Lithium ion battery module

• US 9,577,231 B2
• Filed: 11/02/2015
• Issued: 02/21/2017
• Est. Priority Date: 05/20/2009
• Status: Active Grant

• Current Assignee: Clarios Advanced Solutions GmbH (Johnson Controls International plc)
• Original Assignee: Johnson Controls Advanced Power Solutions, LLC (Johnson Controls International plc)
• Inventors: Fuhr, Jason D., Houchin-Miller, Gary P., Bowen, Gerald K., Dinkelman, John P., Patel, Dharmendra, Molinaroli, Alex
• Primary Examiner(s): Alejandro, Raymond
• Application Number:
  US14/930,443
• Publication Number:
  US 20160126510A1
• Time in Patent Office: 477 Days
• US Class Current: 1/1
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/112 Monobloc comprising multiple compartments
• CPC Class Codes: H01M 50/116 characterised by the material
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 having a layered structure
• CPC Class Codes: H01M 50/1245 characterised by the external coating on the casing
• CPC Class Codes: H01M 50/131 characterised by physical properties, e.g. gas permeability, size or heat resistance
• CPC Class Codes: H01M 50/147 Lids or covers
• CPC Class Codes: H01M 50/148 characterised by their shape
• CPC Class Codes: H01M 50/155 characterised by the material
• CPC Class Codes: H01M 50/16 Organic material
• CPC Class Codes: H01M 50/20 Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders structural combination of accumulators with charging apparatus H01M10/46
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/231 having a layered structure
• CPC Class Codes: H01M 50/258 : Modular batteries; Casings provided with means for assembling
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/289 : characterised by spacing elements or positioning means within frames, racks or packs spacing elements inside cells other than separators, membranes or diaphragms H01M50/471
• CPC Class Codes: H01M 50/60 : Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
• CPC Class Codes: H01M 50/627 : Filling ports
• CPC Class Codes: H01M 50/70 : Arrangements for stirring or circulating the electrolyte
• 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 137/4757 : Battery or electrolytic cell replenishment

Abstract

A lithium-ion battery module includes a housing having a plurality of partitions configured to define a plurality of compartments within a housing. The battery module also includes a lithium-ion cell element provided in each of the compartments of the housing. The battery module further includes a cover coupled to the housing and configured to route electrolyte into each of the compartments. The cover is also configured to seal the compartments of the housing.

Claims

1. A lithium-ion battery module comprising:

a housing having a perimeter and one or more integral dividing walls extending between portions of the perimeter to define a plurality of compartments within the housing, wherein the housing comprises a base material that is electrically insulative; and

a plurality of unformed lithium-ion cell elements, which are uncharged, wherein each unformed lithium-ion cell element of the plurality of unformed lithium-ion cell elements is disposed in a corresponding compartment of the plurality of compartments, and wherein each unformed lithium-ion cell element comprises a first terminal and a second terminal configured to enable formation of the unformed lithium-ion cell element while the unformed lithium-ion cell element is within the corresponding compartment by routing electrolyte through a cover of the housing; and

a plurality of open-ended metal foil pouches, wherein each uniformed lithium-ion cell element of the plurality of unformed lithium-ion cell elements is disposed in a corresponding open-ended metal foil pouch of the plurality of open-ended metal foil pouches.

2. The lithium-ion battery module of claim 1, wherein the first terminal or the second terminal of each unformed lithium-ion cell element is coupled with an adjacent first terminal or an adjacent second terminal of an adjacent unformed lithium-ion cell element to enable substantially simultaneous formation of the unformed lithium-ion cell element and the adjacent unformed lithium-ion cell element.

3. The lithium-ion battery module of claim 1, comprising the cover disposed against at least the one or more integral dividing walls to seal each compartment of the plurality of compartments from an adjacent compartment of the plurality of compartments, wherein the cover comprises a plurality of apertures aligned with the plurality of compartments and configured to enable distribution of the electrolyte to the plurality of compartments.

4. The lithium-ion battery module of claim 3, wherein the plurality of compartments do not include the electrolyte disposed therein.

5. The lithium-ion battery module of claim 1, wherein adjacent unformed lithium-ion cell elements of the plurality of unformed lithium-ion cell elements are connected in series with one another.

6. The lithium-ion battery module of claim 1, comprising a metal permeability barrier.

7. The lithium-ion battery module of claim 6, wherein the metal permeability barrier is embedded within the perimeter of the lithium-ion battery module, within the integral dividing walls of the lithium-ion battery module, or within a combination thereof.

8. The lithium-ion battery module of claim 6, wherein the permeability barrier is coated on the perimeter of the lithium-ion battery module, on the integral dividing walls of the lithium-ion battery module, or on a combination thereof.

9. A lithium-ion battery module comprising:

a housing having a perimeter and one or more integral dividing walls extending between portions of the perimeter to define a plurality of compartments within the housing, wherein the housing comprises a base material that is electrically insulative;

a plurality of lithium-ion cell elements, which are uncharged, wherein each lithium-ion cell element of the plurality of lithium-ion cell elements is disposed in a corresponding compartment of the plurality of compartments;

a plurality of open-ended metal foil pouches, wherein each lithium-ion cell element of the plurality of lithium-ion cell elements is disposed in a corresponding open-ended metal foil pouch of the plurality of open-ended metal foil pouches; and

a lid disposed in contact with the one or more integral dividing walls to seal adjacent compartments of the plurality of compartments from one another, wherein the lid comprises a plurality of apertures aligned with the plurality of compartments to enable distribution of an electrolyte through the plurality of apertures to each compartment of the plurality of compartments, wherein the plurality of compartments does not comprise the electrolyte disposed therein, wherein the plurality of lithium-ion cell elements is a plurality of unformed lithium-ion cell elements, and wherein each unformed lithium-ion cell element of the plurality of unformed lithium-ion cell elements comprises at least one terminal configured to enable formation of the unformed lithium-ion cell element.

10. The lithium-ion battery module of claim 9, wherein the lithium-ion battery module comprises one or more permeability barriers.

11. The lithium-ion battery module of claim 10, wherein the one or more permeability barriers are disposed on outward surfaces of the perimeter.

12. The lithium-ion battery module of claim 10, wherein at least the integral dividing walls of the housing comprise the one or more permeability barriers.

13. The lithium-ion battery module of claim 12, wherein the one or more permeability barriers are disposed on surfaces of the one or more integral dividing walls such that the one or more permeability barriers are exposed to the plurality of compartments.

14. The lithium-ion battery module of claim 13, wherein the one or more permeability barriers are coated or layered onto the surfaces of the one or more integral dividing walls.

15. The lithium-ion battery module of claim 10, wherein the one or more permeability barriers are made of metal.

16. The lithium-ion battery module of claim 9, wherein the lid comprises one or more channels and the plurality of apertures are disposed within the one or more channels.

17. The lithium-ion battery module of claim 9, wherein each lithium-ion cell element of the plurality of lithium-ion cell elements is a cylindrical lithium-ion cell element.

18. The lithium-ion battery module of claim 17, wherein each compartment of the plurality of compartments is a cylindrical compartment.

19. The lithium-ion battery module of claim 9, wherein each lithium-ion cell element of the plurality of lithium-ion cell elements is a prismatic lithium-ion cell element.

20. The lithium-ion battery module of claim 19, wherein each compartment of the plurality of compartments is a prismatic compartment.

21. A lithium-ion battery module, comprising:

a housing having an outer wall, an inner area within the outer wall, and one or more partitions extending inwardly from the outer wall and into the inner area of the housing, wherein the housing comprises an electrically non-conductive base material, and wherein the one or more partitions define a plurality of compartments within the inner area of the housing;

a plurality of lithium-ion cell elements, each lithium-ion cell element being disposed in a corresponding compartment of the plurality of compartments;

a plurality of open-ended metal foil pouches, each open-ended metal foil pouch being disposed around only a portion of a corresponding lithium-ion cell element of the plurality of lithium-ion cell elements; and

a lid disposed against at least the one or more partitions and having a plurality of openings aligned with the plurality of compartments, wherein the plurality of openings is configured to enable distribution of an electrolyte therethrough to the plurality of compartments, and wherein the plurality of compartments do not comprise the electrolyte disposed therein, wherein the plurality of lithium-ion cell elements is a plurality of unformed lithium-ion cell elements, which are uncharged, and each unformed lithium-ion cell element of the plurality of unformed lithium-ion cell elements comprises at least one terminal configured to enable formation of the unformed lithium-ion cell element.

22. The lithium-ion battery module of claim 21, wherein the one or more partitions are integral with the outer wall of the housing and with each other.

23. The lithium-ion battery module of claim 21, wherein the plurality of openings is disposed in one or more recesses of the lid.