ENERGY STORAGE SYSTEM

• US 20190319249A1
• Filed: 06/27/2019
• Published: 10/17/2019
• Est. Priority Date: 01/20/2017
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Inc.
• Inventors: Barton, Augusto E., Lane, Robert Clinton, Chidiac, Nathan Khalil, Carl, Julian Christian, Ross, Hugh Burnett, Stockton, William B., Manov, Nicholas Paul
• Granted Patent: US 11,217,862 B2
• Time in Patent Office: Days
• CPC Class Codes: H01M 10/0422 Cells or battery with cylindrical casing
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/6552 Closed pipes transferring heat by thermal conductivity or phase transition, e.g. heat pipes
• CPC Class Codes: H01M 10/6554 Rods or plates
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/3425 in the form of rupturable membranes or weakened parts, e.g. pierced with the aid of a sharp member
• CPC Class Codes: H01M 50/502 Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

An energy storage system includes a module housing and multiple battery cells with insulating material and discharge directing material positioned inside the module housing. Each of the battery cells has a first end and a second end. Further, each of the battery cells has a positive terminal and a negative terminal. The energy storage system includes a first interconnect and a second interconnect positioned over the battery cells. Multiple first cell connectors connect the positive terminals of the battery cells to the first interconnect. Multiple second cell connectors connect the negative terminals of the battery cells to the second interconnect. A top plate having an interior side and an exterior side is positioned over the first interconnect and the second interconnect. The top plate includes one or more weak areas with reduced integrity positioned above one or more battery cells.

Claims

1. An energy storage system comprising:

a module housing;

a plurality of battery cells positioned inside the module housing, each of the plurality of battery cells including a first end and a second end, each of the plurality of battery cells further including a positive terminal and a negative terminal;

a first interconnect positioned over the plurality of battery cells;

a second interconnect positioned over the plurality of battery cells;

a plurality of first cell connectors connecting the positive terminals of the battery cells to the first interconnect;

a plurality of second cell connectors connecting the negative terminals of the battery cells to the second interconnect; and

a top plate comprising an interior side and an exterior side and positioned over the first interconnect and the second interconnect, wherein the top plate includes one or more weak areas positioned above one or more battery cell.

2. The energy storage system of claim 1, wherein the weak areas in the top plate are physically weaker portions of the top plate.

3. The energy storage system of claim 2, wherein the weak areas are structural depressions in the top plate such that the structural depressions are on the interior side of the top plate and the exterior side is planar.

4. The energy storage system of claim 2, wherein the top plate is prepared from a single material and a portion of material is removed from the weak areas.

5. The energy storage system of claim 2, wherein the top plate is prepared from a composite material.

6. The energy storage system of claim 1 further comprising an interconnect layer, wherein the interconnect layer includes the first interconnect and the second interconnect.

7. The energy storage system of claim 1, wherein the first interconnect and the second interconnect collect current from the positive terminal and the negative terminal of the battery cells respectively.

8. The energy storage system of claim 1, further comprising interstitial material between the plurality of battery cells inside the module housing.

9. The energy storage system of claim 1, wherein the interstitial material is comprised of a silicone-based material.

10. The energy storage system of claim 1, further comprising a sleeve positioned around the plurality of battery cells.

11. The energy storage system of claim 1, further comprising a cold plate in thermal connection with the plurality of battery cells.

12. A method of assembling an energy storage system, the method comprising:

positioning a plurality of battery cells inside a module housing, wherein each of the plurality of battery cells includes a first end and a second end, each of the plurality of battery cells further includes a positive terminal and a negative terminal;

coupling the positive terminal of the plurality of battery cells to a first interconnect through a plurality of first cell connectors;

coupling the negative terminal of the plurality of battery cells to a second interconnect through a plurality of second cell connectors; and

positioning a top plate over the first interconnect and the second interconnect, wherein the top plate includes one or more weak areas positioned above the one or more battery cell.

13. The method of claim 12 further comprising adding interstitial material between the plurality of battery cells.

14. The method of claim 12 further comprising adding a sleeve around one or more of the plurality of battery cells.

15. The method of claim 12 further comprising adding one or more heat pipes between or under the plurality of battery cells.

16. The method of claim 12, wherein the energy storage system further comprises an interconnect layer, the interconnect layer including the first interconnect and the second interconnect.

17. The method of claim 12, wherein the weak areas in the top plate are physically weaker portions of the top plate.

18. The method of claim 12, wherein the weak areas are structural depressions in the top plate.

19. An energy storage system comprising:

a module housing;

a plurality of battery cells positioned inside the module housing, each of the plurality of battery cells including a first end and a second end, each of the plurality of battery cells further including a positive terminal and a negative terminal;

material for insulating the plurality of battery cells;

material for directing a discharge from a failure of one or more battery cells;

a plurality of first cell connectors coupled to the positive terminal of the battery cells;

a plurality of second cell connectors coupled to the negative terminal of the battery cells;

an interconnect layer positioned over the plurality of battery cells, the interconnect layer including;

a first interconnect configured to couple the plurality of first cell connectors to the first interconnect; and

a second interconnect configured to couple the plurality of second cell connectors to the second interconnect;

wherein the first interconnect and the second interconnect lie in a same horizontal plane above the plurality of battery cells; and

a top plate positioned over the interconnect layer, wherein the top plate includes one or more weaker portions above one or more battery cell.

20. The energy storage system of claim 19, wherein the material for insulating the battery cells and the material for directing the discharge from the failure of one or more battery cells are the same material.