least 50 μm, preferably of 60 μm. High-performance battery according to one of the preceding claims, characterized in that the base film ( 12 ) has a thickness of at least 10 μm, preferably 25 μm. High-performance battery according to one of the preceding claims, characterized in that the base film ( 12 ) comprises or is an oriented polyamide film. High-power battery according to one of the preceding claims, characterized in that the inner layer ( 5 ) comprises at least one, in particular oriented, polypropylene film and / or consists of at least one, in particular oriented, polypropylene film. High-performance battery according to one of the preceding claims, characterized in that inner layer ( 5 ) is the innermost laminate film layer. High-power battery according to one of the preceding claims, characterized in that between the base film ( 12 ) and the metal foil ( 8th ) a base film side adhesive layer ( 11 ) made of thermoset material and a metal layer side primer layer ( 10 ) are arranged. High-performance battery according to claim 8, characterized in that the adhesive layer ( 11 ) of thermosetting material more free isocyanate groups than the primer layer ( 10 ). High-power battery according to one of the preceding claims, characterized in that the protective layer ( 7 ) comprises at least one of the substances and / or at least one oxide of the substances of the following group: chromium, fluorine, tungsten, titanium, silicon. High-power battery according to one of the preceding claims, characterized in that, preferably each formed as a lithium-polymer battery, batteries ( 2 ) has a capacity of at least 30,000 mAh, preferably of at least 50,000 mAh, more preferably of at least 90,000 mAh, and / or a voltage of at least 3 V, preferably of at least 4 V, preferably of at least 10 V, most preferably of at least 20 V. emits. High-performance battery according to one of the preceding claims, characterized in that the high-performance battery ( 13 ) has a peak power output capability and / or continuous power output capability of at least 5 kW, preferably at least 10 kW, preferably at least 20 kW, preferably at least 30 kW, more preferably at least 40 kW, even more preferably at least 75 kW. High-performance battery according to one of the preceding claims, characterized in that at least one of the battery packs ( 1 ) have a volume of at least 50 cm ³ and / or that the high-performance battery ( 13 ) has a volume of at least 1 dm ³ , preferably of at least 5 dm ³ . System, in particular a motor vehicle, comprising an electrical load, in particular a drive motor and a high-performance battery ( 13 ), according to one of claims 1 to 13. Use of a laminate film ( four ) for sheathing at least one of a plurality of electrically interconnected battery packs ( 1 ) of a high-performance battery ( 13 ), wherein the laminate film ( four ): a metal foil ( 8th ), • one on the battery ( 2 ) facing away from the metal foil ( 8th ) arranged base film ( 12 ) made of plastic, • at least one on the metal foil ( 8th ) applied protective layer ( 7 ) on the battery ( 2 ) facing side of the metal foil ( 8th ), • an inner layer ( 5 ) made of plastic, • one between the protective layer ( 7 ) and the inner layer ( 5 ) adhesive layer ( 6 ), the adhesive layer ( 6 ) comprises or is a thermosetting adhesive layer.

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