Battery system with a high-thermal-conductivity split shell structural support
First Claim
1. A battery system, comprising:
- a battery cell having a battery cell housing;
a housing support external to the battery cell housing, the housing support comprising at least two split shell segments, each split shell segment includinga heat-conductor inner layer comprising a plurality of heat-conducting fibers, each of the heat-conducting fibers having a sink end thereof, anda structural support outer layer overlying the heat conductor inner layer, the structural support layer being made of a fiber-reinforced composite material;
a layer of a structural adhesive bonding the respective heat conductor inner layer of each split shell segment to the battery cell housing; and
a thermal sink in thermal contact with the sink ends of the plurality of heat-conducting fibers of each of the split shell segments.
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Accused Products
Abstract
A battery system includes a battery cell having a battery cell housing, and a housing support external to the battery cell housing. The housing support is formed of at least two split shell segments. Each split shell segment includes a heat conductor inner layer having a plurality of heat-conducting fibers with heat sink ends, and a structural support outer layer overlying the heat conductor inner layer. The structural support layer is made of a fiber-reinforced composite material. A layer of a structural adhesive bonds the respective heat conductor inner layer of each split shell segment to the battery cell housing. A thermal sink is in thermal contact with the sink ends of the plurality of heat-conducting fibers of each of the split shell segments, and the structural support outer layer of each split shell segment is joined to a structural base. Preferably, a number of the battery cells and overlying housing supports extend between a single thermal sink at one end and a single structure base at the other end, forming a battery pack.
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Citations
17 Claims
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1. A battery system, comprising:
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a battery cell having a battery cell housing; a housing support external to the battery cell housing, the housing support comprising at least two split shell segments, each split shell segment including a heat-conductor inner layer comprising a plurality of heat-conducting fibers, each of the heat-conducting fibers having a sink end thereof, and a structural support outer layer overlying the heat conductor inner layer, the structural support layer being made of a fiber-reinforced composite material; a layer of a structural adhesive bonding the respective heat conductor inner layer of each split shell segment to the battery cell housing; and a thermal sink in thermal contact with the sink ends of the plurality of heat-conducting fibers of each of the split shell segments. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A battery system, comprising:
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a battery cell having a generally cylindrical battery cell housing with a cylindrical axis and a cylindrical external surface; a housing support external to the cylindrical housing, the housing support comprising at least two split shell segments, each of the split shell segments including a heat-conductor inner layer comprising a plurality of heat-conducting fibers aligned substantially parallel to the cylindrical axis of the battery cell housing, each of the heat-conducting fibers being made of high-thermal-conductivity graphite and having a sink end thereof, and a structural support outer layer overlying the plurality of heat-conducting fibers, the structural support outer layer being made of a graphite fiber-reinforced composite material; a layer of a structural adhesive bonding the heat conductor inner layer of each split shell segment to the battery cell housing; and a thermal sink in thermal contact with the sink ends of the plurality of heat-conducting fibers, the thermal sink being disposed at a first end of the battery cell housing. - View Dependent Claims (8, 9, 10)
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11. A battery system, comprising:
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a plurality of battery cells, each of the battery cells having a battery cell housing; a respective housing support external to and overlying each battery cell housing, each housing support comprising at least two split shell segments, each split shell segment including a heat conductor inner layer comprising a plurality of heat-conducting fibers, each of the heat-conducting fibers having a sink end thereof, and a structural support outer layer overlying the heat conductor inner layer, the structural support layer being made of a fiber-reinforced composite material; a layer of a structural adhesive bonding the heat conductor inner layer of each respective split shell segment to its battery cell housing; a thermal sink in thermal contact with the sink ends of the plurality of heat-conducting fibers of each of the housing supports; and a structural base to which the structural support outer layer of each of the housing supports is joined. - View Dependent Claims (12, 13, 14, 15)
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16. A method for preparing a battery system, comprising the steps of
furnishing a battery cell having a generally cylindrical battery cell housing with a cylindrical axis and a cylindrical external surface; -
furnishing a mandrel having a mandrel cylindrical axis and a generally cylindrical mandrel surface of substantially the same diameter as the battery cell housing; assembling a housing shell over the mandrel, the step of assembling including the steps of applying a heat-conductor inner layer overlying the cylindrical mandrel surface, the heat-conductor inner layer comprising a plurality of heat-conducting fibers aligned generally parallel to the mandrel cylindrical axis, the heat-conducting fibers being made of high-thermal-conductivity graphite and having a sink end thereof, applying a structural support outer layer overlying the plurality of heat-conducting fibers, the structural support outer layer being made of a fiber-reinforced composite material, and curing the heat-conductor inner layer and structural support outer layer in place on the mandrel; splitting the housing shell parallel to the mandrel cylindrical axis at two circumferential locations to form two split shell segments, and removing the split shell segments from the mandrel; supplying a structural adhesive; attaching each split shell segment to the battery cell housing using the structural adhesive; and affixing the sink ends of the heat-conducting fibers of each of the split shell segments to a thermal sink, the thermal sink being disposed at a first end of the battery cell housing. - View Dependent Claims (17)
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Specification