Battery housing system and method

• US 8,575,891 B2
• Filed: 08/23/2010
• Issued: 11/05/2013
• Est. Priority Date: 08/23/2010
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Sheahan, James J. Jr.
• Primary Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US12/861,010
• Publication Number:
  US 20120043924A1
• Time in Patent Office: 1,170 Days
• Field of Search: 320/107
• US Class Current: 320/107
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/30 Arrangements for facilitating escape of gases
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery system including a housing that defines an internal volume and a venting system that fluidly couples the internal volume with an atmosphere surrounding the housing and a support structure within the internal volume, the support structure being configured to support a number of battery cell modules in the internal volume.

Claims

1. A battery system comprising:

a housing at least partially enclosing an internal volume, said housing being made of a heat-resistant material and including at least one vent that fluidly couples said internal volume with an atmosphere surrounding said housing;

at least one containment device located within said internal volume;

at least one battery cell module placed in said at least one containment device, said containment device being configured to retain electrolyte and debris released during a thermal runaway of said at least one battery cell module; and

a support structure within said internal volume, said support structure configured to support said at least one containment device in said internal volume.

2. The battery system of claim 1, further comprising said containment device being configured to retain one of heat or plasma expelled from said at least one battery cell module during said thermal runaway event.

3. The battery system of claim 2, wherein said at least one battery cell module is selected from at least one rechargeable cell, at least one electrochemical cell, at least one lithium-ion cell, at least one lithium polymer cell, at least one lead-acid cell, at least one nickel cadmium cell, and at least one nickel metal hydride cell.

4. The battery system of claim 2, wherein said at least one containment device includes one of a cover, a sleeve and a pouch.

5. The battery system of claim 4, wherein said at least one containment device comprises a layer of woven ceramic fabric and a layer of oxidized polyacrylonitrile fibers.

6. The battery system of claim 1, wherein said housing comprises a resealable opening into said internal volume for maintenance or modification of said at least one battery cell module.

7. The battery system of claim 1, wherein said support structure defines a plurality of ports for receiving and securing said at least one battery cell module.

8. The battery system of claim 7, wherein each port of said plurality of ports is resizable.

9. The battery system of claim 1, further comprising a charging system electrically connectable to said plurality of battery cell modules.

10. The battery system of claim 9, wherein said charging system is integrated with said housing.

11. The battery system of claim 9, wherein said charging system comprises electronics configured to identify malfunctioning cell modules and non-malfunctioning cell modules within said plurality of battery cell modules.

12. The battery system of claim 11, wherein said charging system is further configured to electrically isolate said malfunctioning cell modules from said non-malfunctioning cell modules.

13. The battery system of claim 12, wherein said charging system is further configured to supply a charging voltage to said non-malfunctioning cell modules and to increase said charging voltage within a safe battery charge range when said malfunctioning cell modules are isolated.

14. A battery system comprising:

a housing defining an internal volume, said housing being made of a heat-resistant material, said housing fully enclosing said internal volume and including at least one vent that fluidly couples said internal volume with an atmosphere surrounding said housing;

a plurality of containment devices located within said internal volume;

a plurality of battery cell modules being placed in said plurality of containment devices, said plurality of containment devices being configured to retain electrolyte and debris released during a thermal runaway of one of said plurality of battery cell modules placed therein;

a support structure within said internal volume, said support structure supporting said plurality of containment devices in said internal volume; and

a charging system configured to identify malfunctioning cell modules and non-malfunctioning cell modules within said plurality of battery cell modules and to electrically isolate said malfunctioning cell modules from said non-malfunctioning cell modules, wherein said charging system supplies a charging voltage to said non-malfunctioning cell modules and increases said charging voltage to maintain operating ratings when said malfunctioning cell modules are isolated.

15. The battery system of claim 14, wherein said support structure defines a plurality of ports for receiving and securing and securing said plurality of battery cell modules.

16. The battery system of claim 14, wherein said plurality of containment devices are configured to retain material selected from at least one of heat or plasma expelled from said plurality of battery cell modules during said thermal runaway event.

17. The battery system of claim 14, wherein said plurality of containment devices is selected from a cover, a sleeve and a pouch.

18. The battery system of claim 14, wherein said housing comprises a resealable opening into said internal volume.

19. The battery system of claim 14, wherein each of said plurality of containment devices comprises a layer of woven ceramic fabric and a layer of oxidized polyacrylonitrile fibers.

20. A method for operating a battery system at a target voltage, the method comprising:

providing a housing defining an internal volume, said housing being made of a heat-resistant material and including a vent that fluidly couples said internal volume with an atmosphere surrounding said housing, said housing fully enclosing said internal volume but for said vent;

placing a plurality of battery cell modules into a plurality of containment devices, said containment devices each being configured to retain electrolyte and debris released during a thermal runaway of one or more of said plurality of battery cell modules placed therein;

providing a support structure within said internal volume, and supporting said plurality of containment devices on said support structure;

applying a charging voltage to said plurality of battery cell modules;

monitoring each battery cell module of said plurality to identify a malfunctioning battery cell module within said plurality; and

when said malfunctioning battery cell module is identified,

electrically isolating said malfunctioning battery cell module from said other battery cell modules of said plurality; and

increasing said charging voltage applied to said other battery cell modules of said plurality.

21. A battery system comprising:

a housing at least partially enclosing an internal volume, said housing being made of a heat-resistant material and including at least one vent that fluidly couples said internal volume with an atmosphere surrounding said housing;

at least one containment device located within said internal volume and configured to contain at least one battery cell module, said containment device being configured to retain electrolyte and debris released during a thermal runaway of said at least one battery cell module; and

a support structure within said internal volume, said support structure configured to support said at least one containment device in said internal volume.