Sealed battery enclosure

• US 20100136402A1
• Filed: 04/22/2009
• Published: 06/03/2010
• Est. Priority Date: 04/22/2009
• Status: Abandoned Application

• Current Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Kohn, Scott Ira, Mehta, Vineet Haresh, Hermann, Weston Arthur, Kelty, Kurt Russell, Kishiyama, Clay Hajime
• Application Number:
  US12/386,684
• Publication Number:
  US 20100136402A1
• Time in Patent Office: Days
• US Class Current: 429/120
• 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 10/52 Removing gases inside the secondary cell, e.g. by absorption vent plugs or other mechanical arrangements for facilitating escape of gases H01M50/30
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/6567 Liquids
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/229 Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: H01M 50/231 having a layered structure
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/262 with fastening means, e.g. locks
• CPC Class Codes: H01M 50/276 Inorganic material
• CPC Class Codes: H01M 50/278 Organic material
• CPC Class Codes: H01M 50/28 Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: H01M 50/282 having a layered structure
• CPC Class Codes: H01M 50/30 Arrangements for facilitating escape of gases
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A sealed battery enclosure to extend the life of the batteries contained therein is provided, the sealed battery enclosure significantly reducing contamination from water or other liquids and gases.

Claims

1. A sealed battery pack enclosure, comprising:

a first housing member configured to hold a plurality of batteries, wherein said first housing member is comprised of a first impermeable material;

a second housing member configured to be coupled to said first housing member, wherein said second housing member is comprised of a second impermeable material;

an impermeable sealing gasket configured to fit between a first sealing surface corresponding to said first housing member and a second sealing surface corresponding to said second housing member;

means to secure said first housing member to said second housing member with said impermeable sealing gasket interposed between said first and second sealing surfaces;

a pressure management system coupled to said sealed battery pack enclosure, wherein said pressure management system limits a pressure differential between an inner volume of said sealed battery pack enclosure and the outside environment; and

means for maintaining a low humidity environment within said inner volume of said sealed battery pack enclosure.

2. The sealed battery pack enclosure of claim 1, wherein said first and second impermeable materials are selected from the group consisting of metals, plastics and composites.

3. The sealed battery pack enclosure of claim 1, wherein said first impermeable material is comprised of a base material and a coating of an impermeable material.

4. The sealed battery pack enclosure of claim 1, wherein said second impermeable material is comprised of a base material and a coating of an impermeable material.

5. The sealed battery pack enclosure of claim 1, wherein said impermeable sealing gasket is comprised of a gasket material selected from the group consisting of polyurethanes, polychloroprenes, rubber-edged composite materials, coated polymers, uncoated polymers, synthetic rubbers, and acrylic impregnated polyurethanes.

6. The sealed battery pack enclosure of claim 1, wherein said securing means is comprised of a plurality of bolts.

7. The sealed battery pack enclosure of claim 1, wherein said pressure management system is comprised of at least one pressure relief valve.

8. The sealed battery pack enclosure of claim 7, wherein said at least one pressure relief valve is a two-way pressure relief valve.

9. The sealed battery pack enclosure of claim 1, wherein said means for maintaining said low humidity environment is comprised of a desiccant.

10. The sealed battery pack enclosure of claim 1, wherein said means for maintaining said low humidity environment is comprised of at least one container of desiccant mounted within said inner volume of said sealed battery pack enclosure.

11. The sealed battery pack enclosure of claim 1, further comprising at least one electrical connector hermitically sealed to said sealed battery pack enclosure, said at least one electrical connector electrically connected to said plurality of batteries.

12. The sealed battery pack enclosure of claim 1, further comprising:

means for actively cooling said plurality of batteries; and

means for coupling said means for actively cooling said plurality of batteries with an external cooling source, wherein said coupling means is hermitically sealed to said sealed battery pack enclosure.

13. The sealed battery pack enclosure of claim 12, wherein said means for actively cooling said plurality of batteries is comprised of a liquid coolant contained within a coolant line in thermal communication with said plurality of batteries, and wherein said coupling means is a coolant line coupler.

14. The sealed battery pack enclosure of claim 1, wherein said sealed battery pack enclosure is partially evacuated and back-filled with an inert gas.

15. The sealed battery pack enclosure of claim 1, wherein said sealed battery pack enclosure is partially evacuated and back-filled with dry air.

16. A sealed battery pack enclosure, comprising:

a first housing member configured to hold a plurality of batteries, wherein said first housing member is comprised of a first impermeable material, and wherein said first housing member further comprises a mounting flange;

a second housing member configured to be coupled to said mounting flange of said first housing member, wherein said second housing member is comprised of a second impermeable material;

an impermeable sealing gasket interposed between said mounting flange of said first housing member and a corresponding sealing surface of said second housing member;

means to secure said first housing member to said second housing member with said impermeable sealing gasket interposed between said mounting flange of said first housing member and said corresponding sealing surface of said second housing member;

at least one two-way pressure relief valve coupled to said sealed battery pack enclosure, wherein said at least one two-way pressure relief valve limits a pressure differential between an inner volume of said sealed battery pack enclosure and the outside environment;

at least one container of desiccant mounted within said inner volume of said sealed battery pack enclosure; and

at least one electrical connector hermitically sealed to said sealed battery pack enclosure, said at least one electrical connector electrically connected to said plurality of batteries.

17. The sealed battery pack enclosure of claim 16, further comprising:

means for actively cooling said plurality of batteries; and

means for coupling said means for actively cooling said plurality of batteries with an external cooling source, wherein said coupling means is hermitically sealed to said sealed battery pack enclosure.

18. The sealed battery pack enclosure of claim 17, wherein said means for actively cooling said plurality of batteries is comprised of a liquid coolant contained within a coolant line in thermal communication with said plurality of batteries, and wherein said coupling means is a coolant line coupler.

19. The sealed battery pack enclosure of claim 16, wherein said sealed battery pack enclosure is partially evacuated and back-filled with an inert gas.

20. The sealed battery pack enclosure of claim 16, wherein said sealed battery pack enclosure is partially evacuated and back-filled with dry air.