WO2019028511A1 - A structural battery - Google Patents

A structural battery Download PDF

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Publication number
WO2019028511A1
WO2019028511A1 PCT/AU2018/050831 AU2018050831W WO2019028511A1 WO 2019028511 A1 WO2019028511 A1 WO 2019028511A1 AU 2018050831 W AU2018050831 W AU 2018050831W WO 2019028511 A1 WO2019028511 A1 WO 2019028511A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
structural
structural battery
battery
electric
Prior art date
Application number
PCT/AU2018/050831
Other languages
French (fr)
Inventor
Kim Schlunke
Peter BASKOVICH
Lindsay WOOD
Original Assignee
Cape Bouvard Technologies Pty Ltd
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
Priority claimed from AU2017903147A external-priority patent/AU2017903147A0/en
Application filed by Cape Bouvard Technologies Pty Ltd filed Critical Cape Bouvard Technologies Pty Ltd
Publication of WO2019028511A1 publication Critical patent/WO2019028511A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • 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
    • H01M50/107—Primary casings; Jackets or wrappings characterised by their shape or physical structure having curved cross-section, e.g. round or elliptic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb 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
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
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    • 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
    • H01M10/653—Means for temperature control structurally associated with the cells characterised by electrically insulating or thermally conductive materials
    • 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
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6554—Rods or plates
    • H01M10/6555—Rods or plates arranged between the cells
    • 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
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6556—Solid parts with flow channel passages or pipes for heat exchange
    • H01M10/6557—Solid parts with flow channel passages or pipes for heat exchange arranged between the cells
    • H—ELECTRICITY
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    • 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
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • 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
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • 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
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • 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
    • H01M50/20—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
    • H01M50/293—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 the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/302—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/542—Shear strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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    • B32B2457/00—Electrical equipment
    • B32B2457/10—Batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • 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 relates to a structural battery.
  • the Applicant has developed a composite structure suitable as a structural battery. More specifically, the Applicant has developed a structural battery comprising a container of a first material; and a core of a second material for accommodating a plurality of electric cells provided within said container wherein the container and the core of the composite structure together form a structural member having resistance to shear forces and longitudinal and transverse bending forces imposed on said structural member by the application. Further description of this composite structure is provided in the Applicant's copending International Patent Application, filed 8 August 2018 under Attorney Docket No. P42453PCAU, the contents of which are hereby incorporated herein by reference.
  • the core of the Applicant's structural battery provides shear resistance and compressive strength.
  • the core also accommodates the electric cells. It would be desirable for the core to accommodate the electric cells in a manner which does not compromise shear resistance and resistance to bending forces of the structural battery. At the same time, it would be desirable to accommodate the electric cells in a manner which offers potential for performance enhancement of the battery. Achieving these dual objectives presents design challenges.
  • the present invention provides a structural battery that addresses the above challenges and which facilitates the efficient use of electric power in a range of applications, whether for home use or use in a range of vehicles including automotive vehicles, aircraft including drones and mobility devices. [0005] With this object in view, the present invention provides a structural battery comprising:
  • a core of a second material for accommodating a plurality of electric cells provided within said container
  • the container and the core together form a structural member having resistance to shear forces, compression forces, tension forces, torsional forces and longitudinal and transverse bending forces imposed on said structural member by the application and wherein said core comprises pre-formed spaces for accommodating electric cells, said spaces having a shape compatible with the shape of an opposing surface of the electric cells.
  • the container may conveniently be of a first composite material or a lightweight conductive metal such as aluminium or aluminium alloy.
  • the core advantageously accommodates the electric cells within spaces pre-formed within a second material or a sub-structure of second material resistant to compression and shear loads.
  • Honeycomb or like core structures of lightweight material such as a conductive light metal or light metal alloy; for example aluminium, are advantageous.
  • Suitable core structures are also described in the Applicant's copending International Patent Applications filed 8 August 2018 under Attorney Docket Nos. P42453PCAU and P43209PCAU, the contents of which are incorporated herein by reference. Such core structures have high strength and stiffness yet are cost effective to produce.
  • Accommodation for electric cells in such core structures is provided by spaces formed by the layout of core elements or layers forming the framework of the core structure through which electric cells are conveniently longitudinally disposed, though these spaces may be open at each end of a core element or layer.
  • One or more electric cells may be accommodated per space though one electric cell per space is preferred.
  • Electric cells are desirably close packed within the core, desirably with a packing factor approaching that for hexagonal geometry.
  • Such spaces have a compatible shape including in section and volume to the opposing or external surface of an electric cell. Conveniently, this compatible shape is of the same or similar shape to an external surface of a selected electric cell.
  • each space of the core has a generally circular or ovoid cross-section and a generally cylindrical volume.
  • the spaces then include defining wall(s) the same shape as an opposing cylindrical surface of a cylindrical electric cell though these may be spaced apart by approximately the diameter of a cylindrical electric cell or greater. The number of electric cells and number of spaces selected to accommodate such electric cells is determined with reference to the electric power requirements of the application.
  • the core elements forming the framework of the honeycomb or like core structure form walls or adjacent layers or sheets, between which are defined spaces for accommodating electric cells. These walls may fully or partly enclose, i.e. define, the electric cell(s) accommodated within the space. Conveniently, and for matching with cylindrically shaped electric cells, the walls may be of circular, part circular or arcuate shape. In this case, a layer of the honeycomb core structure may have a corrugated shape with arcuate shape, such as semi-circular shape, corrugations. Portions of spaces not occupied by electric cells may be left empty or filled with another material.
  • Such a material could be included within a manufacturing blank for the honeycomb structure or an insulating material spacing the particularly preferred conductive layer(s), for example in a laminated structure such as a laminated sheet, the sheet for example being of aluminium or copper.
  • a ceramic insulating material may be used for insulating layers.
  • the material could be included within a structural link.
  • An insulating spacer could perform all these roles being also a blank and a structural link. Where electric cells are cylindrical, a convenient structural link may have dogbone shape matching the compatible shape of neighbouring corrugated layers of the honeycomb core structure described above.
  • the structural battery may include temperature control means for controlling the battery operating temperature, for example as described in the Applicant's co-pending International Patent Application filed 8 August 2018 under Attorney Docket No. P42683PCAU, the contents of which are hereby incorporated herein by reference.
  • Core elements may include fluid passage means for circulation of heat transfer fluids for temperature control. Contact between surfaces of an electric cell and a wall of its accommodating space assists heat transfer and, where desired, electrical conduction between electric cells and the core elements of the core structure. The latter option is described in the Applicant's co-pending International Patent Application filed 8 August 2017 under Attorney Docket No. P42682PCAU, the contents of which are hereby incorporated herein by reference.
  • Electric cells are included in number required to provide the required power for the composite structure so it functions as a structural battery.
  • the cell type is not critical though suitable batteries could be selected from rechargeable batteries, such as from the lithium ion battery class, such as for example 18650 type batteries rated at 3.7v approximately or 2170 type batteries rated at a higher voltage.
  • Such batteries have cylindrical geometry.
  • the structural battery can be used in a range of applications. Any application that can draw electric power from electric cells could adopt the composite structure as a structural battery.
  • a potential application is to electric motor vehicles.
  • the composite structure could accommodate a very large number of electric cells conveniently in the form of a floor pan for an electric motor vehicle. Weight is then focussed in the typically lowest point of the vehicle where it may provide a beam between front and rear wheels, left and right wheels (where provided) and a torsionally rigid member between all wheels.
  • Fig. 1 shows an orthogonal cutaway view of a structural battery according to one embodiment of the present invention.
  • Fig. 2 shows a plan view of the core structure of the structural battery of Fig. 1 .
  • FIG. 3 shows a detail view of a core element of the core structure of Figs. 1 and 2.
  • Fig. 4 shows an insulating spacer from the core structure as shown in Figs. 1 and 2.
  • Structural battery 10 for delivering electric power to an application requiring electric power such as an electric motor vehicle (not shown) but not limited to this.
  • Structural battery 10 includes a container 12 of a first, fibre reinforced composite material such as CFRP; and a core 130 of a second material for accommodating a plurality of electric cells 134 provided within the container 12.
  • the first material may also include other materials resistant to longitudinal and transverse bending forces, preferably lightweight materials which may include light metals or metal alloys such as aluminium alloys.
  • Container 12 includes respective upper and lower facing layers 12a and 12b (which though shown curved would typically be flat in practice) of sufficient strength to treat tension and compression loads. Facing layers 12a and 12b are of CFRP having significantly less electrical conductivity than metallic elements of the core described below.
  • the structural battery 10 therefore has a composite sandwich structure.
  • the structural battery 10 forms a structural member having resistance to compressive, shear and longitudinal and transverse bending forces imposed on the structural member by the electric motor vehicle whether stationary or in operation. Further description of the structural battery 10 and its composite sandwich structure, which approximates an "I" beam in structural characteristics, is provided in the Applicant's co-pending International Patent Application filed 8 August 2018 under Attorney Docket No. P42453PCAU, incorporated herein by reference.
  • Structure 130 forms the core of the structural battery 10.
  • Core structure 130 which is intended to be resistant to compressive and shear loads, is also electrically and thermally conductive comprising a framework of multiple corrugated aluminium or copper sheets or layers 131 A and 131 B which are bonded together with a laminated structure in a corrugation moulding process in such a way as to leave generally cylindrical spaces 132 of circular section for accommodating electric cells 134 longitudinally disposed within spaces 132 and connecting tabs or electrodes 135 and 136 in a manner avoiding short circuiting and other electrical malfunctions.
  • One electric cell 134 is accommodated by each space 132.
  • Electric cells 134 are desirably close packed within the core structure 130, desirably with a packing factor approaching that for hexagonal geometry.
  • layers 131 A and 131 B are spaced apart by approximately the diameter of an electric cell 134 and spaces 132 are open at each cell end.
  • Layers 131 A and 131 B are spaced apart by elongate insulating spacers 141 which also serve as structural links assisting in the provision of compressive strength and shear resistance.
  • Insulating spacers 141 one of which is shown in detail in Fig. 4, have arcuate or concave surfaces 141 A and 141 B and a dogbone shape when viewed end on or in plan.
  • Such insulating spacers 141 having the requisite compatible shape, are included as blanks and may facilitate corrugation moulding.
  • a ceramic insulating material or a polymeric insulating material, such as polyamide, may be used for spacers 141 .
  • the spacer material may be intumescent.
  • Spacers 141 may also include information links, such as a thermistor 141 C, for sensing battery parameters such as battery operating temperature which may form part of thermal control.
  • Each electric cell accommodating space 132 is substantially defined by the corrugated walls 133 of neighbouring layers 131 A and 131 B of the core structure 130 which, to be compatible with or match the cylindrical shape of the accommodated electric cells 134, have a part circular or arcuate geometry section as shown in Figs. 2 and 3.
  • Each space 132 also has a generally cylindrical volume.
  • layers 131 A and 131 B have corrugation walls 133 with part circular or arcuate portions, the same shape as a cylindrical electric cell 134.
  • a relatively minor portion of the wall defining each space 132 is provided by a portion of neighbouring insulating spacers 141 which are diametrically spaced apart relative to space 132.
  • Each electric cell 134 is in electrical and heat transfer contact with the neighbouring layers 131 A and 131 B of elements 131 of honeycomb structure core 130.
  • Each electrical cell 134 should be neatly fitted, and advantageously bonded, within its accommodating space 132 with an object to provide superior shear resistance.
  • Such fitting also enables electrical connectivity as described in the Applicant's co-pending International Application filed 8 August 2018 under Attorney Docket No. P42682PCAU, the contents of which are incorporated by reference.
  • the further heat transfer contact facilitates control over structural battery 10 operating temperature as described in the Applicant's co-pending International Application filed 8 August 2018 under Attorney Docket No. P42683PCAU, the contents of which are incorporated by reference.
  • each core element 131 of the honeycomb structure core 130 has a laminated structure here made up of multiple plies of aluminium as second lightweight material. For convenience, just two 131 AA and 131 AB are shown. Greater than two plies could be used.
  • spacers 157 are included during the moulding process to provide further structural framework for the layers 131 AA and 131 AB. Spacers 157 may be made from a wide range of materials, preferably a lightweight polymeric material such as a closed cell polyurethane foam or other plastic material. A metal or elastomeric material which may also be intumescent could also be employed.
  • Spacers 157 do not extend the full length of layers 131 AA and 131 AB, rather leaving inter-connected galleries 150 and 152 allowing thermal control by a heat transfer fluid flow C, for example of a refrigerant selected not to interfere with structural battery 10 operation and circulated by fixed or variable speed pump P during structural battery 10 operation to maintain battery operating temperature in a desired range of 15 Q C to 35 Q C. Further description of temperature control is described in the Applicant's co-pending International Application filed 8 August 2018 under Attorney Docket No. P42683PCAU, the contents of which are incorporated by reference.
  • Electric cells 134 of various types could be selected and this is not critical though suitable cylindrically shaped batteries could be selected from rechargeable batteries especially from the lithium ion battery class, such as for example 18650 or 2170 type batteries which have a cylindrical geometry and are rated at 3.7v per cell. In the case of an electric motor vehicle, the selected electrical cells 134 would enable the structural battery 10, while having the required structural properties as described herein and in incorporated references to act as a structural member, to have a relatively shallow depth in relation to length and breadth.
  • the structural battery 10 can be used in a range of applications including in fixed structures, mobility devices and portability devices.
  • a potential application is to electric motor vehicles.
  • a bank of structural batteries 10 could accommodate a very large number of electric cells 34, potentially thousands, and form a floor pan for an the electric motor vehicle.
  • Weight which is significantly lower than that involved with conventional metal and metal alloy battery containers or trays, would then be focussed in the lowest point of the vehicle where one or a bank of structural batteries provides a load bearing beam between front and rear wheels, left and right wheels (where provided) and a torsionally rigid member between all wheels.
  • Structural battery 10 is rechargeable and not intended for replacement under normal circumstances. However, it could be made replaceable if desired. This itself could depend on the application.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Battery Mounting, Suspending (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)

Abstract

A structural battery (10) comprising: a container (12) of a first material; and a core (130) of a second material for accommodating a plurality of electric cells (134) provided within said container (12); wherein the container (12) and the core (130) together form a structural member having resistance to shear forces, compression forces, tension forces, torsional forces and longitudinal and transverse bending forces imposed on said structural member by the application and wherein said core (130) comprises pre- formed spaces (132) for accommodating electric cells (134), said spaces (132) having a shape compatible with the shape of an opposing surface of the electric cells (134).

Description

A STRUCTURAL BATTERY
[0001 ] The present invention relates to a structural battery.
[0002] The Applicant has developed a composite structure suitable as a structural battery. More specifically, the Applicant has developed a structural battery comprising a container of a first material; and a core of a second material for accommodating a plurality of electric cells provided within said container wherein the container and the core of the composite structure together form a structural member having resistance to shear forces and longitudinal and transverse bending forces imposed on said structural member by the application. Further description of this composite structure is provided in the Applicant's copending International Patent Application, filed 8 August 2018 under Attorney Docket No. P42453PCAU, the contents of which are hereby incorporated herein by reference.
[0003] Structurally, the core of the Applicant's structural battery provides shear resistance and compressive strength. The core also accommodates the electric cells. It would be desirable for the core to accommodate the electric cells in a manner which does not compromise shear resistance and resistance to bending forces of the structural battery. At the same time, it would be desirable to accommodate the electric cells in a manner which offers potential for performance enhancement of the battery. Achieving these dual objectives presents design challenges.
[0004] It is an object of the present invention to provide a structural battery that addresses the above challenges and which facilitates the efficient use of electric power in a range of applications, whether for home use or use in a range of vehicles including automotive vehicles, aircraft including drones and mobility devices. [0005] With this object in view, the present invention provides a structural battery comprising:
a container of a first material; and
a core of a second material for accommodating a plurality of electric cells provided within said container;
wherein the container and the core together form a structural member having resistance to shear forces, compression forces, tension forces, torsional forces and longitudinal and transverse bending forces imposed on said structural member by the application and wherein said core comprises pre-formed spaces for accommodating electric cells, said spaces having a shape compatible with the shape of an opposing surface of the electric cells.
[0006] The container may conveniently be of a first composite material or a lightweight conductive metal such as aluminium or aluminium alloy. The core advantageously accommodates the electric cells within spaces pre-formed within a second material or a sub-structure of second material resistant to compression and shear loads. Honeycomb or like core structures of lightweight material such as a conductive light metal or light metal alloy; for example aluminium, are advantageous. Suitable core structures are also described in the Applicant's copending International Patent Applications filed 8 August 2018 under Attorney Docket Nos. P42453PCAU and P43209PCAU, the contents of which are incorporated herein by reference. Such core structures have high strength and stiffness yet are cost effective to produce.
[0007] Accommodation for electric cells in such core structures is provided by spaces formed by the layout of core elements or layers forming the framework of the core structure through which electric cells are conveniently longitudinally disposed, though these spaces may be open at each end of a core element or layer. One or more electric cells may be accommodated per space though one electric cell per space is preferred. Electric cells are desirably close packed within the core, desirably with a packing factor approaching that for hexagonal geometry. [0008] Such spaces have a compatible shape including in section and volume to the opposing or external surface of an electric cell. Conveniently, this compatible shape is of the same or similar shape to an external surface of a selected electric cell. Where the electric cell is cylindrical, each space of the core has a generally circular or ovoid cross-section and a generally cylindrical volume. The spaces then include defining wall(s) the same shape as an opposing cylindrical surface of a cylindrical electric cell though these may be spaced apart by approximately the diameter of a cylindrical electric cell or greater. The number of electric cells and number of spaces selected to accommodate such electric cells is determined with reference to the electric power requirements of the application.
[0009] The core elements forming the framework of the honeycomb or like core structure form walls or adjacent layers or sheets, between which are defined spaces for accommodating electric cells. These walls may fully or partly enclose, i.e. define, the electric cell(s) accommodated within the space. Conveniently, and for matching with cylindrically shaped electric cells, the walls may be of circular, part circular or arcuate shape. In this case, a layer of the honeycomb core structure may have a corrugated shape with arcuate shape, such as semi-circular shape, corrugations. Portions of spaces not occupied by electric cells may be left empty or filled with another material. Such a material could be included within a manufacturing blank for the honeycomb structure or an insulating material spacing the particularly preferred conductive layer(s), for example in a laminated structure such as a laminated sheet, the sheet for example being of aluminium or copper. A ceramic insulating material may be used for insulating layers. The material could be included within a structural link. An insulating spacer could perform all these roles being also a blank and a structural link. Where electric cells are cylindrical, a convenient structural link may have dogbone shape matching the compatible shape of neighbouring corrugated layers of the honeycomb core structure described above. [0010] In that regard, the structural battery may include temperature control means for controlling the battery operating temperature, for example as described in the Applicant's co-pending International Patent Application filed 8 August 2018 under Attorney Docket No. P42683PCAU, the contents of which are hereby incorporated herein by reference. Core elements may include fluid passage means for circulation of heat transfer fluids for temperature control. Contact between surfaces of an electric cell and a wall of its accommodating space assists heat transfer and, where desired, electrical conduction between electric cells and the core elements of the core structure. The latter option is described in the Applicant's co-pending International Patent Application filed 8 August 2017 under Attorney Docket No. P42682PCAU, the contents of which are hereby incorporated herein by reference.
[001 1 ] Electric cells are included in number required to provide the required power for the composite structure so it functions as a structural battery. A potentially very large number of electric cells, perhaps thousands, could be included within a vehicle, with a single structural battery or bank of structural batteries as described herein being used. The cell type is not critical though suitable batteries could be selected from rechargeable batteries, such as from the lithium ion battery class, such as for example 18650 type batteries rated at 3.7v approximately or 2170 type batteries rated at a higher voltage. Such batteries have cylindrical geometry.
[0012] As described above, the structural battery can be used in a range of applications. Any application that can draw electric power from electric cells could adopt the composite structure as a structural battery. A potential application is to electric motor vehicles. In such case, the composite structure could accommodate a very large number of electric cells conveniently in the form of a floor pan for an electric motor vehicle. Weight is then focussed in the typically lowest point of the vehicle where it may provide a beam between front and rear wheels, left and right wheels (where provided) and a torsionally rigid member between all wheels. [0013] The structural battery of the invention may be more fully understood from the following description of exemplary embodiments thereof made with reference to the drawings in which:
[0014] Fig. 1 shows an orthogonal cutaway view of a structural battery according to one embodiment of the present invention.
[0015] Fig. 2 shows a plan view of the core structure of the structural battery of Fig. 1 .
[0016] Fig. 3 shows a detail view of a core element of the core structure of Figs. 1 and 2.
[0017] Fig. 4 shows an insulating spacer from the core structure as shown in Figs. 1 and 2.
[0018] Referring now to Fig. 1 , there is shown a cutaway view of a structural battery 10 for delivering electric power to an application requiring electric power such as an electric motor vehicle (not shown) but not limited to this. Structural battery 10 includes a container 12 of a first, fibre reinforced composite material such as CFRP; and a core 130 of a second material for accommodating a plurality of electric cells 134 provided within the container 12. The first material may also include other materials resistant to longitudinal and transverse bending forces, preferably lightweight materials which may include light metals or metal alloys such as aluminium alloys. Container 12 includes respective upper and lower facing layers 12a and 12b (which though shown curved would typically be flat in practice) of sufficient strength to treat tension and compression loads. Facing layers 12a and 12b are of CFRP having significantly less electrical conductivity than metallic elements of the core described below. The structural battery 10 therefore has a composite sandwich structure.
[0019] The structural battery 10 forms a structural member having resistance to compressive, shear and longitudinal and transverse bending forces imposed on the structural member by the electric motor vehicle whether stationary or in operation. Further description of the structural battery 10 and its composite sandwich structure, which approximates an "I" beam in structural characteristics, is provided in the Applicant's co-pending International Patent Application filed 8 August 2018 under Attorney Docket No. P42453PCAU, incorporated herein by reference.
[0020] Structure 130 forms the core of the structural battery 10. Core structure 130, which is intended to be resistant to compressive and shear loads, is also electrically and thermally conductive comprising a framework of multiple corrugated aluminium or copper sheets or layers 131 A and 131 B which are bonded together with a laminated structure in a corrugation moulding process in such a way as to leave generally cylindrical spaces 132 of circular section for accommodating electric cells 134 longitudinally disposed within spaces 132 and connecting tabs or electrodes 135 and 136 in a manner avoiding short circuiting and other electrical malfunctions. One electric cell 134 is accommodated by each space 132. Electric cells 134 are desirably close packed within the core structure 130, desirably with a packing factor approaching that for hexagonal geometry. As shown in Figs. 1 and 2, layers 131 A and 131 B are spaced apart by approximately the diameter of an electric cell 134 and spaces 132 are open at each cell end.
[0021 ] Layers 131 A and 131 B are spaced apart by elongate insulating spacers 141 which also serve as structural links assisting in the provision of compressive strength and shear resistance. Insulating spacers 141 , one of which is shown in detail in Fig. 4, have arcuate or concave surfaces 141 A and 141 B and a dogbone shape when viewed end on or in plan. Such insulating spacers 141 , having the requisite compatible shape, are included as blanks and may facilitate corrugation moulding. A ceramic insulating material or a polymeric insulating material, such as polyamide, may be used for spacers 141 . The spacer material may be intumescent. Spacers 141 may also include information links, such as a thermistor 141 C, for sensing battery parameters such as battery operating temperature which may form part of thermal control. [0022] Each electric cell accommodating space 132 is substantially defined by the corrugated walls 133 of neighbouring layers 131 A and 131 B of the core structure 130 which, to be compatible with or match the cylindrical shape of the accommodated electric cells 134, have a part circular or arcuate geometry section as shown in Figs. 2 and 3. Each space 132 also has a generally cylindrical volume. To emphasise, layers 131 A and 131 B have corrugation walls 133 with part circular or arcuate portions, the same shape as a cylindrical electric cell 134. A relatively minor portion of the wall defining each space 132 is provided by a portion of neighbouring insulating spacers 141 which are diametrically spaced apart relative to space 132.
[0023] Each electric cell 134 is in electrical and heat transfer contact with the neighbouring layers 131 A and 131 B of elements 131 of honeycomb structure core 130. Each electrical cell 134 should be neatly fitted, and advantageously bonded, within its accommodating space 132 with an object to provide superior shear resistance. Such fitting also enables electrical connectivity as described in the Applicant's co-pending International Application filed 8 August 2018 under Attorney Docket No. P42682PCAU, the contents of which are incorporated by reference. The further heat transfer contact facilitates control over structural battery 10 operating temperature as described in the Applicant's co-pending International Application filed 8 August 2018 under Attorney Docket No. P42683PCAU, the contents of which are incorporated by reference.
[0024] As shown in more detail in Fig. 3, each core element 131 of the honeycomb structure core 130 has a laminated structure here made up of multiple plies of aluminium as second lightweight material. For convenience, just two 131 AA and 131 AB are shown. Greater than two plies could be used. To provide improved compressive and shear resistance, spacers 157 are included during the moulding process to provide further structural framework for the layers 131 AA and 131 AB. Spacers 157 may be made from a wide range of materials, preferably a lightweight polymeric material such as a closed cell polyurethane foam or other plastic material. A metal or elastomeric material which may also be intumescent could also be employed.
[0024] Spacers 157 do not extend the full length of layers 131 AA and 131 AB, rather leaving inter-connected galleries 150 and 152 allowing thermal control by a heat transfer fluid flow C, for example of a refrigerant selected not to interfere with structural battery 10 operation and circulated by fixed or variable speed pump P during structural battery 10 operation to maintain battery operating temperature in a desired range of 15QC to 35QC. Further description of temperature control is described in the Applicant's co-pending International Application filed 8 August 2018 under Attorney Docket No. P42683PCAU, the contents of which are incorporated by reference.
[0025] Electric cells 134 of various types could be selected and this is not critical though suitable cylindrically shaped batteries could be selected from rechargeable batteries especially from the lithium ion battery class, such as for example 18650 or 2170 type batteries which have a cylindrical geometry and are rated at 3.7v per cell. In the case of an electric motor vehicle, the selected electrical cells 134 would enable the structural battery 10, while having the required structural properties as described herein and in incorporated references to act as a structural member, to have a relatively shallow depth in relation to length and breadth.
[0026] The structural battery 10 can be used in a range of applications including in fixed structures, mobility devices and portability devices. A potential application is to electric motor vehicles. In such case, a bank of structural batteries 10 could accommodate a very large number of electric cells 34, potentially thousands, and form a floor pan for an the electric motor vehicle. Weight, which is significantly lower than that involved with conventional metal and metal alloy battery containers or trays, would then be focussed in the lowest point of the vehicle where one or a bank of structural batteries provides a load bearing beam between front and rear wheels, left and right wheels (where provided) and a torsionally rigid member between all wheels.
[0027] Structural battery 10 is rechargeable and not intended for replacement under normal circumstances. However, it could be made replaceable if desired. This itself could depend on the application.
[0028] Modifications and variations to the structural battery described herein may be apparent to the skilled reader of this disclosure. Such modifications and variations are deemed within the scope of the present invention.

Claims

CLAIMS:
1 . A structural battery comprising:
a container of a first material; and
a core of a second material for accommodating a plurality of electric cells provided within said container;
wherein the container and the core together form a structural member having resistance to shear forces, compression forces, tension forces, torsional forces and longitudinal and transverse bending forces imposed on said structural member by the application and wherein said core comprises pre-formed spaces for accommodating electric cells, said spaces having a shape compatible with the shape of an opposing surface of the electric cells.
2. The structural battery of claim 1 , wherein said core structure is formed by a framework of core elements or layers.
3. The structural battery of claim 2 wherein said core structure has a honeycomb structure.
4. The structural battery of claim 2 or 3, wherein said core elements are electrically and thermally conductive.
5. The structural battery of any one of claims 2 to 4, wherein the core elements are laminated sheets.
6. The structural battery of claim 5 wherein the laminated sheets are corrugated to accommodate electric cells.
7. The structural battery as claimed in any one of the preceding claims wherein each core space is at least partly defined by a wall having circular, part circular or arcuate shape.
8. The structural battery of any one of claims 5 to 7, wherein laminated sheet layers are spaced apart by elongate insulating spacers, preferably having dogbone shape and comprising arcuate or concave surfaces for neatly accommodating electric cells.
9 The structural battery of claim 8, wherein said insulating spacers comprise high shear strength polymeric material.
10. The structural battery of any one of claims 5 to 9, wherein the laminated sheets of the core are spaced apart within the container.
1 1 . The structural battery of claim 10, wherein the laminated sheets of the core are spaced apart by approximately or greater than the diameter of a cylindrical electric cell.
12. The structural battery of claim 1 1 , wherein spaces defined between said laminated sheets are open at each end.
13. The structural battery of any one of the preceding claims, wherein electric cells are close packed within the core, optionally with a packing factor approaching that for hexagonal geometry.
14. An electric device comprising a structural battery as claimed in any one of claims 1 to 13 as a structural member within said electric device.
15. The device of claim 14 selected from the group consisting of portable devices, mobility devices and electric vehicles.
PCT/AU2018/050831 2017-08-08 2018-08-08 A structural battery WO2019028511A1 (en)

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