A forming device is configured to form metal laminated sheet material into a tray-shaped case half while allowing the material to form pleats in the corners of the recess during the forming process while preventing formation of pleats along the flange. The device forms the flange so that excess material in the corners of the case halves is arranged in an undulating shape. As a result, the flange has a waved or ruffled configuration at each corner. Two such case halves are sealed together along the flange to form a reliably sealed package. A method of forming pouch cell is also described.
A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.
H01M 50/00 - Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
H01M 50/124 - Primary casingsJackets or wrappings characterised by the material having a layered structure
H01M 50/15 - Lids or covers characterised by their shape for prismatic or rectangular cells
H01M 50/103 - Primary casingsJackets or wrappings characterised by their shape or physical structure prismatic or rectangular
H01M 50/166 - Lids or covers characterised by the methods of assembling casings with lids
H01M 50/169 - Lids or covers characterised by the methods of assembling casings with lids by welding, brazing or soldering
H01M 50/131 - Primary casingsJackets or wrappings characterised by physical properties, e.g. gas permeability, size or heat resistance
A battery system includes a pair of current collectors that are configured to provide a parallel electrical connection between electrochemical cells of a cell array. The pair of current collectors includes a first current collector plate that provides an electrical connection between the ends of the respective cells, and a second current collector plate that includes openings that receive the cells therein, and provide an electrical connection between the sidewalls of the respective cells. The current collectors are each on the same end of the cells and the opposed end of the cell can be protected or electrically isolated for a multitude of functions, such as cell cooling.
An electrochemical pouch cell includes a pouch cell housing and an electrode assembly disposed in the housing. The housing is formed of a single blank that is progressively drawn to form first and second recesses in the sheet, where the first recess coincides with a portion of the second recess. The blank is then folded so that the recesses are aligned and open facing each other. The electrode assembly is disposed in the space defined within and between the recesses, and flange portions of the material surrounding the recesses are sealed together to form a sealed electrochemical cell in which one side of the cell is free of the flange. The progressive drawing process along with the configuration of the recesses allows the cell housing to have an increased depth relative to some conventional pouch cell housings.
H01M 50/124 - Primary casingsJackets or wrappings characterised by the material having a layered structure
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
H01M 50/116 - Primary casingsJackets or wrappings characterised by the material
An electrochemical cell includes a housing, and an electrode assembly disposed in the housing. The electrode assembly comprises a positive electrode, a negative electrode and a separator disposed between the positive electrode and the negative electrode. The housing is formed of a first case half and a second case half. Each case half is formed of a metal foil laminate material and includes a wedge-shaped central recess that is surrounded by a flange. The flange of the first case half is joined to the flange of the second case half along a seal line that surrounds the respective central recesses. The central recesses cooperate to define an interior space of the housing that contains the electrode assembly, and the interior space has the shape of a rectangular prism. The seal line extends along a diagonal of a side of the rectangular prism. A method of forming the housing is described.
B29C 43/14 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles in several steps
B29C 51/26 - Component parts, details or accessoriesAuxiliary operations
A method for current sensor fault detection in a battery system comprises receiving a sequence of battery voltage samples from a voltage sensor configured to measure a battery voltage of a battery and a sequence of battery current samples from a current sensor configured to measure a battery current of the battery; determining a change in the battery voltage samples over a predetermined number of samples and a change in the battery current samples over the predetermined number of samples; checking whether a ratio of the change in the battery voltage samples and the change in the battery current samples is within an expected range for one of (i) a resistance of the battery and (ii) a conductance of the battery; and detecting a fault in the current sensor based on whether the ratio is within the expected range.
G01R 31/382 - Arrangements for monitoring battery or accumulator variables, e.g. SoC
G01R 31/08 - Locating faults in cables, transmission lines, or networks
G01R 31/374 - Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC] with means for correcting the measurement for temperature or ageing
G01R 31/3842 - Arrangements for monitoring battery or accumulator variables, e.g. SoC combining voltage and current measurements
G01R 31/28 - Testing of electronic circuits, e.g. by signal tracer
G01R 31/389 - Measuring internal impedance, internal conductance or related variables
A battery module incorporates features of both prismatic housings and metal foil laminate pouch housings, and is configured to receive and support electrochemical cells. The battery module housing includes a rigid tubular frame and flexible cover elements that are joined to the frame and close the open ends of the frame. The frame has an inner surface that faces the cells, an outer surface that is opposed to the inner surface, a first edge that joins the inner surface to the outer surface at one open end of the frame, and a second edge that joins the inner surface to the outer surface at the opposed open end of the frame. The first cover element overlies and closes the one open end of the frame and the second cover element overlies and closes the other open end of the frame.
H01M 2/10 - Mountings; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 10/6556 - Solid parts with flow channel passages or pipes for heat exchange
An electrochemical cell includes a prismatic cell housing including a lid plate that closes one end of the housing. The cell also includes a terminal assembly having a simple structure that is supported on the lid plate. The terminal assembly includes the lid plate, a terminal and an adhesive layer that is disposed between and secures the terminal to the lid plate. The terminal assembly includes features that allow the adhesive layer to flow in a controlled and reproducible manner over the entirety of a predetermined area without flowing beyond the predetermined area. The features result from forming a stop line in the predetermined area by applying a surface treatment to the predetermined area. The stop line delineates a desired adhesive later outer boundary and engages the adhesive so as to maintain the adhesive within the predetermined area.
An electrochemical cell includes a cell housing and an electrode assembly disposed in the cell housing. The electrode assembly includes an electrode pair that is arranged to form a winding having a polygonal spiral wound shape in which a radius of the corner portions of each turn of the winding is constant, regardless of the number of turns. In addition, a length of the linear portions of one turn of the winding is different than a length of the linear portions of another turn of the winding. Since each turn of the winding includes the corner portions having a desired radius, the volumetric efficiency of the electrode assembly including the winding within a cell housing is improved relative to some cells that use conventional windings. An apparatus and method of forming a polygonal spiral wound winding are disclosed.
H01M 10/0587 - Construction or manufacture of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
An electrochemical pouch cell includes a stacked or rolled arrangement of electrode plates disposed in a cell housing, and a lead tab that protrudes through the cell housing. The lead tab forms an electrical connection with the electrode plates within the cell and permits transfer of current out of the cell via an opening in a seal joint of the pouch cell housing. The lead tab has a configuration that improves reliability of the seal between the lead tab and the opening.
A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and a current collector device disposed in the cell housing. The electrode assembly includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis. The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing via an opening formed in the cell housing. The opening is formed in a side wall of the cell housing at a location spaced apart from the sealed joint that closes the cell housing and at a location facing the stack axis.
An electrochemical cell has a flexible low-profile sensor device that includes a solid state device or series of solid state devices on a common carrying material that enable the device(s) to sense battery cell conditions and actively perform cell control functions. At least a portion of the sensor device resides outside the cell. When arranged in a stack, cells including the sensor automatically form a communication network.
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 10/42 - Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
A pouch cell includes a generally rectangular cell housing formed of a metal laminated film that includes a box portion and a lid portion that is formed separately from the box portion. The active material including the electrode and an electrolyte is placed into the box portion and the lid portion is welded to the box portion. The box portion and the lid portion are formed and assembled together without using a drawing or a punching process. Instead, the pouch cell housing is formed via a series of folding and welding steps, whereby the pouch cell size is not limited by the draw depth of the metal laminated film.
A pouch cell (20A, 20) includes a generally rectangular cell housing (20, 21) formed of a metal laminated film, an electrode assembly (60) that is sealed within the cell housing (20, 21), and a current collector device disposed in the cell housing (20, 21). The electrode assembly (60) includes positive electrode portions alternating with negative electrode portions, the positive electrode portions and the negative electrode portions being separated by at least one separator and stacked along a stack axis (66). The current collector device is electrically connected to one of the positive electrode portions and the negative electrode portions and exits the cell housing (20, 21) via an opening (28, 428) formed in the cell housing (20, 21). The opening (28, 428) is formed in a side (22, 24) wall of the cell housing (20, 21) at a location spaced apart from the sealed joint (40) that closes the cell housing (20, 21) and at a location facing the stack axis (66).
A battery system includes a first battery cell that is electrically connected to a second battery cell via directed contact between compliant terminals of the first and second battery cells. The compliant terminals include a first end that is electrically connected an electrode assembly disposed within the cell, a second end disposed outside the cell, and an elastically compliant portion disposed between the second end and a cell housing.
A pouch cell includes a generally rectangular cell housing formed of a metal laminated film, an electrode assembly that is sealed within the cell housing, and an elastic restraint that surrounds a plate stack of the electrode assembly.
H01M 10/04 - Construction or manufacture in general
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
17.
Device and method for forming complex joints in layered sheet material
The sealing device includes a heatable base plate that cooperates with a heatable split plate to simultaneously form three intersecting seal lines. The split plate includes an alpha plate and a beta plate. The alpha plate and the beta plate each include a first heated surface that cooperate with the base heated surface to form a pair of co-linear seal lines. In addition, the alpha plate and the beta plate each include a second heated surface that cooperate together to form a third seal line that extends in a direction perpendicular to the co-linear seal lines and intersects the co-linear seal lines. A method of forming a complex seal joint is also described.
B29C 65/24 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated tool characterised by the means for heating the tool
H01M 10/04 - Construction or manufacture in general
B29C 65/00 - Joining of preformed partsApparatus therefor
B29C 65/18 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated tool
H01M 50/116 - Primary casingsJackets or wrappings characterised by the material
An electrochemical cell includes an electrode assembly disposed in a cell housing. A first U-shaped current collector is disposed between the cell housing and the electrode assembly, and is electrically connected to a positive electrode portion of the electrode assembly. A second U-shaped current collector is disposed between the cell housing and the electrode assembly, and is electrically connected to a negative electrode portion of the electrode assembly. The first and second current collectors cooperate to surround all sides of the electrode assembly and to retain the electrode assembly in the desired configuration without requiring a separate restraint.
A electrode assembly includes an electrode pair having a positive electrode and a negative electrode that are arranged crosswise and each z-folded while being cross-woven together in a continuous manner. The electrode assembly includes an electrode stack in which portions of the positive electrode are stacked along a stack axis so as to alternate with portions of the negative electrode.
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
H01M 10/04 - Construction or manufacture in general
A circuit that measures isolation resistance in a battery pack that is associated with a load includes four resistors. Two resistors are connected between terminals of the battery pack and another two resistors are connected in the load in parallel to the resistors in the battery pack. A controller operates two contactors to disconnect the battery from the load and measure first and second voltages in the battery pack and one of the two resistors. The controller operates the two contactors to connect the battery to the load and measures third and fourth voltages in the battery pack and one of the two resistors. The controller identifies the isolation resistance with reference to resistance values of the four resistors and the first, second, third, and fourth measured voltages.
G01R 31/36 - Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
G01R 27/02 - Measuring real or complex resistance, reactance, impedance, or other two-pole characteristics derived therefrom, e.g. time constant
H02J 7/00 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
A pressure relief device attached to an outer surface of a battery pack includes an adhesive arranged around an opening in the outer surface of the battery pack and a hat portion arranged over the opening. The hat portion includes an outer ring portion attached to the outer surface of the battery pack via the adhesive and an inner portion that is recessed from the outer surface of the battery pack to form a gap between the opening and the inner portion. A diameter of the inner portion is greater than a diameter of the opening, and a diameter of the gap is greater than the diameter of the opening.
A pressure relief device attached to an outer surface of a battery pack includes an adhesive arranged around an opening in the outer surface of the battery pack and a hat portion arranged over the opening. The hat portion includes an outer ring portion attached to the outer surface of the battery pack via the adhesive and an inner portion that is recessed from the outer surface of the battery pack to form a gap between the opening and the inner portion. A diameter of the inner portion is greater than a diameter of the opening, and a diameter of the gap is greater than the diameter of the opening.
A battery control system for an electric vehicle including a battery pack includes a dew point calculation module that receives at least a first signal indicative of humidity within the battery pack and a second signal indicative of temperature within the battery pack, and that calculates a dew point within the battery pack based on the humidity and the temperature. A coolant system control module receives the dew point and a requested coolant temperature, sets a desired coolant temperature based on the dew point and the requested coolant temperature, and selectively operates a coolant system of the battery pack based on the desired coolant temperature.
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
A battery disconnect unit (BDU) is arranged to selectively enable current flow between a power source and a battery pack of a vehicle, and between the battery pack and the vehicle. The battery disconnect unit includes a housing having an exterior and an interior, a first exterior surface and a first interior surface, and an opening opposite the first interior surface. A plurality of BDU components are mounted within the interior of the housing. The BDU components are mounted at least one of on and adjacent to the first interior surface of the housing, and respective fasteners used to mount the BDU components to the first interior surface of the housing are not exposed on the first exterior surface of the housing. When the housing is mounted on a mounting surface associated with the battery pack, the opening is arranged adjacent to the mounting surface and the first interior surface is arranged opposite the mounting surface relative to the opening.
H01M 2/10 - Mountings; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
H01M 2/20 - Current-conducting connections for cells
H01M 2/34 - Current-conducting connections for cells with provision for preventing undesired use or discharge
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 10/42 - Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
B60L 11/18 - using power supplied from primary cells, secondary cells, or fuel cells
A lithium ion cell includes a housing and positive and negative terminals. The housing includes top and bottom surfaces. The housing includes first, second, third, and fourth side surfaces, perpendicular to the top and bottom surfaces. A cell isolator includes first and second portions made of an electrically non-conductive material. The first portion includes first, second, and third wall members. The first wall member directly contacts the first side surface. The second wall member directly contacts a portion of the second side surface. The third wall member directly contacts a portion of the third side surface. The second portion includes fourth, fifth, and sixth wall members. The fourth wall member directly contacts the fourth side surface. The fifth wall member directly contacts portions of the second side surface and the second wall member. The sixth wall directly contacts portions of the third side surface and the third wall member.
A battery module for enclosing at least one battery cell includes a cooling plate. At least one compressible pad is arranged on the cooling plate. The at least one compressible pad has a first surface in contact with the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell. A compression limiting device is arranged adjacent to the at least one compressible pad. The compression limiting device has a first surface facing the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell. A compressibility of the compression limiting device is less than a compressibility of the at least one compressible pad.
A system includes a battery control module that determines at least one temperature associated with a battery pack of an electric vehicle. An electric vehicle control module selects between a plurality of operating modes of the electric vehicle based on the at least one temperature. The plurality of operating modes includes a first mode and a second mode. In the first mode the electric vehicle control module prevents the electric vehicle from being turned on. In second mode the electric vehicle control module allows the electric vehicle to be turned on in response to a determination that the battery pack has sufficient energy to adjust the at least one temperature a predetermined amount and to drive the vehicle a predetermined distance.
B60L 11/18 - using power supplied from primary cells, secondary cells, or fuel cells
B60L 3/00 - Electric devices on electrically-propelled vehicles for safety purposesMonitoring operating variables, e.g. speed, deceleration or energy consumption
B60L 3/04 - Cutting-off the power supply under fault conditions
A system (120) includes a battery control module (116) that determines at least one temperature associated with a battery pack (104) of an electric vehicle (100). An electric vehicle control module (108) selects between a plurality of operating modes of the electric vehicle (100) based on the at least one temperature. The plurality of operating modes includes a first mode and a second mode. In the first mode the electric vehicle control module (108) prevents the electric vehicle (100) from being turned on. In second mode the electric vehicle control module (108) allows the electric vehicle (100) to be turned on in response to a determination that the battery pack (104) has sufficient energy to adjust the at least one temperature a predetermined amount and to drive the vehicle (100) a predetermined distance.
B60L 3/00 - Electric devices on electrically-propelled vehicles for safety purposesMonitoring operating variables, e.g. speed, deceleration or energy consumption
B60L 3/04 - Cutting-off the power supply under fault conditions
B60L 11/18 - using power supplied from primary cells, secondary cells, or fuel cells
A battery module according to the principles of the present disclosure includes a plurality of battery cells, a pair of sideplates, and a pair of endplates. The sideplates are disposed on opposite sides of the plurality of battery cells and the endplates are disposed at opposite ends of the battery module. The sideplates include a first mating portion and the endplates include a second mating portion that engages the first mating portion to provide an interference fit. The interference fit joins the sideplates and the endplates together and bands the plurality of cells together between the sideplates and the endplates.
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 10/50 - Heating or cooling or regulating temperature (control of temperature in general G05D 23/00)
30.
EXPECTED BATTERY LIFE DETERMINATION SYSTEM AND METHOD
A method includes: generating a first (operating) age factor value (356) for a battery based on: a cycle period (340) of the battery; a required operational life (308) of the battery; and a cycle life (332) of the battery. The method further includes generating a second (resting) age factor value (348) for the battery based on: the required operational life (308); and a resting life (324) of the battery. The method further includes generating a third (combined) age factor value (364) for the battery based on: the required operational life (308); the first age factor value (356); the second age factor value (348); and at least one of an expected period of cycling of the battery during the required operational life and expected period of resting of the battery during the required operational life. The method further includes: generating an expected life (372) of the battery based on the required operational life (30) and the third age factor value (364); and displaying the expected life.
G01R 31/36 - Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
patents
