Rechargeable battery including battery cell separators

• US 10,044,077 B2
• Filed: 02/24/2014
• Issued: 08/07/2018
• Est. Priority Date: 02/26/2013
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Callahan, Kevin S., Drolen, Bruce L., Russell, James C., Lowell, John R., Barrera, Thomas P., North, Timothy R.
• Primary Examiner(s): Lee, James
• Application Number:
  US14/188,663
• Publication Number:
  US 20140242435A1
• Time in Patent Office: 1,625 Days
• Field of Search: 429120
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/658 by thermal insulation or shielding
• CPC Class Codes: H01M 2200/00 Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/293 characterised by the material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A rechargeable battery comprises a plurality of individual sealed battery cells, and dielectric separators between the battery cells for creating thermal barriers between opposing surfaces of the battery cells. The dielectric separators are made of a fiber composite.

Claims

1. A rechargeable battery comprising:

a plurality of individual sealed battery cells;

a chassis for containing the battery cells, the chassis including;

a frame defining an interior space;

upper and lower fixation plates provided at a top and a bottom, respectively, of the frame and formed of a non-conductive material, the upper fixation plate fastened to the frame;

an imperforate dielectric separator disposed in the frame and configured to divide the frame interior space into a plurality of openings, the dielectric separator being formed of a fiber composite;

wherein each opening of the plurality of openings receives an associated, single battery cell and is bounded by the dielectric separator, the frame, and the upper and lower fixation plates; and

wherein the dielectric separator, the frame, and the upper and lower fixation plates are sized to completely enclose each opening, thereby covering an entire surface area of the single, associated battery cell disposed within each opening to create a complete thermal barrier between adjacent openings and to electrically isolate each battery cell from all other battery cells to prevent current paths between the battery cells.

2. The battery of claim 1, wherein each battery cell includes first and second electrodes, a case for the electrodes, and electrolyte sealed within the case.

3. The battery of claim 1, wherein the fiber composite includes fibers in a phenolic resin matrix.

4. The battery of claim 1, wherein the fiber composite includes a glass fiber phenolic.

5. The battery of claim 1, wherein the fiber composite includes fiber basalts.

6. The battery of claim 1, wherein each battery cell is wrapped with a polyimide film.

7. The battery of claim 1, wherein the battery cells are prismatic and the battery cells are arranged in an array, the battery further including a plurality of imperforate dielectric separators formed as a lattice.

8. The battery of claim 7, wherein the dielectric separator comprises at least two interlockable dielectric separator pieces.

9. The battery of claim 7, wherein the battery cells are lithium-ion battery cells, and wherein the battery is configured for a passenger vehicle.

10. A rechargeable battery comprising:

a chassis including;

a frame defining an interior space;

upper and lower fixation plates provided at a top and a bottom, respectively, of the frame and formed of a non-conductive material, the upper fixation plate fastened to the frame; and

a lattice of imperforate dielectric separators disposed in the frame and dividing the frame interior space into a plurality of openings, the lattice of dielectric separators composed of fibers in a phenolic resin matrix;

wherein each opening of the plurality of openings receives an associated, single battery cell and is bounded by the dielectric separator, the frame, and the upper and lower fixation plates; and

wherein the lattice of imperforate dielectric separators, the frame, and the upper and lower fixation plates are sized to completely enclose each opening, thereby covering an entire surface area of the single, associated battery cell disposed within each opening, to create a complete thermal barrier between adjacent openings and to electrically isolate each battery cell from all other battery cells to prevent current paths between the battery cells.

11. The battery of claim 10, wherein the lattice of dielectric separators are composed of glass fiber phenolic.

12. The battery of claim 10, wherein the lattice of dielectric separators comprises interlockable dielectric separators.

13. The battery of claim 10, wherein the battery cells are lithium-ion battery cells, and wherein the battery is configured for a passenger vehicle.

14. Apparatus for preventing thermal runaway from propagating in an array of rechargeable battery cells, the apparatus comprising:

a frame defining an interior space;

a lower fixation plate provided at a bottom of the frame and formed of a non-conductive material;

an upper fixation plate provided at a top of the frame and formed of a non-conductive material, the upper fixation plate fastened to the frame; and

a plurality of imperforate dielectric separators that are interlocked to form a lattice, the lattice being disposed in the frame and dividing the frame interior space into a plurality of openings;

wherein each opening of the plurality of openings receives an associated, single battery cell and is bounded by the dielectric separator, the frame, and the upper and lower fixation plates; and

wherein the plurality of imperforate dielectric separators, the frame, and the upper and lower fixation plates are sized to completely enclose each opening, thereby covering an entire surface area of the single, associated battery cell disposed within each opening, to create a complete thermal barrier between adjacent openings and to electrically isolate each battery cell from all other battery cells to prevent current paths between the battery cells.

15. The apparatus of claim 14, wherein the dielectric separators are composed of glass fiber phenolic.

16. The apparatus of claim 14, wherein dielectric separators are configured for an array of prismatic lithium-ion battery cells.

17. The apparatus of claim 14, wherein the fibers include quartz fibers, ceramic fibers, or silicon carbide fibers.