Modular battery, an interconnector for such batteries and methods related to modular batteries

• US 8,865,337 B2
• Filed: 03/23/2009
• Issued: 10/21/2014
• Est. Priority Date: 03/24/2008
• Status: Active Grant

• Current Assignee: Lightening Energy
• Original Assignee: Lightening Energy
• Inventors: Culver, Duncan, Dyer, Christopher K., Epstein, Michael L.
• Primary Examiner(s): Gupta, Yogendra
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US12/383,334
• Publication Number:
  US 20090239130A1
• Time in Patent Office: 2,038 Days
• Field of Search: 429/121, 429/151, 429/158, 429/159, 429/160, 429/188, 429/211
• US Class Current: 429/151
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• 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
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A modular battery includes a first planar battery cell having a first planar electrode surface, a second planar battery cell having a second planar electrode surface, and a compressible interconnector disposed between the first planar surface and the second planar surface and electrically connecting the first and second planar electrode surfaces. Other embodiments of a modular battery, an interconnector and methods are also disclosed.

Claims

1. A modular battery comprising:

a first planar battery cell including a plurality of positive electrodes connected to each other in parallel and a plurality of negative electrodes connected to each other in parallel, one of the electrodes of the first planar battery cell having a first planar electrode surface;

a second planar battery cell including a plurality of positive electrodes connected to each other in parallel and a plurality of negative electrodes connected to each other in parallel, one of the electrodes of the second planar battery cell having a second planar electrode surface; and

a compressible interconnector disposed between the first planar surface and the second planar surface and electrically connecting the first and second planar electrode surfaces.

2. The battery as recited in claim 1 wherein the compressible interconnector includes a layer containing electrically conducting fibers.

3. The battery as recited in claim 2 wherein the fibers include metallic wire.

4. The battery as recited in claim 3 wherein the metallic wire includes an inner metallic core and an outer tin coating.

5. The battery as recited in claim 1 wherein the compressible interconnector includes a fiber mesh.

6. The battery as recited in claim 1 wherein the compressible interconnector includes an electrically conducting material lowering a resistance between the first and second planar electrode surfaces.

7. The battery as recited in claim 1 wherein the compressible interconnector has an uncompressed volume and wherein the compressible interconnector is compressed to less than 90 percent of the uncompressed volume when disposed between the first planar battery cell and the second planar battery cell.

8. The battery as recited in claim 1 wherein the first planar electrode surface defines a positive terminal of the first planar battery cell and the second planar electrode surface defines a negative terminal of the second planar battery cell.

9. The battery as recited in claim 1 wherein the first planar electrode surface is made of aluminum and the second planar electrode surface is made of aluminum.

10. The battery as recited in claim 1 wherein the first planar electrode surface is made of aluminum and the second planar electrode surface is made of copper.

11. The battery as recited in claim 1 further comprising a pressurizer for compressing the interconnector.

12. The battery as recited in claim 11 wherein the pressurizer is a spring.

13. The battery as recited in claim 1 wherein the second planar battery cell has a further planar electrode surface and further comprising a third planar battery cell having a third planar electrode surface and a second compressible interconnector disposed between the further planar surface and the third planar surface and electrically connecting the further and third planar electrode surfaces.

14. A vehicle comprising the battery as recited in claim 1.

18. The battery as recited in claim 1 wherein the compressible interconnector is removable as a modular unit with respect to the first and second planar battery cells.

15. A modular battery comprising:

a first planar battery cell having a first planar electrode surface;

a second planar battery cell having a second planar electrode surface; and

an interconnector disposed between the first planar surface and the second planar surface and electrically connecting the first and second planar electrode surfaces, the interconnector including electrically conducting fibers, the compressible interconnector having an uncompressed volume and being compressed to less than 90 percent of the uncompressed volume when disposed between the first planar battery cell and the second planar battery cell.

19. The battery as recited in claim 15 wherein the first planar battery cell has a plurality of positive and negative electrodes connected in parallel, one of the electrodes of the first planar battery cell having the first planar electrode surface, the second planar battery cell having a plurality of positive and negative electrodes connected in parallel, one of the electrodes of the second planar battery cell having the second planar electrode surface.

16. A method for assembling a modular battery comprising:

placing a first planar battery cell in a housing, the first planar battery cell including a plurality of positive electrodes connected to each other in parallel and a plurality of negative electrodes connected to each other in parallel, one of the electrodes of the first planar battery cell having a first planar electrode surface,

placing an interconnector over the first planar battery cell, the interconnector being one of a compressible interconnector, an interconnector including electrically conductive fibers, or a modular interconnector unit,

placing a second planar battery cell over the interconnector, the second planar battery cell including a plurality of positive electrodes connected to each other in parallel and a plurality of negative electrodes connected to each other in parallel, one of the electrodes of the second planar battery cell having a second planar electrode surface; and

forcing the first planar battery cell and the second planar battery cell toward each other.

17. A method of maintaining a battery comprising:

monitoring a set of planar battery cells;

identifying a defective planar battery cell from the set of substantially planar battery cells;

removing the defective planar battery cell, causing a compressible interconnector to expand from a compressed state to an uncompressed state having an uncompressed volume; and

inserting a non-defective planar battery cell in a manner that compresses the compressible interconnector from the uncompressed state to the compressed state, the compressible interconnector compressed to less than 90 percent of the uncompressed volume when in the compressed state.