U.S. patent application number 15/252941 was filed with the patent office on 2018-02-01 for battery cell structural integration.
This patent application is currently assigned to NIO USA, INC. The applicant listed for this patent is NIO USA, INC.. Invention is credited to Austin Newman, Joshua Smith.
Application Number | 20180034018 15/252941 |
Document ID | / |
Family ID | 61010530 |
Filed Date | 2018-02-01 |
United States Patent
Application |
20180034018 |
Kind Code |
A1 |
Newman; Austin ; et
al. |
February 1, 2018 |
BATTERY CELL STRUCTURAL INTEGRATION
Abstract
A battery including supporting material is disclosed. The
battery comprises a plurality of modules, each of which further
comprises a plurality of battery cells that store and discharge
electrical energy. To support the battery modules, a supporting
material such as foam is inserted in the space between the battery
modules. To support the cells within the modules, a supporting
material such as foam is also inserted in between the battery cells
in each of the modules.
Inventors: |
Newman; Austin; (San Jose,
CA) ; Smith; Joshua; (Los Gatos, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIO USA, INC. |
SAN JOSE |
CA |
US |
|
|
Assignee: |
NIO USA, INC
SAN JOSE
CA
|
Family ID: |
61010530 |
Appl. No.: |
15/252941 |
Filed: |
August 31, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62369736 |
Aug 1, 2016 |
|
|
|
62369738 |
Aug 1, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M 2/1077 20130101;
H01M 2/1061 20130101; H01M 2/1094 20130101; Y02E 60/10 20130101;
H01M 2/105 20130101; H01M 2/1055 20130101; H01M 2220/20
20130101 |
International
Class: |
H01M 2/10 20060101
H01M002/10 |
Claims
1. A battery module, comprising: a plurality of battery cells; a
battery module enclosure enclosing the plurality of battery cells;
and supporting material between the plurality of battery cells
within the battery module enclosure.
2. The battery module of claim 1, wherein: the supporting material
comprises a polymer-based foam.
3. The battery module of claim 1, wherein: the supporting material
comprises a metallic foam.
4. The battery module of claim 3, wherein: the battery cells are at
least partially insulated from the metallic foam.
5. The battery module of claim 1, wherein the supporting material
occupies substantially all space between the battery cells.
6. The battery module of claim 1, wherein: the cells of the
plurality of battery cells are coupled either or both of in
parallel or in series.
7. The battery module of claim 1, wherein: the battery cells have
one of a cylindrical shape, a prismatic shape, and a pouch
shape.
8. A battery pack, comprising: a plurality of battery modules, each
comprising: a plurality of battery cells; a battery module
enclosure enclosing the plurality of battery cells; and supporting
material between the plurality of battery cells within the battery
module enclosure.
9. The battery pack of claim 8, wherein: the supporting material
comprises a polymer-based foam.
10. The battery pack of claim 8, wherein: the supporting material
comprises a metallic foam.
11. The battery pack of claim 10, wherein: the battery cells are at
least partially insulated from the metallic foam.
12. The battery pack of claim 8, wherein the supporting material
occupies substantially all space between the battery cells.
13. The battery pack of claim 8, wherein: the cells of the
plurality of battery cells are coupled either or both of in
parallel or in series.
14. The battery pack of claim 8, wherein: the battery cells have
one of a cylindrical shape, a prismatic shape, and a pouch
shape.
15. An autonomous vehicle comprising: vehicle components; and a
battery pack powering at least some of the vehicle components, the
battery pack comprising: a plurality of battery modules, each
comprising: a plurality of battery cells; a battery module
enclosure; and supporting material between the plurality of battery
cells within the battery module enclosure.
16. The autonomous vehicle of claim 15, wherein: the supporting
material comprises a polymer-based foam.
17. The autonomous vehicle of claim 15, wherein: the supporting
material comprises a metallic foam.
18. The autonomous vehicle of claim 17, wherein: the battery cells
are at least partially insulated from the metallic foam.
19. The autonomous vehicle of claim 15, wherein the supporting
material occupies substantially all space between the battery
cells.
20. The autonomous vehicle of claim 15, wherein: the cells of the
plurality of battery cells are coupled either or both of in
parallel or in series.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit both of U.S. Provisional
Patent Application No. 62/369,736, filed Aug. 1, 2016, and U.S.
Provisional Patent Application No. 62/369,738, filed Aug. 1, 2016,
both of which are incorporated by reference as if fully set
forth.
FIELD OF INVENTION
[0002] This application is related to batteries for electric
vehicles, and, more specifically, to battery cell structural
integration.
BACKGROUND
[0003] An autonomous car is a vehicle that is capable of sensing
its environment and navigating without human input. Numerous
companies and research organizations have developed working
prototype autonomous vehicles.
[0004] Many electrical autonomous cars exist. Electrical cars are
cars that use a supply of electrical energy, rather than an
internal combustion engine, for powering the car. Typically,
electrical cars are powered by batteries that are rechargeable.
There have been rapid advancements in electrical vehicle batteries
in recent years but further advancements are desirable.
SUMMARY
[0005] A battery module is disclosed. The battery module includes a
plurality of battery cells, a battery module enclosure enclosing
the plurality of battery cells, and supporting material between the
plurality of battery cells within the battery module enclosure.
[0006] A battery pack is also disclosed. The battery pack includes
a plurality of battery modules. Each battery module includes a
plurality of battery cells, a battery module enclosure enclosing
the plurality of battery cells, and supporting material between the
plurality of battery cells within the battery module enclosure.
[0007] An autonomous vehicle is also disclosed. The autonomous
vehicle includes vehicle components and a battery pack powering at
least some of the vehicle components. The battery pack includes a
plurality of battery modules. Each battery module includes a
plurality of battery cells, a battery module enclosure enclosing
the plurality of battery cells, and supporting material between the
plurality of battery cells within the battery module enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing Summary and the following detailed description
will be better understood when read in conjunction with the
appended drawings, which illustrate a preferred embodiment of the
invention. In the drawings:
[0009] FIG. 1 is an illustration of an electric vehicle, according
to an example;
[0010] FIG. 2 illustrates additional details of the battery pack
illustrated in FIG. 1, according to an example;
[0011] FIG. 3 is a top-down, open view of the battery pack of FIG.
1, according to an example; and
[0012] FIG. 4 is a top-down view of one of the modules of FIGS.
1-3, according to an example.
DETAILED DESCRIPTION OF THE DRAWINGS
[0013] A battery including supporting material is disclosed. The
battery comprises a plurality of modules, each of which further
comprises a plurality of battery cells that store and discharge
electrical energy. To support the battery modules, a supporting
material such as foam is inserted in the space between the battery
modules. To support the cells within the modules, a supporting
material such as foam is also inserted in between the battery cells
in each of the modules. In addition to providing structural
strength to the parts of the battery, the structural material can
also provide thermal insulation.
[0014] FIG. 1 is an illustration of an electric vehicle 100,
according to an example. As shown, the vehicle includes a battery
pack 102. The electric vehicle 100 also includes other vehicle
components not shown, including typical components for electronic
vehicles such as a motor, steering components, passenger comfort
electronics, driver controls, signaling, and the like. The battery
pack 102 stores energy and provides electrical power to the various
components of the vehicle 100 on demand, including to the electric
motor in order to provide power to propel the vehicle 100.
[0015] The vehicle 100 also includes an on-board computer 104 and
sensors 106. Although shown in particular locations, the sensors
106 may be located anywhere on the vehicle 100. The on-board
computer 104 provides various data-processing operations for the
vehicle 100, including autonomously piloting the vehicle 100. The
on-board computer 104 may include various components for performing
such functionality, such as a hardware microprocessor, memory,
storage (e.g., non-volatile), input devices (including sensors
106), output devices (including outputs provided to operate various
systems of the vehicle 100), and other components typically
included in an autonomous vehicle. The sensors may include various
sensors for detecting aspects of the environment of the vehicle 100
for performing the autonomous driving functions, such as radar
devices, cameras, sound sensing devices, and other technically
feasible devices for obtaining inputs for autonomous piloting of
the vehicle 100.
[0016] Autonomously piloting the vehicle may include autonomously
controlling acceleration, steering, and braking, as well as other
functions. These functions may be performed by processing inputs
received from input devices (sensors 106) based on algorithms
stored by or accessible to the on-board computer 104.
[0017] FIG. 2 illustrates additional details of the battery pack
102 illustrated in FIG. 1, according to an example. As shown, the
battery pack is divided into modules 202. Modules 202 are groupings
of cells 204 that physically group and electrically connect the
cells (e.g., in parallel and/or in series) into a cohesive unit.
The cells 204 each include energy storage materials that store
chemical energy and convert that chemical energy into electrical
energy. The cells 204 in a module 202 are connected together in
parallel and/or in series to satisfy specific electrical
requirements of the vehicle 100.
[0018] Each module 202 may include a single external connection for
electrical access to the collection of cells 204 within the module
202. Multiple modules 202 are included in the battery pack 102 and
are coupled together electrically in order to satisfy particular
electrical requirements (e.g., current requirements, voltage
requirements, power requirements, or the like) of the vehicle 100.
The contents of the battery pack 102 are held within and protected
by an enclosure 206.
[0019] FIG. 3 is a top-down, open view of the battery pack 102 of
FIG. 1, according to an example. A top wall (or lid) of the battery
pack 102 is not shown so that the inside of the battery pack 102
can be seen in FIG. 3. As shown, the battery pack 102 includes six
modules 202 organized in rows. Although shown as being arranged in
a specific configuration and with specific shapes, the modules 202
may be of any technically feasible shape arranged in any
technically feasible manner.
[0020] A supporting material 302 is present in the space between
the modules 202. The supporting material 302 can be any material
that has light weight and that absorbs mechanical energy. One class
of materials that meets these criteria is foam. Foams are materials
that comprise solid or liquid material having pockets of gas
trapped therein. Some examples of types of foams that could be used
as the supporting material 302 include a polymer-based foam (such
as a polyurethane foam) and aluminum foam. Another material that
could also be used as the supporting material 302 is a
non-Newtonian fluid, or, more specifically, a shear thickening
fluid. Properties of a shear thickening fluid are that viscosity of
such a fluid increases with the rate of shear strain. Such a fluid
would "firm up" when a strong force is applied, thereby helping to
protect the modules 202 and cells 204 in the event that strong
forces are applied to the battery pack 102. The supporting material
302 fills substantially all of the space within the enclosure 206,
including space above, below, and around each of the modules
202.
[0021] The supporting material 302 spreads mechanical forces
throughout the battery pack 102. This force spreading function
helps to spread certain forces to all of the modules 202 instead of
having such forces focus on specific modules 202. For example, in
the event of an impact, the force of the impact is spread, through
the supporting material 302, to more of the modules 202 than if the
supporting material 302 were not present.
[0022] Additionally, vehicles, such as vehicle 100, are typically
subjected to legally required collision tests. The inclusion of
supporting material 302 in the battery pack 102 allows the battery
pack 102 to withstand a larger force than if the supporting
material 302 were not included. Alternatively, the inclusion of
supporting material 302 allows for a smaller amount of "structural
material" to be included within the battery pack 102 and still be
able to withstand the same impact force. Structural material
includes material such as the enclosure 206 wall and the walls of
the cells 204. These walls can be thinner than if supporting
material 302 were not used.
[0023] Compartments for each of the modules 202 may be defined by
structural walls within the enclosure 206. Alternatively,
structural walls may be absent, with the supporting material 302
serving as the structural walls.
[0024] During manufacturing of the battery pack 102, the technique
for inserting the supporting material 302 depends on the specific
material used for the supporting material 302. Some types of foam
may be injected as liquid into the space in which the supporting
material 302 is to exist. For example, liquid material can be
injected and then hardens to form polyurethane foam. A
non-Newtonian fluid may also be used. Such fluid can simply be
injected into the space for the supporting material 302. For metal
foam, such as aluminum foam, the metal foam is pre-formed to
include cavities for the modules 202 and the modules are placed
into those spaces.
[0025] FIG. 4 is a top-down view of one of the modules 202 of FIGS.
1-3, according to an example. A top wall of the module 202 is not
shown so that supporting material 404 can be visible. As shown, the
module 202 includes a module enclosure 203 enclosing a plurality of
cells 204. Other components not shown in FIG. 4 include various
electronics for controlling how power is provided from the cells
204 of the battery.
[0026] Supporting material 404 occupies the space between the cells
204 of the module 202. As with the supporting material 302 of FIG.
3, the supporting material 404 of FIG. 4 is a material that has low
weight and a high ability to absorb energy, such as a foam, a
non-Newtonian fluid, or another material. The specific foam
material used for the supporting material 404 can be the same as
the material used as the supporting material 302 between the
modules 202 or can be different.
[0027] The cells 204 can be any technically feasible shape. For
example, the cells 204 can be cylindrical, "prismatic" (i.e.,
rectangular shapes), or pouches (e.g., a thin, flat sheet in a
vacuum formed aluminum packaging). The cells 204 may be
rechargeable, and can be charged via a connection to an external
power supply. Each cell 204 stores energy that can be converted to
electrical energy through terminals. The cells may be any
technically feasible battery cell type. In one example, the cells
204 are lithium ion cells. The battery pack 102 may include
management electronics and sensors to manage the cells 204. For
example, the management electronics may manage temperature,
charging, current flow, and the like, for the cells 204.
[0028] During manufacturing, the technique for inserting the
supporting material 404 in between the cells 204 depends on the
specific material used for the supporting material 404. For a foam
formed from a material that starts as a liquid, the starting liquid
can be injected into the module 202. The liquid is then converted
to the foam material, thereby causing a foam material to occupy
substantially all of the space between the cells 204 in the module
202. For a metallic foam material, the metallic foam is first cast
into a shape that can hold the cells 204 and then the cells 204 are
placed into the metallic foam material. Further, if a metallic foam
or other metallic material is used, insulation may be required to
prevent portions of the cells 204 from shorting to each other.
Cells 204 may be placed in dielectric sleeves or the aluminum foam
can be potted in an epoxy that is dielectric.
[0029] In some embodiments, structural material is only present in
the modules 202, between the cells 204, but not between the modules
202 in the battery pack 102. In other embodiments, structural
material is only present between the modules 202 in the battery
pack 102, but not between the cells 204 in the modules 202. In yet
other embodiments, structural material is present between the
modules in the battery pack 102 and between the cells 204 in the
modules 202. The structural material serves to mechanically "link"
the various components of the battery pack 102 together,
effectively increasing the structural strength of the battery pack
102. By joining the various components of the battery pack 102
together in such a manner, forces applied to any portion of the
battery pack 102 are spread throughout the battery pack 102 and are
not concentrated at the location at which the force is applied.
This reduces the intensity of force experienced at that location,
since the force is spread among more components.
[0030] Having thus described the presently preferred embodiments in
detail, it is to be appreciated and will be apparent to those
skilled in the art that many physical changes, only a few of which
are exemplified in the detailed description of the invention, could
be made without altering the inventive concepts and principles
embodied therein. It is also to be appreciated that numerous
embodiments incorporating only part of the preferred embodiment are
possible which do not alter, with respect to those parts, the
inventive concepts and principles embodied therein. The present
embodiments and optional configurations are therefore to be
considered in all respects as exemplary and/or illustrative and not
restrictive, the scope of the invention being indicated by the
appended claims rather than by the foregoing description, and all
alternate embodiments and changes to this embodiment which come
within the meaning and range of equivalency of said claims are
therefore to be embraced therein.
[0031] It should be understood that many variations are possible
based on the disclosure herein. Although features and elements are
described above in particular combinations, each feature or element
may be used alone without the other features and elements or in
various combinations with or without other features and
elements.
* * * * *