WO2007112116A2 - Integrated module connection for hev battery - Google Patents

Integrated module connection for hev battery Download PDF

Info

Publication number
WO2007112116A2
WO2007112116A2 PCT/US2007/007672 US2007007672W WO2007112116A2 WO 2007112116 A2 WO2007112116 A2 WO 2007112116A2 US 2007007672 W US2007007672 W US 2007007672W WO 2007112116 A2 WO2007112116 A2 WO 2007112116A2
Authority
WO
WIPO (PCT)
Prior art keywords
battery
battery module
cell
extruded body
medium
Prior art date
Application number
PCT/US2007/007672
Other languages
French (fr)
Other versions
WO2007112116A3 (en
Inventor
Charles J. Warren
Shawn J. Murtha
Todd L. Summe
John W. Cobes
Weiping Zhao
Original Assignee
Alcoa Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Inc. filed Critical Alcoa Inc.
Publication of WO2007112116A2 publication Critical patent/WO2007112116A2/en
Publication of WO2007112116A3 publication Critical patent/WO2007112116A3/en

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/124—Primary casings; Jackets or wrappings characterised by the material having a layered structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/24—Alkaline accumulators
    • H01M10/30—Nickel accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/34—Gastight accumulators
    • H01M10/345—Gastight metal hydride accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/105—Pouches or flexible bags
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/116—Primary casings; Jackets or wrappings characterised by the material
    • H01M50/117—Inorganic material
    • H01M50/119—Metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/172—Arrangements of electric connectors penetrating the casing
    • H01M50/174—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells
    • H01M50/178—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells for pouch or flexible bag cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/211—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for pouch cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/253—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders adapted for specific cells, e.g. electrochemical cells operating at high temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/514—Methods for interconnecting adjacent batteries or cells
    • H01M50/516—Methods for interconnecting adjacent batteries or cells by welding, soldering or brazing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/547—Terminals characterised by the disposition of the terminals on the cells
    • H01M50/548—Terminals characterised by the disposition of the terminals on the cells on opposite sides of the cell
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/547—Terminals characterised by the disposition of the terminals on the cells
    • H01M50/55—Terminals characterised by the disposition of the terminals on the cells on the same side of the cell
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/552—Terminals characterised by their shape
    • H01M50/553—Terminals adapted for prismatic, pouch or rectangular cells
    • H01M50/557—Plate-shaped terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/058—Construction or manufacture
    • H01M10/0587—Construction or manufacture of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/617—Types of temperature control for achieving uniformity or desired distribution of temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6561—Gases
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6561—Gases
    • H01M10/6566—Means within the gas flow to guide the flow around one or more cells, e.g. manifolds, baffles or other barriers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention in one embodiment relates to battery arrangements. In one embodiment, the present invention further relates to nickel metal hydride and lithium ion batteries.
  • Hybrid Electrical Vehicle (HEV) battery packs consist of number of battery modules, wherein each battery module has a plurality of battery cells.
  • the battery modules are in electrical communication through module to module series connections.
  • Module to module connections typically require nut and bolt arrangements that provide a number of difficulties, since this manufacturing method is prone to over-torquing or under-torquing of the nut and bolt fasteners. Additionally, cross threading of the bolts is also common, which may destroy the positive or negative battery post when over-torqued.
  • the concise assembly required for high voltage battery module manufacturing and the need for closely monitored torque control render bolt and nut arrangements uneconomical for high voltage battery module manufacturing. Summary of the Invention
  • the present invention provides a battery module apparatus.
  • the battery module apparatus includes:
  • At least one battery cell comprising an extruded body housing a battery medium, a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the extruded body.
  • the battery medium is a lithium ion or nickel metal hydride battery medium.
  • the battery module system includes a plurality of battery cells having extruded bodies housed within an insulating rack comprising a series of channels and vents, wherein spacing between adjacent rows of battery modules of cells is provided by a series of pegs.
  • the battery module apparatus includes:
  • At least one battery cell comprising a stamped body housing a battery medium, a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the stamped body.
  • the battery module system includes a plurality of battery cells having stamped bodies housed within an insulating rack comprising a series of channels and vents, wherein spacing between each row of battery modules is provided by a convex structure positioned in a sidewall of the stamped body.
  • Figure 1 depicts a perspective view of one embodiment of an extruded pipe having a cross section configured for housing a battery cell, in accordance with the present invention.
  • Figure 2 depicts a perspective view of one embodiment of the extruded pipe depicted in Figure 1 after being sectioned to a length suitable for providing a battery cell, in accordance with the present invention.
  • Figure 3a depicts a perspective view of one embodiment of a battery medium, in accordance with the present invention.
  • Figure 3b depicts a cross sectional view of one embodiment of a battery medium in accordance with the present invention.
  • Figure 4a depicts a perspective view of one embodiment of a battery cell having a housing formed from an extruded pipe, as depicted in Figure 2.
  • Figures 4b and 4c depict perspective views of one embodiment of process steps for providing the battery cell depicted in Figure 4a.
  • Figure 5a depicts a perspective view of another embodiment of a battery cell having a housing formed from an extruded pipe, as depicted in Figure 2.
  • Figures 5b and 5c depict perspective views of one embodiment of process steps for providing the battery cell depicted in Figure 5a.
  • Figures 6b-6c depicts a perspective view of another embodiment of a battery cell having a housing formed from an extruded pipe, as depicted in Figure 2.
  • Figures 7a-7c depict perspective views of some embodiments of a stamped battery cell housing, in accordance with the present invention.
  • Figures 8a-8c depict perspective views of some embodiments of the connectivity assembled battery cells, in accordance with the present invention.
  • Figure 9a depicts a perspective view of one embodiment of a battery module including a plurality of battery cells, in accordance with the present invention.
  • Figure 9b depicts a perspective view of a semi-battery pack including a plurality of battery modules, in accordance with the present invention.
  • Figure 9c depicts a perspective view of one embodiment of a connection for a battery module to provide connectivity to an adjacent battery module, in accordance with the present invention.
  • Figure 9d depicts a perspective view of one embodiment of a semi-battery pack including a plurality of battery cells as depicted in Figures 7a-7c.
  • Figure 9e depicts a perspective view of one embodiment of two interconnected battery modules, in accordance with the present invention.
  • Figure 9f depicts a perspective view of one embodiment of two modules, in which each battery module is separated by a relay and control box.
  • Figure 10a depicts a perspective view of one embodiment of a rack for assembling battery modules, in accordance with the present invention.
  • Figure 10b depicts a perspective view of one embodiment of a rack having pegs for stabilizing the spacing of adjacent battery modules at straight terminal cell to cell connections, in accordance with the present invention.
  • Figure 1 Oc depicts a perspective view of one embodiment of a rack having pegs for stabilizing the spacing of the end portions battery modules a bend terminal cell to cell connections, in accordance with the present invention.
  • Figure 1 Ia depicts a perspective view of one embodiment of the vents to the bottom rack housing the battery modules, in accordance with the present invention.
  • Figures 1 Ib- 11 d depict perspective views of one embodiment of an assembled rack housing battery module, in accordance with the present invention.
  • Figure l ie depicts a cross sectional view of one embodiment of the assembled rack and battery module combination, as depicted in Figures 1 Ib-11 d.
  • Figure 12 depicts one embodiment of battery modules integrated into a battery system in accordance with the present invention.
  • Figure 1 depicts one embodiment of an extruded pipe 1 having a cross section to house a battery medium, which may be sectioned to a length suitable for an extruded body 1 a for a battery cell housing, as depicted in Figure 2, in accordance with the present invention.
  • extruded body means a housing that has a substantially constant cross section along at least a portion of the longitudinal length of the housing. The longitudinal length of the housing extends from the positive terminal to the negative terminal of the battery cell.
  • a substantially constant cross section includes a wall thickness of the housing being substantially constant.
  • a substantially constant wall thickness denotes a deviation ranging from +/- 0.05 mm to +/- 0.5 mm from a thickness value that may range 0.5 mm to 2.5 mm.
  • the wall thickness of the extruded body being substantially constant includes an extruded body having an upper wall, lower wall and sidewalls having substantially equal thickness measured from the exterior face to the interior face.
  • the extruded body is composed of an aluminum alloy.
  • aluminum alloy means an aluminum metal with soluble alloying elements either in the aluminum lattice or in a phase with aluminum.
  • Alloying element include but are not limited to Cu, Fe, Mg, Ni, Si, Zn, Mn, Ti, Cr, V, Ag, Sn, Sc, and Li.
  • the extruded body Ia may include steel, copper, or zinc.
  • the extruded body 1 a may be plastic or a composite material
  • the cross section of the extruded body 1 a is configured to house a battery medium that in one embodiment may include lithium ion or metal nickel hydride, wherein the battery medium may include a cathode and an anode portion.
  • the battery medium 80 may include lithium ion or metal nickel hydride and may be a laminated structure including a foil wrapped around a core.
  • a positive terminal 4 is connected to the cathode portion and a negative terminal 3 is connected to the anode portion.
  • the positive terminal 4 may be provided by an electrically conductive tab that is in electrical communication to the cathode portion of the battery medium 80.
  • the negative terminal 3 may be provided by an electrically conductive tab that is in electrical communication to the anode portion of the battery medium 80.
  • the electrically conductive tab may be provided by a metal, such as aluminum, steel, copper, and nickel alloy.
  • the term electrical communication denotes that the connection is capable of conducting an electrical current.
  • the battery medium may include a cathode portion 82 including a cathode metal current collector 83, and a battery medium positive electrode 84; an anode portion 85 including an anode metal current collector 86 and a battery medium negative electrode 87; and a separator layer 88 insulating the anode portion 85 from the cathode portion 82.
  • the battery medium positive electrode 84 may be composed of Li containing material
  • the battery medium positive electrode 83 may be composed of metal foil, wherein the metal may include but is not limited to Al, Cu or Ni Alloys or combinations thereof.
  • the of the anode portion 85 the battery medium positive electrode 86 may be composed of Li containing material, and the battery medium negative electrode 87 may be composed of metal foil, wherein the metal may include but is not limited to Al, Cu or Ni Alloys or combinations thereof.
  • the separator layer 88 is composed on an electrically insulating material, such as a polymeric material.
  • extrusions of pipe 1 for the extruded body Ia are provided by providing a metal billet, such as a metal billet composed of but not limited to an aluminum extrusion alloy, and pressing the metal billet through an extrusion die.
  • the extrusion operation for forming the extruded body Ia makes use of a die assembly, including an extrusion die itself together with a backer.
  • the extrusion die is a steel disk with an opening, wherein the size and shape of the opening corresponds to the intended cross- section of the extruded pipe 1.
  • the substantially constant cross section of the extruded body Ia has a geometry corresponding to the size and shape of the opening in the extrusion die.
  • the hollow portions are provided by an extrusion die including a mandrel.
  • Figure 2 depicts one embodiment of an extruded body Ia following sectioning of the extruded pipe 1 to the length sufficient to provide a housing for the battery medium 80.
  • Figure 4a depicts one embodiment of a battery cell 10a formed from the extruded body Ia provided from the extruded pipe, in accordance with one aspect of the present invention.
  • the extruded body Ia includes a first end corresponding to the positioning of the positive terminal 4 to the battery medium 80 and a second end corresponding to the negative terminal 3 of the battery medium 80, wherein the first end and the second end of the extruded body Ia oppose one another.
  • the battery medium 80 is positioned within the extruded body 1 a, in which the positive terminal 4 is positioned corresponding to a first end of the extruded body Ia and the negative terminal 3 is positioned at the opposing second end of the extruded body Ia.
  • an insulating material is applied to the first and second ends of the extruded body Ia, in which the insulating material is applied around the positive and negative terminals 4, 3.
  • the amount of insulating material is selected to ensure that following the sealing of the positive and negative terminals from each end of the extruded body that the cell is substantially devoid of air and moisture.
  • insulating material means denotes a substance that does not conduct an electrical current.
  • an insulating material is provided by a nonmetallic material. Examples of insulting materials include, but are not limited to, polymeric and ceramic materials.
  • the insulating material is provided by silicone or a silicone containing material.
  • the first and second end of the extruded body Ia may be sealed, as depicted in Figure 4c.
  • the seal may be characterized as being substantially hermetic.
  • substantially hermetic denotes airtight by fusion or by sealing, wherein airtight means a seal against the substantial entry or exit of air and moisture from the housing 2.
  • the seal is provided by the insulating material applied to the opposing ends of the extruded body Ia.
  • the seal is provided by deforming the ends of the extruded body where the sidewalls at each end of the extruded body contact one another, with the exception of the portions of the sidewalls corresponding to the positive and negative terminals 4, 3.
  • the positive terminal 4 and the negative terminal 3 is insulated from the housing 2 by the insulating medium positioned at the interface of the terminals 3, 4 and the sealed portions of the housing 2. More specifically, the insulating material is applied to the portions of the terminals 3, 4 that extend from the battery medium 80 and are contained within the housing 2 of the battery cell 10a, as well as the portions of the terminals 3, 4 that pass through the sealed end of the extruded body Ia to the exterior of the battery cell 10a.
  • the insulating material is applied to a first end of the extruded body 1 a and then sealed, wherein in a following step the insulating material is applied to the second end of the extruded body and sealed.
  • the insulating material is applied to both the first and second end of the extruded body, wherein following the application of the insulating material to both ends of the extruded body Ia each end is then sealed.
  • the seal is provided by a welding operation selected from the group including but not limited to resistance welding, laser welding, ultrasonic welding and combinations thereof.
  • the seal is provided by a combination of the insulating material and welding operations.
  • the seal at the opposing ends of the extruded body 1 a is provided by a crimping operation. Crimping is joining two pieces of metal or other malleable material by deforming one or both of them to hold the other.
  • the seal engagement at the first and second end may further include an adhesive.
  • the sealed engagement may be provided by any combination of the above.
  • Figure 5a depicts another embodiment of a battery cell 1 Ob formed from an extruded body 1 a, in which the positive terminal 4 and negative terminal 3 to the battery medium 80 correspond to a one end of the extruded body Ia.
  • the end opposite the positive and negative terminals 4 is closed by deforming the sidewalls of the extruded body into contact with one another.
  • the closed end 90 may be sealed, as described above.
  • the closed end 90 may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof.
  • the seal may be characterized as being substantially hermetic.
  • the battery medium may be positioned within the housing 2 provided by the extruded body Ia, as depicted in Figure 5c, and an insulating material is applied to the open end 91.
  • the insulating material does not conduct electricity and in one embodiment may be silicon or a silicon containing material.
  • the amount of insulating material is selected to ensure that following the sealing of the open end 91 the battery cell will be substantially devoid of air and moisture within the housing.
  • the insulating material is applied to the portions of the positive terminal 4 and the negative terminal 3 corresponding to the extruded body Ia to ensure that the positive and negative terminals 3, 4 are insulated from the housing 2. More specifically, the insulating material is applied to the portions of the terminals 3, 4 within the housing 2 extending from the battery medium 80 and is applied to the portions of the terminals 3, 4 passing through the sealed end of the extruded body Ia.
  • the open end 91 of the extruded body Ia is sealed to provide the structure depicted in Figure 5a, in which the positive and negative terminals correspond to a singular end of the battery cell 10b.
  • the open end 91 may be sealed in a manner similar to that described with reference to Figures 4a to 4c.
  • the open end may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof.
  • the seal may be characterized as being substantially hermetic.
  • the method described with reference to Figures 5a to 5c may include intermediary process steps in addition to the above description.
  • Figures 6a and 6b depict embodiment of the battery cell 10c formed from an extruded body 1 a, in accordance with the present invention, in which the negative terminal 4 to the battery medium 80 is in electrical communication to the extruded body Ia.
  • the extruded body may serve as the negative terminal of the cell.
  • Figure 6a depicts one embodiment of a battery cell, in which the positive terminal 4 is positioned in the center of the battery cell's 1 Oc width, in which the width Wl is defined as the dimension from a first edge of the battery cell's sealed end to the second end of the battery cell's sealed end.
  • Figure 6 b depicts one embodiment of a battery cell, in the positive terminal is positioned offset from the center of the battery cell's width Wl .
  • the battery medium 80 is inserted within the extruded body Ia and the negative terminal 3 is connected in electrical communication to a portion of the extruded body's interior.
  • the connection is provided by a welding operation selected from the group including but not being limited to laser welding, resistance welding, and ultrasonic welding.
  • the negative terminal can be arranged to provide electrical communication to the extruded body by maintaining a normal force between the negative terminal and the extruded body.
  • the edge of the extruded body Ia corresponding to the negative terminal 3 is closed by deforming the sidewalls of the extruded body Ia into contact with one another.
  • the end may be sealed, as described above.
  • the closed end may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof.
  • the seal may be characterized as being substantially hermetic.
  • silicone may be utilized as a sealant, wherein the amount of silicon employed is selected to ensure that following the sealing of the extruded body 1 a the battery cell will be substantially devoid of air and moisture within the housing.
  • an insulating material such as silicon is applied to the positive terminal 4 and to the end of the extruded body Ia corresponding to the positive terminal 4.
  • the amount of insulating material is selected to ensure that following the sealing of the battery cell will interior of the cell will be substantially devoid of air and moisture.
  • the insulating material is applied to the positive terminal 4 to ensure that the positive terminal 4 is insulated from the housing 2, such as the portions of the positive terminals 4 passing through the sealed end of the extruded body Ia. Following the application of the insulating material the extruded body Ia is sealed to provide the structure depicted in Figures 6a and 6b.
  • the end corresponding to the positive terminal 4 may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof.
  • the seal may be characterized as being substantially hermetic.
  • the exterior face of the extruded body Ia may be coated or jacked with an insulating material.
  • the insulating material may be provided by a polymeric or ceramic jacking or a polymeric or ceramic jacking. The jacking or coating of insulating material is provided to avoid shorting adjacent battery cells.
  • a portion of the exterior face of the extruded body Ia is substantially clear of the insulating material to provide for electrical communication to the positive terminal 4 of an adjacent battery cell.
  • the battery cell may be coated or jacked to facilitate the hermetic sealing of the battery cell.
  • FIGS 7a-7c depict some other embodiments of a battery cell housing 2, in accordance with the present invention, wherein the battery cell housing 2 is provided by a stamped metal.
  • a stamped metal means a structure provided by a metalworking process by which sheet metal are punched using a press tool which is loaded on a machine press or stamping press to form the sheet into a desired shape.
  • a first sidewall and second sidewall Ib, Ic are stamped separately, as depicted in Figure 7b.
  • a battery medium is positioned between each sidewall Ib, Ic of the housing 2, wherein the perimeter portions of each sidewall Ib, Ic, are sealed.
  • the perimeter portions are provided by a flange 95 that corresponds of each sidewall Ib, Ic.
  • the sealed perimeter portions may be provided by a crimping operation, welding operations, adhesively or a combination thereof. Similar to the embodiments described above with reference to Figures l-6c, in one embodiment, the sealed engagement of the first and second sidewall Ib, Ic, may be characterized as being hermetic.
  • an insulating material may be employed to insulate at least the positive terminal 4 to the battery medium from the stamped housing.
  • the insulating material may be silicone. The amount of insulating material is selected to ensure that following the sealing of the open end 91 the battery cell will be substantially devoid of air or moisture within the housing.
  • the insulating material is applied to the portions of the positive terminal 4 and the negative terminal 3 corresponding to the extruded body Ia to ensure that the positive and negative terminals 4, 3 are insulated from the housing 2. More specifically, the insulating material is applied to the portions of the terminals 3, 4 within the housing 2 extending from the battery medium 80 and is applied to the portions of the terminals 3, 4 passing through the sealed end of the stamped body.
  • the positive terminal is separated from housing 2 and the negative terminal 3 is connected in electrical communication to the stamped housing, in which the stamped body provides the negative terminal of the battery cell.
  • the exterior face of the stamped body Ia may be coated or jacked with an insulating material.
  • the first and second sidewall Ib, Ic further include spacing members 6 configured to provide spacing between the sidewalls of adjacent battery cells.
  • the spacing members are provided by convex structures having the geometry of at least a portion of a sphere, in which the apex the sphere extends from the sidewall away from the center of the battery, hence providing a greater width to the portions of the battery cells having the spacing members in comparison to the portions of the battery cell not having the spacing members.
  • the spacing members 6 provide a separation between adjacent battery cells on the order of greater than approximately 1.5 mm. In one embodiment, contact between adjacent space members 6 provide balance to the heat between adjacent cells.
  • the stamped body is provided by a unitary blank.
  • the term unitary denotes that the blank is formed of a single stamping from sheet metal.
  • the unitary blank includes the first and the second sidewall, wherein the first and the second sidewall share a joining portion 96.
  • the battery medium is positioned between the first and second sidewall and the unitary blank is folded along the joining portion 96, wherein following the folding operation the remaining unjoined sides of the unitary blank are sealed.
  • the seal may be hermetic and may be provide by crimping, adhesive, welding operations or combinations thereof, wherein provisions for a positive 4 and negative terminal 3 are also provided.
  • FIG. 8a-8c in one embodiment, at least two battery cells 10 are interconnected to provide a battery module 15.
  • Figure 8a depicts four series connected battery cells having extruded bodies with positive and negative terminals at opposing ends of each battery cell, as depicted in Figures 4a-4c, or battery cells having a negative terminal in electrical communication to the extruded body as depicted in Figure 6a.
  • Figure 8b depicts six series connected battery cells having an extruded body with positive and negative terminals positioned at a singular end, as depicted in Figures 5a-5c, or battery cells having a negative terminal in electrical communication to the extruded body, as depicted in Figure 6b.
  • Figure 8c depicts two series connected battery cells having stamped bodies, as described with reference to Figures 7a- 7c.
  • the connection between the positive and negative terminals of adjacent battery cells may be provided by a welding operations including but not limited to laser welding, resistance welding, ultrasonic welding or a combination thereof.
  • a battery module 15 is a structure including greater than two battery cells, in which each of the battery cells in the battery module is connected in electrical communication.
  • each battery cell 10 is interconnected to the adjacent battery cell 10 from the positive terminal 4 to the negative terminal 3.
  • each battery cell 10 provides on the order of 4 volts or less, and may be interconnected to provide a battery module 15 providing on the order of 50 volts or less.
  • Figure 9a depicts a battery module 15 having two end cell to cell connections 20a, 20b at opposing ends of the battery modules and two middle cell to cell connections 25 between the end cell to cell connections 20a, 20b of the battery module 15.
  • the first end cell to cell connection 20a includes a first battery end cell l la and a second battery end cell lib, wherein the first battery end cell lla includes a battery module female terminal 12 in electrical connectivity to the positive terminal 4a of the first battery cell 11.
  • the female terminal 12 is configured to provide electrically connectivity to a male pin of an adjacent battery module in series connection.
  • the battery module female terminal 12 may be provide by a coil spring 80 positioned within a groove 81 formed about an opening in a stamped metal connector housing, wherein the groove 81 and opening correspond to the geometry of the male pin 13 of an adjacent battery module.
  • the negative terminal 3a of the first battery end cell 1 Ia is in electrical connectivity to the positive terminal 4b of the second battery end cell 1 Ib.
  • the terminal to terminal connection between the first and second battery end cell may be provided by a straight configuration 29 between each cell.
  • electrical connectivity between end cell to cell connections 20a, 20b, and middle cell to cell connections 25 is provide by terminals having a bend 30 configuration.
  • a bend configuration 30 denotes a terminal having a bend of approximately 90 degrees at each end of the terminal.
  • the negative terminal 3a of the second battery end cell 1 Ib has a bend terminal 30 that provides for electrical connectivity to a middle cell to cell configuration 25, and in one embodiment provides for electrical connectivity to the positive terminal of the battery cell of the middle cell to cell configuration 25.
  • the opposing end of the middle cell to cell configuration 25 may also include a bend terminal 30 for connectivity to a second set of middle cell to cell configuration or to the second end cell to cell connections 20a, 20b.
  • the second end cell to cell connection 20b includes a first battery end cell l ie and a second battery end cell l id, wherein the second battery end cell 1 Id includes a male terminal 13 in electrical connectivity to the negative terminal 3a of the second battery cell 1 Id, in which the terminal to terminal connections of the first battery end cell 1 Ic to the second end battery cell 1 Id may have a straight configuration 29.
  • the battery module male terminal includes a male pin 13 having a geometry for engagement to the female terminal 12 of the adjacent battery module in electrical communication.
  • the terminal connections 29, 30 are provided by electrically conductive junctions. In one embodiment, the terminal connections 29, 30 between adjacent cells 2 are provided by welded connections. In one embodiment, the welded connection may be provided by ultrasonic weld, laser welding, resist welding, and fushion welding.
  • FIG. 9b depicts a semi battery pack module 40 in accordance with the present invention having greater than one module to module connection between each row of modules.
  • each row of the semi battery pack depicted in Figure 9b includes eight cells 10 having seven cell to cell connections.
  • at least one row is constructed as a module.
  • the number of cell to cell connections in each row or module may be increased by cells having straight terminals at opposing ends of the cell.
  • Figure 9c depicts one embodiment of a semi-battery pack having 16 rows of battery modules, in which adjacent rows of battery modules are connected in series by bend terminals 30.
  • Figure 9d depicts one embodiment of battery module having the housing 2 depicted in Figures 7a-7c, wherein spacing 66 between each adjacent row of battery modules is dictated by the convex structures 6.
  • Figure 9e depicts one embodiment of two semi battery packs 40a, 40b in series connection through the male terminal 13 of a first semi-battery pack to the female terminal 12 of an adjacent semi battery pack to provide a battery pack 50.
  • Figure 9f depicts one embodiment of a first semi battery pack 50a being connected to a second semi battery pack 50b, wherein connectivity between the adjacent semi battery packs is provided by the combination of a disconnect switch 53 and a relay and control box 52.
  • FIG. 1 Oa depicts one embodiment of a rack 60 for housing the battery pack 50, in accordance with the present invention.
  • the rack 60 is composed of an insulating material, such as an insulating polymer.
  • the term insulating denotes that the rack 60 does not conduct electricity.
  • the rack 60 provides for ventilation of the battery pack 50 housed therein, wherein in one embodiment the rack 15 stabilizes the spacing between the rows of module to module connections for each battery pack 50.
  • the spacing between rows of module to module connections of the battery cells may be greater than 1.5 mm and less than 3.0 mm.
  • the spacing between rows of module to module connections may range from about approximately 3 mm to approximately 4 mm.
  • Figure 10b depicts one embodiment of a rack 60 having a plurality of pegs 65 each having a geometry corresponding to the geometry of the straight cell to cell connections 29 between each battery cell 2 of at least one row of battery cells in a battery module 35.
  • the pegs 65 stabilize the spacing 66 between each adjacent row of battery cells 2.
  • each of the battery cells 10 has the geometry of the extruded body cells, as depicted in Figures l-6c.
  • Figure 10c depict one embodiment of a rack 60 having a plurality of end pegs 67 having a geometry corresponding to the end portion of each battery cell 10 and each bend terminal 30 interconnecting each of the adjacent battery cells 10.
  • each of the battery cells 10 has the end geometry of the extruded body cells, as depicted in Figures 1-3.
  • the spacing 66 provided by the pegs 65, 61 provides for cooling between adjacent rows of battery modules.
  • the spacing 66 provided between each of the rows of battery cells 10 is provided by the convex structures 6 of the stamped cell housing 2 described in reference to Figures 7a-7c, in which the apex of the portion of the sphere 6 that is facing away from the centerline of the body 2 of the first battery cell contacts the body of the adjacent battery cell in stabilizing the spacing 66 between adjacent battery cells.
  • the convex structures 6 are employed in combination with the pegs 65, 67 of the rack.
  • Figures 1 Ia-I Ie depict one embodiment of an assembled rack housing battery pack 50 and having an upper and lower portion 60a, 60b.
  • the rack 60 further including upper and lower channels 75, 76, which when utilized with upper and lower vents 77, 78 formed in the upper and lower portions 60a, 60b of the rack 60 circulate air through the battery pack 50.
  • Figure 11a depicts one embodiment of a lower rack 60b portion having channels 76 and vents 78 positioned to direct airflow through the battery pack 50. It is noted that although only three channels 76 are depicted, any number of channels 76 are within the scope of the present disclosure.
  • Figure l ib depicts the upper and lower portions 60a, 60b of the rack 60 being assembled and housing the battery pack 50. Similar to the lower portion 60b, the upper portion 60a of the rack also includes a plurality of channels 75 and a series of vents 77. In one embodiment, the vents and channels 77, 75 of the upper portion 60b of the rack 60 are configured to exhaust airflow past the battery pack 50 and out of the rack 60.
  • Figure l ie depicts airflow into one embodiment of a rack 60 in accordance with the present invention, wherein the lower portion 60b of the rack 60 functions as an air inlet 80.
  • Figure 1 Id depicts airflow out of one embodiment of the rack 60 in accordance with the present invention, wherein the upper portion 60a of the rack 60 functions as an air outlet 85 or exhaust.
  • Figure l ie depicts a cross section of one embodiment of the rack 60 housing the battery pack 50, wherein the lower portion 60b of the rack 60 is the air intake 80 and has a greater channel height Hl then the height H2 at the opposing end of the same channel.
  • the heights of the channel Hl and H2 and the configuration of the battery pack 50 form a trapezoidal shape for air flow in the lower portion 60b of the rack 60.
  • the air enters the channels 76 of the lower portion 60b of the rack and passes through the vents 78 of the lower portion 60b of the rack. The air passes over the battery pack 50 and through the spacing 66 separating the battery modules of the battery pack 50.
  • the air After passing over the battery pack 50 through the vents 77 the air then exits the rack 60 through the outlet 85 of the upper portion 60a of the rack 60.
  • the channel height H3 of the upper portion 60a at the outlet 85 is greater than the channel height H4 of the lower portion 60b of the rack 60 at the outlet end.
  • the height H4 of the channel may range from approximately 10 mm to approximately 30 mm.
  • the channel shape is selected so that the air flow rate across each battery cell is approximately equal, hence in one embodiment equally cooling each of the battery cells.
  • Figure 12 depicts one embodiment of the rack 60 and battery pack 50 of the present invention integrated into a battery system.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

The present invention in one embodiment provides a battery module system including a plurality of battery cells in which each battery cell of the plurality of battery cells has an extruded body and comprising a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the extruded body. In another embodiment, the battery cell body is provided by a stamping operation.

Description

INTEGRATED MODULE CONNECTION FOR HEV BATTERY
Cross Reference to Related Application [0001] The present invention claims the benefit of U.S. provisional patent application
60/786,320, filed March 27, 2006, the whole contents and disclosure of which is incorporated by reference as is fully set forth herein, and U.S. provisional patent application 60/888, 262, filed February 5, 2007, the whole contents and disclosure of which is incorporated by reference as is fully set forth herein.
Field of the Invention
[0002] The present invention in one embodiment relates to battery arrangements. In one embodiment, the present invention further relates to nickel metal hydride and lithium ion batteries.
Background of the Invention
[0003] Hybrid Electrical Vehicle (HEV) battery packs consist of number of battery modules, wherein each battery module has a plurality of battery cells. Typically, the battery modules are in electrical communication through module to module series connections. Module to module connections typically require nut and bolt arrangements that provide a number of difficulties, since this manufacturing method is prone to over-torquing or under-torquing of the nut and bolt fasteners. Additionally, cross threading of the bolts is also common, which may destroy the positive or negative battery post when over-torqued. The concise assembly required for high voltage battery module manufacturing and the need for closely monitored torque control render bolt and nut arrangements uneconomical for high voltage battery module manufacturing. Summary of the Invention
[0004] In one embodiment the present invention provides a battery module apparatus. In one embodiment, the battery module apparatus includes:
[0005] at least one battery cell comprising an extruded body housing a battery medium, a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the extruded body.
[0006] In one embodiment, the battery medium is a lithium ion or nickel metal hydride battery medium. In one embodiment, the battery module system includes a plurality of battery cells having extruded bodies housed within an insulating rack comprising a series of channels and vents, wherein spacing between adjacent rows of battery modules of cells is provided by a series of pegs.
[0007] In another embodiment, the battery module apparatus includes:
[0008] at least one battery cell comprising a stamped body housing a battery medium, a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the stamped body.
[0009] In one embodiment, the battery module system includes a plurality of battery cells having stamped bodies housed within an insulating rack comprising a series of channels and vents, wherein spacing between each row of battery modules is provided by a convex structure positioned in a sidewall of the stamped body.
Brief Description of the Drawings [0010] The following detailed description, given by way of example and not intended to limit the invention solely thereto, will best be appreciated in conjunction with the accompanying drawings, wherein like reference numerals denote like elements and parts, in which:
[0011] Figure 1 depicts a perspective view of one embodiment of an extruded pipe having a cross section configured for housing a battery cell, in accordance with the present invention.
[0012] Figure 2 depicts a perspective view of one embodiment of the extruded pipe depicted in Figure 1 after being sectioned to a length suitable for providing a battery cell, in accordance with the present invention.
[0013] Figure 3a depicts a perspective view of one embodiment of a battery medium, in accordance with the present invention.
[0014] Figure 3b depicts a cross sectional view of one embodiment of a battery medium in accordance with the present invention.
[0015] Figure 4a depicts a perspective view of one embodiment of a battery cell having a housing formed from an extruded pipe, as depicted in Figure 2.
[0016] Figures 4b and 4c depict perspective views of one embodiment of process steps for providing the battery cell depicted in Figure 4a.
[0017] Figure 5a depicts a perspective view of another embodiment of a battery cell having a housing formed from an extruded pipe, as depicted in Figure 2.
[0018] Figures 5b and 5c depict perspective views of one embodiment of process steps for providing the battery cell depicted in Figure 5a.
[0019] Figures 6b-6c depicts a perspective view of another embodiment of a battery cell having a housing formed from an extruded pipe, as depicted in Figure 2. [0020] Figures 7a-7c depict perspective views of some embodiments of a stamped battery cell housing, in accordance with the present invention.
[0021] Figures 8a-8c depict perspective views of some embodiments of the connectivity assembled battery cells, in accordance with the present invention.
[0022] Figure 9a depicts a perspective view of one embodiment of a battery module including a plurality of battery cells, in accordance with the present invention.
[0023] Figure 9b depicts a perspective view of a semi-battery pack including a plurality of battery modules, in accordance with the present invention.
[0024] Figure 9c depicts a perspective view of one embodiment of a connection for a battery module to provide connectivity to an adjacent battery module, in accordance with the present invention.
[0025] Figure 9d depicts a perspective view of one embodiment of a semi-battery pack including a plurality of battery cells as depicted in Figures 7a-7c.
[0026] Figure 9e depicts a perspective view of one embodiment of two interconnected battery modules, in accordance with the present invention.
[0027] Figure 9f depicts a perspective view of one embodiment of two modules, in which each battery module is separated by a relay and control box.
[0028] Figure 10a depicts a perspective view of one embodiment of a rack for assembling battery modules, in accordance with the present invention.
[0029] Figure 10b depicts a perspective view of one embodiment of a rack having pegs for stabilizing the spacing of adjacent battery modules at straight terminal cell to cell connections, in accordance with the present invention. {0030] Figure 1 Oc depicts a perspective view of one embodiment of a rack having pegs for stabilizing the spacing of the end portions battery modules a bend terminal cell to cell connections, in accordance with the present invention.
[0031] Figure 1 Ia depicts a perspective view of one embodiment of the vents to the bottom rack housing the battery modules, in accordance with the present invention.
[0032] Figures 1 Ib- 11 d depict perspective views of one embodiment of an assembled rack housing battery module, in accordance with the present invention.
[0033] Figure l ie depicts a cross sectional view of one embodiment of the assembled rack and battery module combination, as depicted in Figures 1 Ib-11 d.
[0034] Figure 12 depicts one embodiment of battery modules integrated into a battery system in accordance with the present invention.
Detailed Description of Preferred Embodiments
[0035] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that maybe embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention are intended to be illustrative, and not restrictive. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0036] Figure 1 depicts one embodiment of an extruded pipe 1 having a cross section to house a battery medium, which may be sectioned to a length suitable for an extruded body 1 a for a battery cell housing, as depicted in Figure 2, in accordance with the present invention. For the purposes of this disclosure, the term "extruded body" means a housing that has a substantially constant cross section along at least a portion of the longitudinal length of the housing. The longitudinal length of the housing extends from the positive terminal to the negative terminal of the battery cell. In one embodiment, a substantially constant cross section includes a wall thickness of the housing being substantially constant. In one embodiment, a substantially constant wall thickness denotes a deviation ranging from +/- 0.05 mm to +/- 0.5 mm from a thickness value that may range 0.5 mm to 2.5 mm. In one embodiment, the wall thickness of the extruded body being substantially constant includes an extruded body having an upper wall, lower wall and sidewalls having substantially equal thickness measured from the exterior face to the interior face.
[0037] In one embodiment, the extruded body is composed of an aluminum alloy. As used herein the term aluminum alloy means an aluminum metal with soluble alloying elements either in the aluminum lattice or in a phase with aluminum.. Alloying element include but are not limited to Cu, Fe, Mg, Ni, Si, Zn, Mn, Ti, Cr, V, Ag, Sn, Sc, and Li. In another embodiment, the extruded body Ia may include steel, copper, or zinc. In an even further embodiment, the extruded body 1 a may be plastic or a composite material
[0038] The cross section of the extruded body 1 a is configured to house a battery medium that in one embodiment may include lithium ion or metal nickel hydride, wherein the battery medium may include a cathode and an anode portion. Referring to Figure 3a, in one embodiment, the battery medium 80 may include lithium ion or metal nickel hydride and may be a laminated structure including a foil wrapped around a core. A positive terminal 4 is connected to the cathode portion and a negative terminal 3 is connected to the anode portion. [0039] In one embodiment, the positive terminal 4 may be provided by an electrically conductive tab that is in electrical communication to the cathode portion of the battery medium 80. hi one embodiment, the negative terminal 3 may be provided by an electrically conductive tab that is in electrical communication to the anode portion of the battery medium 80. In one embodiment, the electrically conductive tab may be provided by a metal, such as aluminum, steel, copper, and nickel alloy. The term electrical communication denotes that the connection is capable of conducting an electrical current.
[0040] The cross section of the laminated cell structure is depicted in Figure 3b. In one embodiment, the battery medium may include a cathode portion 82 including a cathode metal current collector 83, and a battery medium positive electrode 84; an anode portion 85 including an anode metal current collector 86 and a battery medium negative electrode 87; and a separator layer 88 insulating the anode portion 85 from the cathode portion 82. In one embodiment of the cathode portion 82 the battery medium positive electrode 84 may be composed of Li containing material, and the battery medium positive electrode 83 may be composed of metal foil, wherein the metal may include but is not limited to Al, Cu or Ni Alloys or combinations thereof.
[0041] In one embodiment, the of the anode portion 85 the battery medium positive electrode 86 may be composed of Li containing material, and the battery medium negative electrode 87 may be composed of metal foil, wherein the metal may include but is not limited to Al, Cu or Ni Alloys or combinations thereof. The separator layer 88 is composed on an electrically insulating material, such as a polymeric material.
[0042] In one embodiment, extrusions of pipe 1 for the extruded body Ia are provided by providing a metal billet, such as a metal billet composed of but not limited to an aluminum extrusion alloy, and pressing the metal billet through an extrusion die. hi one embodiment, the extrusion operation for forming the extruded body Ia makes use of a die assembly, including an extrusion die itself together with a backer. In one embodiment, the extrusion die is a steel disk with an opening, wherein the size and shape of the opening corresponds to the intended cross- section of the extruded pipe 1. The substantially constant cross section of the extruded body Ia has a geometry corresponding to the size and shape of the opening in the extrusion die. In one embodiment, the hollow portions are provided by an extrusion die including a mandrel. Figure 2 depicts one embodiment of an extruded body Ia following sectioning of the extruded pipe 1 to the length sufficient to provide a housing for the battery medium 80.
[0043] Figure 4a depicts one embodiment of a battery cell 10a formed from the extruded body Ia provided from the extruded pipe, in accordance with one aspect of the present invention. The extruded body Ia includes a first end corresponding to the positioning of the positive terminal 4 to the battery medium 80 and a second end corresponding to the negative terminal 3 of the battery medium 80, wherein the first end and the second end of the extruded body Ia oppose one another.
[0044J Referring to Figure 4b, in one embodiment, to provide the battery cell 10 a depicted in Figure 4a, the battery medium 80 is positioned within the extruded body 1 a, in which the positive terminal 4 is positioned corresponding to a first end of the extruded body Ia and the negative terminal 3 is positioned at the opposing second end of the extruded body Ia. In a next step, an insulating material is applied to the first and second ends of the extruded body Ia, in which the insulating material is applied around the positive and negative terminals 4, 3. In one embodiment, the amount of insulating material is selected to ensure that following the sealing of the positive and negative terminals from each end of the extruded body that the cell is substantially devoid of air and moisture. The term insulating material means denotes a substance that does not conduct an electrical current. In one embodiment, an insulating material is provided by a nonmetallic material. Examples of insulting materials include, but are not limited to, polymeric and ceramic materials. In one embodiment, the insulating material is provided by silicone or a silicone containing material.
[0045] In one embodiment, following application of the insulating material, the first and second end of the extruded body Ia may be sealed, as depicted in Figure 4c. In one embodiment, the seal may be characterized as being substantially hermetic. The term substantially hermetic denotes airtight by fusion or by sealing, wherein airtight means a seal against the substantial entry or exit of air and moisture from the housing 2. In one embodiment, the seal is provided by the insulating material applied to the opposing ends of the extruded body Ia. In one embodiment, the seal is provided by deforming the ends of the extruded body where the sidewalls at each end of the extruded body contact one another, with the exception of the portions of the sidewalls corresponding to the positive and negative terminals 4, 3. hi one embodiment, the positive terminal 4 and the negative terminal 3 is insulated from the housing 2 by the insulating medium positioned at the interface of the terminals 3, 4 and the sealed portions of the housing 2. More specifically, the insulating material is applied to the portions of the terminals 3, 4 that extend from the battery medium 80 and are contained within the housing 2 of the battery cell 10a, as well as the portions of the terminals 3, 4 that pass through the sealed end of the extruded body Ia to the exterior of the battery cell 10a.
[0046] In one embodiment, the insulating material is applied to a first end of the extruded body 1 a and then sealed, wherein in a following step the insulating material is applied to the second end of the extruded body and sealed. In another embodiment, the insulating material is applied to both the first and second end of the extruded body, wherein following the application of the insulating material to both ends of the extruded body Ia each end is then sealed.
[0047] In one embodiment, the seal is provided by a welding operation selected from the group including but not limited to resistance welding, laser welding, ultrasonic welding and combinations thereof. In another embodiment, the seal is provided by a combination of the insulating material and welding operations. In yet another embodiment, the seal at the opposing ends of the extruded body 1 a is provided by a crimping operation. Crimping is joining two pieces of metal or other malleable material by deforming one or both of them to hold the other. In a further embodiment, the seal engagement at the first and second end may further include an adhesive. In an even further embodiment, the sealed engagement may be provided by any combination of the above.
[0048] It is noted that the method described with reference to Figures 4a to 4c may include intermediary process steps in addition to the above description.
[0049] Figure 5a depicts another embodiment of a battery cell 1 Ob formed from an extruded body 1 a, in which the positive terminal 4 and negative terminal 3 to the battery medium 80 correspond to a one end of the extruded body Ia. Referring to Figure 5b, in one embodiment of a method for forming the battery cell 10b depicted in Figure 5a, the end opposite the positive and negative terminals 4 is closed by deforming the sidewalls of the extruded body into contact with one another. In a next step, the closed end 90 may be sealed, as described above. For example, the closed end 90 may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof. In one embodiment, the seal may be characterized as being substantially hermetic.
[0050] In a following process step, the battery medium may be positioned within the housing 2 provided by the extruded body Ia, as depicted in Figure 5c, and an insulating material is applied to the open end 91. As described above, the insulating material does not conduct electricity and in one embodiment may be silicon or a silicon containing material. The amount of insulating material is selected to ensure that following the sealing of the open end 91 the battery cell will be substantially devoid of air and moisture within the housing. In one embodiment, the insulating material is applied to the portions of the positive terminal 4 and the negative terminal 3 corresponding to the extruded body Ia to ensure that the positive and negative terminals 3, 4 are insulated from the housing 2. More specifically, the insulating material is applied to the portions of the terminals 3, 4 within the housing 2 extending from the battery medium 80 and is applied to the portions of the terminals 3, 4 passing through the sealed end of the extruded body Ia.
[0051] Following the application of the insulating material the open end 91 of the extruded body Ia is sealed to provide the structure depicted in Figure 5a, in which the positive and negative terminals correspond to a singular end of the battery cell 10b. The open end 91 may be sealed in a manner similar to that described with reference to Figures 4a to 4c. For example, the open end may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof. In one embodiment, the seal may be characterized as being substantially hermetic. [0052] It is noted that the method described with reference to Figures 5a to 5c may include intermediary process steps in addition to the above description.
[0053] Figures 6a and 6b depict embodiment of the battery cell 10c formed from an extruded body 1 a, in accordance with the present invention, in which the negative terminal 4 to the battery medium 80 is in electrical communication to the extruded body Ia. In the embodiments depicted in Figures 6a and 6b, the extruded body may serve as the negative terminal of the cell. Figure 6a depicts one embodiment of a battery cell, in which the positive terminal 4 is positioned in the center of the battery cell's 1 Oc width, in which the width Wl is defined as the dimension from a first edge of the battery cell's sealed end to the second end of the battery cell's sealed end. Figure 6 b depicts one embodiment of a battery cell, in the positive terminal is positioned offset from the center of the battery cell's width Wl .
[0054] Referring to Figure 6c, in one embodiment of a method for forming the battery cells 10c, 1Od depicted in Figures 6a and 6b, the battery medium 80 is inserted within the extruded body Ia and the negative terminal 3 is connected in electrical communication to a portion of the extruded body's interior. In one embodiment, the connection is provided by a welding operation selected from the group including but not being limited to laser welding, resistance welding, and ultrasonic welding. In another embodiment, the negative terminal can be arranged to provide electrical communication to the extruded body by maintaining a normal force between the negative terminal and the extruded body.
[0055] Following the connection of the negative terminal 3 to the extruded body Ia, the edge of the extruded body Ia corresponding to the negative terminal 3 is closed by deforming the sidewalls of the extruded body Ia into contact with one another. In a next step, the end may be sealed, as described above. For example, the closed end may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof. In one embodiment, the seal may be characterized as being substantially hermetic. In one embodiment, silicone may be utilized as a sealant, wherein the amount of silicon employed is selected to ensure that following the sealing of the extruded body 1 a the battery cell will be substantially devoid of air and moisture within the housing.
[0056] In one embodiment, in a following process step similar to the embodiments described above, an insulating material, such as silicon, is applied to the positive terminal 4 and to the end of the extruded body Ia corresponding to the positive terminal 4. The amount of insulating material is selected to ensure that following the sealing of the battery cell will interior of the cell will be substantially devoid of air and moisture. In one embodiment, the insulating material is applied to the positive terminal 4 to ensure that the positive terminal 4 is insulated from the housing 2, such as the portions of the positive terminals 4 passing through the sealed end of the extruded body Ia. Following the application of the insulating material the extruded body Ia is sealed to provide the structure depicted in Figures 6a and 6b. In one embodiment, the end corresponding to the positive terminal 4 may be sealed adhesively, in a crimping operation, or by a welding operation including but not limited to resistance welding, ultrasonic welding, laser welding or combinations thereof. In one embodiment, the seal may be characterized as being substantially hermetic.
[0057] In the embodiments of the present invention in which the housing 2 of the body cell functions as a negative terminal, such as the embodiments described with Reference to Figures 6a-6c, the exterior face of the extruded body Ia may be coated or jacked with an insulating material. In one embodiment, the insulating material may be provided by a polymeric or ceramic jacking or a polymeric or ceramic jacking. The jacking or coating of insulating material is provided to avoid shorting adjacent battery cells. In one embodiment, a portion of the exterior face of the extruded body Ia is substantially clear of the insulating material to provide for electrical communication to the positive terminal 4 of an adjacent battery cell. In another embodiment, the battery cell may be coated or jacked to facilitate the hermetic sealing of the battery cell.
[0058] Figures 7a-7c depict some other embodiments of a battery cell housing 2, in accordance with the present invention, wherein the battery cell housing 2 is provided by a stamped metal. A stamped metal means a structure provided by a metalworking process by which sheet metal are punched using a press tool which is loaded on a machine press or stamping press to form the sheet into a desired shape. In one embodiment, a first sidewall and second sidewall Ib, Ic are stamped separately, as depicted in Figure 7b. Following, the stamping process a battery medium is positioned between each sidewall Ib, Ic of the housing 2, wherein the perimeter portions of each sidewall Ib, Ic, are sealed. In one embodiment, the perimeter portions are provided by a flange 95 that corresponds of each sidewall Ib, Ic. In one embodiment, the sealed perimeter portions may be provided by a crimping operation, welding operations, adhesively or a combination thereof. Similar to the embodiments described above with reference to Figures l-6c, in one embodiment, the sealed engagement of the first and second sidewall Ib, Ic, may be characterized as being hermetic.
[0059] Similar to the battery cells formed using an extruded body, an insulating material may be employed to insulate at least the positive terminal 4 to the battery medium from the stamped housing. In one embodiment, the insulating material may be silicone. The amount of insulating material is selected to ensure that following the sealing of the open end 91 the battery cell will be substantially devoid of air or moisture within the housing. In one embodiment, the insulating material is applied to the portions of the positive terminal 4 and the negative terminal 3 corresponding to the extruded body Ia to ensure that the positive and negative terminals 4, 3 are insulated from the housing 2. More specifically, the insulating material is applied to the portions of the terminals 3, 4 within the housing 2 extending from the battery medium 80 and is applied to the portions of the terminals 3, 4 passing through the sealed end of the stamped body.
[0060] In another embodiment, only the positive terminal is separated from housing 2 and the negative terminal 3 is connected in electrical communication to the stamped housing, in which the stamped body provides the negative terminal of the battery cell. In the embodiments of the present invention in which the housing 2 of the body cell functions as the negative terminal, the exterior face of the stamped body Ia may be coated or jacked with an insulating material.
[0061] In one embodiment, the first and second sidewall Ib, Ic further include spacing members 6 configured to provide spacing between the sidewalls of adjacent battery cells. In one embodiment, the spacing members are provided by convex structures having the geometry of at least a portion of a sphere, in which the apex the sphere extends from the sidewall away from the center of the battery, hence providing a greater width to the portions of the battery cells having the spacing members in comparison to the portions of the battery cell not having the spacing members. In one embodiment, the spacing members 6 provide a separation between adjacent battery cells on the order of greater than approximately 1.5 mm. In one embodiment, contact between adjacent space members 6 provide balance to the heat between adjacent cells.
[0062] Referring to Figure 7c, in another embodiment, the stamped body is provided by a unitary blank. The term unitary denotes that the blank is formed of a single stamping from sheet metal. In one embodiment, the unitary blank includes the first and the second sidewall, wherein the first and the second sidewall share a joining portion 96. In one embodiment, the battery medium is positioned between the first and second sidewall and the unitary blank is folded along the joining portion 96, wherein following the folding operation the remaining unjoined sides of the unitary blank are sealed. Similar to the embodiments described above, the seal may be hermetic and may be provide by crimping, adhesive, welding operations or combinations thereof, wherein provisions for a positive 4 and negative terminal 3 are also provided.
[0063] Referring to Figures 8a-8c, in one embodiment, at least two battery cells 10 are interconnected to provide a battery module 15. Figure 8a depicts four series connected battery cells having extruded bodies with positive and negative terminals at opposing ends of each battery cell, as depicted in Figures 4a-4c, or battery cells having a negative terminal in electrical communication to the extruded body as depicted in Figure 6a. Figure 8b depicts six series connected battery cells having an extruded body with positive and negative terminals positioned at a singular end, as depicted in Figures 5a-5c, or battery cells having a negative terminal in electrical communication to the extruded body, as depicted in Figure 6b. Figure 8c depicts two series connected battery cells having stamped bodies, as described with reference to Figures 7a- 7c. The connection between the positive and negative terminals of adjacent battery cells may be provided by a welding operations including but not limited to laser welding, resistance welding, ultrasonic welding or a combination thereof.
[0064] A battery module 15 is a structure including greater than two battery cells, in which each of the battery cells in the battery module is connected in electrical communication. In one embodiment, each battery cell 10 is interconnected to the adjacent battery cell 10 from the positive terminal 4 to the negative terminal 3. In one embodiment, each battery cell 10 provides on the order of 4 volts or less, and may be interconnected to provide a battery module 15 providing on the order of 50 volts or less.
[0065] Figure 9a depicts a battery module 15 having two end cell to cell connections 20a, 20b at opposing ends of the battery modules and two middle cell to cell connections 25 between the end cell to cell connections 20a, 20b of the battery module 15. The first end cell to cell connection 20a includes a first battery end cell l la and a second battery end cell lib, wherein the first battery end cell lla includes a battery module female terminal 12 in electrical connectivity to the positive terminal 4a of the first battery cell 11. The female terminal 12 is configured to provide electrically connectivity to a male pin of an adjacent battery module in series connection. The battery module female terminal 12 may be provide by a coil spring 80 positioned within a groove 81 formed about an opening in a stamped metal connector housing, wherein the groove 81 and opening correspond to the geometry of the male pin 13 of an adjacent battery module. The negative terminal 3a of the first battery end cell 1 Ia is in electrical connectivity to the positive terminal 4b of the second battery end cell 1 Ib. In one embodiment, the terminal to terminal connection between the first and second battery end cell may be provided by a straight configuration 29 between each cell.
[0066] In one embodiment, electrical connectivity between end cell to cell connections 20a, 20b, and middle cell to cell connections 25 is provide by terminals having a bend 30 configuration. In one embodiment, a bend configuration 30 denotes a terminal having a bend of approximately 90 degrees at each end of the terminal. In one embodiment, the negative terminal 3a of the second battery end cell 1 Ib has a bend terminal 30 that provides for electrical connectivity to a middle cell to cell configuration 25, and in one embodiment provides for electrical connectivity to the positive terminal of the battery cell of the middle cell to cell configuration 25. In one embodiment, the opposing end of the middle cell to cell configuration 25 may also include a bend terminal 30 for connectivity to a second set of middle cell to cell configuration or to the second end cell to cell connections 20a, 20b.
[0067] In one embodiment, the second end cell to cell connection 20b includes a first battery end cell l ie and a second battery end cell l id, wherein the second battery end cell 1 Id includes a male terminal 13 in electrical connectivity to the negative terminal 3a of the second battery cell 1 Id, in which the terminal to terminal connections of the first battery end cell 1 Ic to the second end battery cell 1 Id may have a straight configuration 29. In one embodiment, the battery module male terminal includes a male pin 13 having a geometry for engagement to the female terminal 12 of the adjacent battery module in electrical communication.
[0068] In one embodiment, the terminal connections 29, 30 are provided by electrically conductive junctions. In one embodiment, the terminal connections 29, 30 between adjacent cells 2 are provided by welded connections. In one embodiment, the welded connection may be provided by ultrasonic weld, laser welding, resist welding, and fushion welding.
[0069] Figure 9b depicts a semi battery pack module 40 in accordance with the present invention having greater than one module to module connection between each row of modules. Specifically, each row of the semi battery pack depicted in Figure 9b includes eight cells 10 having seven cell to cell connections. In one embodiment at least one row is constructed as a module. In one embodiment the number of cell to cell connections in each row or module may be increased by cells having straight terminals at opposing ends of the cell. Figure 9c depicts one embodiment of a semi-battery pack having 16 rows of battery modules, in which adjacent rows of battery modules are connected in series by bend terminals 30. Figure 9d depicts one embodiment of battery module having the housing 2 depicted in Figures 7a-7c, wherein spacing 66 between each adjacent row of battery modules is dictated by the convex structures 6. Figure 9e depicts one embodiment of two semi battery packs 40a, 40b in series connection through the male terminal 13 of a first semi-battery pack to the female terminal 12 of an adjacent semi battery pack to provide a battery pack 50. Figure 9f depicts one embodiment of a first semi battery pack 50a being connected to a second semi battery pack 50b, wherein connectivity between the adjacent semi battery packs is provided by the combination of a disconnect switch 53 and a relay and control box 52.
[0070] Figure 1 Oa depicts one embodiment of a rack 60 for housing the battery pack 50, in accordance with the present invention. In one embodiment, the rack 60 is composed of an insulating material, such as an insulating polymer. The term insulating denotes that the rack 60 does not conduct electricity. In one embodiment, the rack 60 provides for ventilation of the battery pack 50 housed therein, wherein in one embodiment the rack 15 stabilizes the spacing between the rows of module to module connections for each battery pack 50. Li one embodiment, the spacing between rows of module to module connections of the battery cells may be greater than 1.5 mm and less than 3.0 mm. In embodiment, in which the negative terminal of the battery cell is provided by the cell housing the spacing between rows of module to module connections may range from about approximately 3 mm to approximately 4 mm.
[0071] Figure 10b depicts one embodiment of a rack 60 having a plurality of pegs 65 each having a geometry corresponding to the geometry of the straight cell to cell connections 29 between each battery cell 2 of at least one row of battery cells in a battery module 35. In one embodiment, the pegs 65 stabilize the spacing 66 between each adjacent row of battery cells 2. In one embodiment, each of the battery cells 10 has the geometry of the extruded body cells, as depicted in Figures l-6c. Figure 10c depict one embodiment of a rack 60 having a plurality of end pegs 67 having a geometry corresponding to the end portion of each battery cell 10 and each bend terminal 30 interconnecting each of the adjacent battery cells 10. In one embodiment each of the battery cells 10 has the end geometry of the extruded body cells, as depicted in Figures 1-3. In one embodiment, the spacing 66 provided by the pegs 65, 61 provides for cooling between adjacent rows of battery modules.
[0072] In another embodiment, the spacing 66 provided between each of the rows of battery cells 10 is provided by the convex structures 6 of the stamped cell housing 2 described in reference to Figures 7a-7c, in which the apex of the portion of the sphere 6 that is facing away from the centerline of the body 2 of the first battery cell contacts the body of the adjacent battery cell in stabilizing the spacing 66 between adjacent battery cells. In one embodiment, the convex structures 6 are employed in combination with the pegs 65, 67 of the rack.
[0073] Figures 1 Ia-I Ie depict one embodiment of an assembled rack housing battery pack 50 and having an upper and lower portion 60a, 60b. In one embodiment, the rack 60 further including upper and lower channels 75, 76, which when utilized with upper and lower vents 77, 78 formed in the upper and lower portions 60a, 60b of the rack 60 circulate air through the battery pack 50. Figure 11a depicts one embodiment of a lower rack 60b portion having channels 76 and vents 78 positioned to direct airflow through the battery pack 50. It is noted that although only three channels 76 are depicted, any number of channels 76 are within the scope of the present disclosure.
[0074] Figure l ib depicts the upper and lower portions 60a, 60b of the rack 60 being assembled and housing the battery pack 50. Similar to the lower portion 60b, the upper portion 60a of the rack also includes a plurality of channels 75 and a series of vents 77. In one embodiment, the vents and channels 77, 75 of the upper portion 60b of the rack 60 are configured to exhaust airflow past the battery pack 50 and out of the rack 60. Figure l ie depicts airflow into one embodiment of a rack 60 in accordance with the present invention, wherein the lower portion 60b of the rack 60 functions as an air inlet 80. Figure 1 Id depicts airflow out of one embodiment of the rack 60 in accordance with the present invention, wherein the upper portion 60a of the rack 60 functions as an air outlet 85 or exhaust.
[0075] Figure l ie depicts a cross section of one embodiment of the rack 60 housing the battery pack 50, wherein the lower portion 60b of the rack 60 is the air intake 80 and has a greater channel height Hl then the height H2 at the opposing end of the same channel. The heights of the channel Hl and H2 and the configuration of the battery pack 50 form a trapezoidal shape for air flow in the lower portion 60b of the rack 60. In one embodiment, the air enters the channels 76 of the lower portion 60b of the rack and passes through the vents 78 of the lower portion 60b of the rack. The air passes over the battery pack 50 and through the spacing 66 separating the battery modules of the battery pack 50. After passing over the battery pack 50 through the vents 77 the air then exits the rack 60 through the outlet 85 of the upper portion 60a of the rack 60. The channel height H3 of the upper portion 60a at the outlet 85 is greater than the channel height H4 of the lower portion 60b of the rack 60 at the outlet end. In one embodiment, the height H4 of the channel may range from approximately 10 mm to approximately 30 mm. In one embodiment, the channel shape is selected so that the air flow rate across each battery cell is approximately equal, hence in one embodiment equally cooling each of the battery cells.
[0076] Figure 12 depicts one embodiment of the rack 60 and battery pack 50 of the present invention integrated into a battery system. [0077] While the present invention has been particularly shown and described with respect to the preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms of details may be made without departing form the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims.

Claims

What is claimed is:
1. A battery module system comprising:
at least one battery cell comprising an extruded body housing a battery medium, a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the extruded body.
2. The battery module system of Claim 1, wherein the battery medium is a lithium ion or nickel metal hydride battery medium.
3. The battery module system of Claim 1, wherein at least one battery cell comprises at least one battery module where each battery cell of the at least one battery module is in electrical connection through a welded connection.
4. The battery module system of Claim 3, wherein the welded connection comprises resistance welding, laser welding or ultrasonic welding.
5. The battery module system of Claiml, wherein the plurality of battery cells are housed within an insulating rack comprising a series of channels and vents.
6. The battery module system of Claim 5, wherein the insulating rack further comprises a series of pegs for providing spacing between each row of battery cells in the plurality of battery cells.
7. The battery module system of Claim 1, wherein the extruded body comprises aluminum.
8. The battery module of Claim 1, wherein the positive and negative terminals are positioned at opposing ends of the extruded body.
9. The battery module of Claim 1 , wherein the positive and negative terminals are positioned at a singular end of the extruded body.
10. The battery module of Claim 1 , wherein the negative terminal is in electrical communication with the extruded body.
11. The battery module of Claim 10, wherein an exterior surface of the extruded body is jacketed with an insulating material.
13. The battery module of Claim 1 , wherein the battery medium is hermetically sealed within the extruded body.
14. The battery module of Claim I3 wherein the at least one of the positive terminal and the negative terminal are insulated from the extruded body by a silicone containing material.
15. A battery module system comprising:
at least one battery cell comprising a stamped body housing a battery medium, a positive terminal and a negative terminal, wherein at least one of the positive terminal and the negative terminal are insulated from the stamped body.
16. The battery module system of Claim 15, wherein the battery medium is a lithium ion or nickel metal hydride battery medium.
17. The battery module system of Claim 12, wherein at least one battery cell comprises at least one battery module where each battery cell of the at least one battery module is in electrical connection through a welded connection.
18. The battery module system of Claim 15 further comprising a plurality of battery modules housed in rows within an insulating rack, wherein spacing between each row of battery modules is provided by a convex structure positioned in a sidewall of the stamped body.
19. The battery module system of Claim 15, wherein the stamped body comprises aluminum.
20. The battery module system of Claim 15, wherein the stamped body comprises a unitary structure.
PCT/US2007/007672 2006-03-27 2007-03-27 Integrated module connection for hev battery WO2007112116A2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US78632006P 2006-03-27 2006-03-27
US60/786,320 2006-03-27
US88826207P 2007-02-05 2007-02-05
US60/888,262 2007-02-05

Publications (2)

Publication Number Publication Date
WO2007112116A2 true WO2007112116A2 (en) 2007-10-04
WO2007112116A3 WO2007112116A3 (en) 2008-01-31

Family

ID=38541748

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2007/007672 WO2007112116A2 (en) 2006-03-27 2007-03-27 Integrated module connection for hev battery

Country Status (1)

Country Link
WO (1) WO2007112116A2 (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2025019A1 (en) * 2006-05-15 2009-02-18 LG Chem, Ltd. Middle or large-sized battery module
WO2010003979A1 (en) * 2008-07-08 2010-01-14 Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V. Improved electrochemical storage element
EP2075808A3 (en) * 2007-12-28 2010-10-20 TDK Corporation Electrochemical device and method of manufacturing electrochemical device
DE102009047490A1 (en) 2009-12-04 2011-06-09 Robert Bosch Gmbh Process for the preparation of an electrically conductive compound
US8394525B2 (en) 2010-06-22 2013-03-12 Ford Global Technologies, Llc Support assembly for an array of battery cells
US8647766B2 (en) 2010-06-22 2014-02-11 Ford Global Technologies, Llc Voltage detection in a battery
US10374263B2 (en) 2017-08-22 2019-08-06 International Business Machines Corporation Cooled containment compartments for packaged battery cells
GB2600147A (en) * 2020-10-23 2022-04-27 Ricardo Uk Ltd Battery packs

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5558950A (en) * 1993-03-05 1996-09-24 Ovonic Battery Company, Inc. Optimized cell pack for large sealed nickel-metal hydride batteries
US5695891A (en) * 1992-02-10 1997-12-09 C & D Charter Power Systems, Inc. Battery thermal management system
EP1143540A1 (en) * 2000-04-06 2001-10-10 Wilson Greatbatch Ltd. Cell design for improved energy density
WO2001082393A2 (en) * 2000-04-25 2001-11-01 Polystor Corporation Custom geometry battery cells and methods and tools for their manufacture
EP1524717A2 (en) * 2003-10-14 2005-04-20 Nissan Motor Co., Ltd. Battery module and combination battery

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5695891A (en) * 1992-02-10 1997-12-09 C & D Charter Power Systems, Inc. Battery thermal management system
US5558950A (en) * 1993-03-05 1996-09-24 Ovonic Battery Company, Inc. Optimized cell pack for large sealed nickel-metal hydride batteries
EP1143540A1 (en) * 2000-04-06 2001-10-10 Wilson Greatbatch Ltd. Cell design for improved energy density
WO2001082393A2 (en) * 2000-04-25 2001-11-01 Polystor Corporation Custom geometry battery cells and methods and tools for their manufacture
EP1524717A2 (en) * 2003-10-14 2005-04-20 Nissan Motor Co., Ltd. Battery module and combination battery

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2025019A1 (en) * 2006-05-15 2009-02-18 LG Chem, Ltd. Middle or large-sized battery module
US9640790B2 (en) 2006-05-15 2017-05-02 Lg Chem, Ltd. Middle or large-sized battery module
EP2025019A4 (en) * 2006-05-15 2010-05-05 Lg Chemical Ltd Middle or large-sized battery module
EP2075808A3 (en) * 2007-12-28 2010-10-20 TDK Corporation Electrochemical device and method of manufacturing electrochemical device
US7855013B2 (en) 2007-12-28 2010-12-21 Tdk Corporation Electric double-layer capacitor and method of manufacturing electric double-layer capacitor
WO2010003979A1 (en) * 2008-07-08 2010-01-14 Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V. Improved electrochemical storage element
DE102009047490A1 (en) 2009-12-04 2011-06-09 Robert Bosch Gmbh Process for the preparation of an electrically conductive compound
WO2011067025A1 (en) 2009-12-04 2011-06-09 Robert Bosch Gmbh Method for producing an electrically conductive connection
US8394525B2 (en) 2010-06-22 2013-03-12 Ford Global Technologies, Llc Support assembly for an array of battery cells
US8647766B2 (en) 2010-06-22 2014-02-11 Ford Global Technologies, Llc Voltage detection in a battery
US10374263B2 (en) 2017-08-22 2019-08-06 International Business Machines Corporation Cooled containment compartments for packaged battery cells
US10797359B2 (en) 2017-08-22 2020-10-06 International Business Machines Corporation Cooled containment compartments for packaged battery cells
GB2600147A (en) * 2020-10-23 2022-04-27 Ricardo Uk Ltd Battery packs
WO2022084648A1 (en) * 2020-10-23 2022-04-28 Ricardo Uk Limited Battery packs
GB2600147B (en) * 2020-10-23 2022-11-23 Ricardo Uk Ltd Battery packs

Also Published As

Publication number Publication date
WO2007112116A3 (en) 2008-01-31

Similar Documents

Publication Publication Date Title
WO2007112116A2 (en) Integrated module connection for hev battery
JP4555549B2 (en) Battery with case
KR100612364B1 (en) Secondary battery
EP0869564B1 (en) Nonaqueous electrolyte secondary battery
US9461296B2 (en) Secondary battery and secondary battery module
US10411227B2 (en) Energy storage device, energy storage apparatus and method of manufacturing energy storage device
KR100599732B1 (en) Secondary battery
EP1914817B1 (en) Rechargeable battery and battery module using the same
CN106025373A (en) Prismatic secondary battery and assembled battery using the same
US20080266752A1 (en) Thermal interconnects for coupling energy storage devices
US20070053140A1 (en) Flexible enclosure for energy storage devices
KR101472167B1 (en) Pouch of improved safety for secondary battery and secondary battery, battery pack using the same
US6833010B2 (en) Prismatic battery module and method for manufacturing the same
EP3076454B1 (en) Battery pack
US9318735B2 (en) Terminal-attached plate, plate assembly, and battery module
US20120177978A1 (en) Secondary battery, method of assembling the same, and battery pack including the secondary battery
US20120231641A1 (en) Unit cell connecting device, assembled battery having the same, and method of producing the assembled battery
WO2009047893A2 (en) Sealed battery
US20090029244A1 (en) Battery, and battery manufacturing method
WO2014040734A2 (en) Insulation of electrochemical energy storage devices
WO2020152857A1 (en) Battery pack and battery system
US20190296283A1 (en) Integrated battery cell modules with plug-in battery cells for electric vehicles
CN113728508B (en) Multi-layer contact plate and method thereof
CN111527617B (en) Battery cell for an electric vehicle battery pack
JP2021120961A (en) Square secondary battery and battery pack using the same

Legal Events

Date Code Title Description
NENP Non-entry into the national phase

Ref country code: DE

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 07754225

Country of ref document: EP

Kind code of ref document: A2

122 Ep: pct application non-entry in european phase

Ref document number: 07754225

Country of ref document: EP

Kind code of ref document: A2