Battery thermal management system

• US 5,695,891 A
• Filed: 07/20/1995
• Issued: 12/09/1997
• Est. Priority Date: 02/10/1992
• Status: Expired due to Fees

• Current Assignee: C&D Technologies Incorporated (Angel Holdings LLC)
• Original Assignee: C & D Charter Power Systems, Inc.
• Inventors: Wagner, Franz, Misra, Sudhan S.
• Primary Examiner(s): NUZZOLILLO, MARIA
• Application Number:
  US08/504,486
• Time in Patent Office: 873 Days
• Field of Search: 429/66, 429/72, 429/82, 429/96, 429/97, 429/98, 429/99, 429/100, 429/123, 429/129, 429/149, 429/157, 429/159, 429/163, 429/225, 429/246
• US Class Current: 429/157
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/20 with direct contact, e.g. using "mirror"
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/7802 Positioning the parts to be joined, e.g. aligning, indexing or centring
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/53461 joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/542 joining hollow covers or hollow bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/72521 comprising corrugated cores
• CPC Class Codes: B29C 66/7254 honeycomb structures
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29L 2031/7146 Battery-cases
• CPC Class Codes: H01M 10/12 Construction or manufacture
• CPC Class Codes: H01M 10/16 Suspending or supporting electrodes or groups of electrodes in the case
• CPC Class Codes: H01M 10/342 Gastight lead accumulators H01M10/121 takes precedence
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/6557 : arranged between the cells
• CPC Class Codes: H01M 10/6562 : with free flow by convection only
• CPC Class Codes: H01M 10/6563 : with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/6566 : Means within the gas flow to guide the flow around one or more cells, e.g. manifolds, baffles or other barriers H01M10/6565 takes precedence
• CPC Class Codes: H01M 4/73 : for lead-acid accumulators, e.g. frame plates
• CPC Class Codes: H01M 50/103 : prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/169 : by welding, brazing or soldering
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/253 : adapted for specific cells, e.g. electrochemical cells operating at high temperature
• CPC Class Codes: H01M 50/466 : U-shaped, bag-shaped or folded
• 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

A lead-acid cell includes a case, positive and negative plates within the case, microporous separator material between adjacent plates and electrolyte in a starved amount, with the case having jar and covers joined by a weldment along overlapping cover and jars. The positive plates include a grid frame with an intermediate member extending between spaced apart generally peripheral portions of the frame, with pasted active material on the grid frame separated substantially into two portions by the intermediate member. Compressive force is adjustably continuously applied to the positive and negative plates within the case. The plates are suspended within the case at positions removed from the wall of the case, while plate growth is permitted in a manner that plate shorting is avoided.

Claims

1. A battery comprising:

a. a plurality of cells longitudinally elongated in one horizontal dimension arranged in at least one horizontal row with the cells generally parallel to one another and transversely spaced apart from one another to provide convection paths for air flow between the cells; and

b. support for each horizontal row of cells, including a support shelf having holes through the shelf so grouped to permit air flow through the convection paths between the cells.

2. The battery of claim 1 in which the holes are grouped in rows transverse to the elongated dimension of the cells.

3. The battery of claim 1 in which a plurality of rows of cells are provided, each supported on a horizontal shelf.

4. The battery of claim 3 in which support for the shelves relative to one another extends generally from one row to the next so that vertical convection paths can be maintained.

5. The battery of claim 4 in which the support for the shelves extends from one shelf to the next and below the lowest shelf to space the lowest shelf from a support surface in order to provide for air circulation from below the lowest shelf.

6. The battery of claim 4 in which additional partitions generally parallel to the shelves between the respective rows are perforated so that the vertical convection paths are not interrupted.

7. The battery of claim 6 in which the additional partitions are non-supporting and made of material having perforations over essentially its entire surface.

8. The battery of claim 5 in which the additional partitions are made at least partially of a perforate material.

9. The battery of claim 5 in which additional partitions generally parallel to the shelves between the respective rows are perforated so that the vertical convection paths are not interrupted.

10. The battery of claim 9 in which the additional partitions are non-supporting and made of material having perforations over essentially its entire surface.

11. The battery of claim 10 in which the additional partitions are made at least partially of a screen-like material.

12. A battery comprising:

a. a plurality of horizontally elongated cells arranged in at least one row and generally parallel to and spaced apart from one another to provide convection paths for air flow therebetween; and

b. an apertured support shelf for each row of cells, the apertures being grouped for convective air flow along said paths including through said apertures.

13. A battery comprising:

a. a plurality of cells elongated in one horizontal dimension arranged in at least one horizontal row with the cells generally parallel to one another and spaced apart from one another to provide convection paths for air flow between the cells;

b. support for each horizontal row of cells, including a support shelf having holes through the shelf for permitting air flow through the convection paths between the cells;

c. the holes being grouped in rows transverse to the elongated dimension of the cells;

d. said plurality of cells being arranged in a plurality of rows each supported on a horizontal shelf;

e. support for said shelves relative to one another extending generally from one row to the next so that vertical convection paths can be maintained; and

f. support for said shelves extending from one shelf to the next and below the lowest shelf to space the lowest shelf from a support surface in order to provide air circulation from below the lowest shelf.

14. A lead-acid battery comprising:

a. a plurality of longitudinally elongated cells having vertically upstanding longitudinally elongated plates therewithin;

b. said cells being arranged in at least one transverse row with cells of a row being generally parallel with and transversely spaced one from another to provide paths for convective air flow between transversely adjacent cells;

c. means for vertically supporting said cells in said transverse rows along the transverse cell length while permitting air flow along said convection paths between transversely adjacent cells.

15. The lead-acid battery of claim 14 wherein said paths for convective air flow are substantially vertical.

16. The lead-acid battery of claim 15 wherein said paths run substantially along the longitudinal length of transversely adjacent ones of said cells.

17. The lead-acid battery of claim 14 wherein said paths run substantially along the longitudinal length of said plates.

18. The lead-acid battery of claim 14 wherein said cells are in a plurality of vertically stacked transverse rows and said means for vertically supporting said cells further comprise means for supporting said cells in said vertically stacked transverse rows with said air flow convection paths running along vertically adjacent cells in said rows.

19. The lead-acid battery of claim 18 wherein said means for vertically supporting said cells further comprises at least one shelf supporting at least a pair of transversely adjacent cells in a row, with apertures in said shelf defining said convection paths between transversely adjacent cells.

20. The lead-acid battery of claim 19 wherein at least some of said apertures in said shelf are partially blocked by one or more cells on said shelf.

21. The lead-acid battery of claim 19 wherein at least some of said apertures in said shelf are unimpinged by any cell on said shelf.

22. The lead-acid battery of claim 14 wherein said plates are planar and said convection paths are parallel with said plates.

23. A lead-acid battery comprising:

a. a plurality of longitudinally elongated cells having vertically upstanding longitudinally elongated plates therewithin;

b. said cells being arranged in a plurality of vertically stacked transverse rows with cells of a row being generally parallel with and transversely spaced one from another to provide paths for substantially vertical convective air flow between transversely adjacent cells, with said paths running substantially along the longitudinal length of transversely adjacent ones of said cells;

c. shelf means for vertically supporting said cells in said transverse rows while permitting air flow along said convection paths between transversely adjacent cells, with apertures in said shelf defining said convection paths running between transversely adjacent cells and extending between vertically adjacent cells in said stacked rows.

24. A lead-acid battery having a plurality of cells, comprising:

a. a case;

b. positive and negative lead metal plates within said case;

c. electrolyte absorbent separator material between respective positive and negative plates;

d. means collapsably deforming responsively to plate growth for supportingly maintaining plate edges spaced from said case; and

e. means for vertically supporting said cells while permitting convective cooling air flow through space between adjacent cells.

25. A lead-acid battery having a plurality of cells, comprising:

a. a case;

b. positive and negative lead metal plates within said case; and

c. planar means for supporting said cells by facing contact therewith over the entirety of a cell surface transverse to said support direction while permitting convective cooling air flow through space between adjacent cells.

26. A lead-acid cell, comprising:

a. positive and negative lead metal plates within a case;

b. electrolyte absorbent separator material between respective positive and negative plates; and

c. means collapsably deforming responsively to plate growth for supportingly maintaining plate edges spaced from said case.

27. A battery comprising:

a. a plurality of lead-acid cells arranged in a plurality of vertically stacked horizontal rows, each cell comprising;

i. positive and negative plates positioned transversely to an associated row;

b. apertured plate means for vertically supporting said cells from below while permitting convective air flow via apertures therein through space between adjacent cells; and

c. means, including a planar portion perpendicular to said plates, inboard of and parallel to a planar portion of said cases, for supporting plate edges spaced from and within a respective case and collapsably deforming toward said planar case portion responsively to plate growth.

28. The battery of claim 27 wherein said planar means is perpendicular to said plates.

29. The battery of claim 27 further comprising means for maintaining adjacent cells spaced from one another for serial convective air flow through respective space separating adjacent cells in respective vertically stacked rows and said apertures in respective plate means vertically supporting said cells in said rows from below.

30. The battery of claim 27 wherein said apertures in a respective plate means are below said spaces separating adjacent cells supported by said plate means.

31. The battery of claim 27 wherein said means for vertically supporting said cells from below while permitting convective cooling air flow therethrough into space between vertically supported adjacent cells define vertically extending channels between the cells communicating with said apertures in said planar means.

32. The battery of claim 28 wherein said support means planar portion is inboard of and parallel to said case planar portion to define an expansion space therebetween.

33. The battery of claim 27 further comprising a protruding member connected to said support means planar portion and extending from a surface thereof facing oppositely from said plates for contacting said case planar portion and thereby supporting a central portion of said support means planar portion as said support means flexes and deformingly accommodates plate growth.

34. The battery of claim 32 wherein said support means contacts plate edges along the length thereof.

35. The battery of claim 34 wherein said support means contacts plate edges continuously along the length thereof.

36. The battery of claim 34 wherein said contacted plates are positive plates.

37. The battery of claim 28 wherein said plates are rectangular and said support means contacts plate edges along the shorter side of said rectangle.

38. The battery of claim 28 wherein said plates are rectangular and said support means contacts plate edges which are remote from cell electrical terminal connections.

39. A battery comprising:

a. a plurality of lead-acid cells arranged in a plurality of vertically stacked horizontal rows, each cell comprising;

i. positive and negative plates positioned transversely to an associated row;

b. apertured plate means for vertically supporting said cells from below while permitting convective air flow via apertures therein thorough space between adjacent cells;

c. means for maintaining adjacent cells spaced from one another for convective air flow serially through respective spaces separating adjacent cells in respective vertically stacked rows and said apertures in respective plate means vertically supporting said cells in said rows from below.

40. The battery of claim 39 wherein said apertures in a respective plate means are below said spaces separating adjacent cells supported by said plate means.

41. The battery of claim 39 wherein said means for vertically supporting said cells from below while permitting convective cooling air flow therethrough into space between vertically supported adjacent cells define vertically extending channels between the cells communicating with said apertures in said planar means.

49. The battery of claim 39 wherein said plates are rectangular and said support means contacts plate edges along the shorter side of said rectangle.

50. The battery of claim 39 wherein said plates are rectangular and said support means contacts plate edges which are remote from cell electrical terminal connections.

42. A battery comprising:

a. a plurality of lead-acid cells arranged in a plurality of vertically stacked horizontal rows, each cell comprising;

i. positive and negative plates positioned transversely to an associated row; and

b. means, including a planar portion perpendicular to said plates, inboard of and parallel to a planar portion of a cell case housing said plates, for supporting plate edges spaced from and within a respective case and collapsably deforming toward said planar case portion responsively to plate growth.

43. The battery of claim 42 wherein said planar portion of said support means is perpendicular to said plates.

44. The battery of claim 43 wherein said support means planar portion is inboard of and parallel to said case planar portion to define an expansion space therebetween.

45. The battery of claim 42 further comprising a protruding member connected to said support means planar portion and extending from a surface thereof facing oppositely from said plates for contacting said case planar portion and thereby supporting a central portion of said support means planar portion as said support means flexes and deformingly accommodates plate growth.

46. The battery of claim 44 wherein said support means contacts plate edges along the length thereof.

47. The battery of claim 46 wherein said support means contacts plate edges continuously along the length thereof.

48. The battery of claim 44 wherein said contacted plates are positive plates.

51. A lead-acid cell, comprising:

a. a case;

b. positive and negative lead metal plates within said case;

c. electrolytically inactive means collapsably deforming responsively to plate growth for supportingly maintaining plate edges spaced from said case; and

d. means for vertically supporting said cells while permitting convective cooling air flow through space between adjacent cells.

52. A lead-acid cell, comprising:

a. positive and negative lead metal plates within a case; and

b. electrolytically inactive means collapsably deforming responsively to plate growth for supportingly maintaining plate edges spaced from said case.

53. A battery including:

a. spaced apart horizontally adjacent lead-acid cells arranged in vertically stacked horizontal rows, each cell including electrochemically active rectangular positive and negative plates positioned transversely to an associated row;

b. apertured plates for vertically supporting the cells from below while permitting convective air flow between adjacent cells via the apertures;

i. the apertured plates being perpendicular to the electrochemically active plates;

ii. the apertures in a respective plate being below spaces separating adjacent cells supported by the plate;

c. means, contacting edges of the electrochemically active plates which are remote from cell electrical connection, including a flat portion perpendicular to the plates, inboard of and parallel to a flat portion of the cell case, for supporting plate edges spaced from and within a respective case and collapsably deforming toward the case flat portion responsively to plate growth, wherein the edge support means flat portion is inboard of and parallel to the case flat portion to define an expansion space therebetween; and

d. means for maintaining adjacent cells spaced from one another defining channels for serial convective air flow through respective spaces separating adjacent cells in respective vertically stacked rows and through the apertures in respective support plates vertically supporting cells in respective rows.

54. The cell of claim 53 further including a protruding member connected to the support means flat portion and extending from a surface thereof facing oppositely from the plates for contacting the case flat portion and thereby supporting a central portion of the support means flat portion as the support means flexes and deformingly accommodates plate growth.