BATTERY DEVICE

Abstract

A battery device (100) comprising a battery cell pack including a plurality of battery cells (118). The battery device further includes a structure (104) disposed on top of the battery cell pack, the structure including an insulating material (106), and a housing (102), in which the battery cell pack and the structure are arranged. At least an upper surface (110) of the structure has heat- and fire-resistant properties. The insulating material includes a plurality of weakened portions or cuts (112) extending through the insulating material. The structure is arranged such that, in case of burnout of a cell (118a), a ventilation passage (116) is formed over the cell through a weakened portion or cut in the insulating material.

Claims

1. A battery device comprising: a battery cell pack including a plurality of battery cells a layered structure disposed on top of the battery cell pack, said structure including an electrically conductive layer an insulating material and a cover layer or coating forming an upper surface of the layered structure; and a housing in which said battery cell pack and said structure are arranged; wherein said electrically conductive layer is arranged in contact with the battery cell pack to electrically connect the plurality of battery cells, and said electrically conductive layer comprises a plurality of openings said insulating material includes a plurality of weakened portions or cuts (112) extending through the insulating material; said cover layer or coating includes a heat- and fire-resistant material comprising mica or a ceramic, and further comprises a plurality of weakened portions or pre-cuts forming flaps a flap being openable by an increase in pressure resulting from burn-out of a battery cell; and said structure is arranged such that, in case of burnout of a cell of said plurality of battery cells, a ventilation passage is formed over said cell through: an opening of said plurality of openings in said electrically conductive layer, a weakened portion or cut in said insulating material, and an opened flap of said flaps in the cover layer or coating.

2. The battery device of claim 1, wherein said insulating material has a thermal conductivity which is lower than or substantially equal to 1 W/m.Math.K.

3. The battery device of claim 1, wherein said insulating material is electrically insulating.

4. The battery device of claim 1, wherein a thickness (h.sub.1) of said insulating material is in the range 0.5-4 mm.

5. The battery device of claim 1, wherein said insulating material comprises a fluoroelastomer material.

6. The battery device of claim 1, wherein said cover layer or coating is electrically insulating.

7. The battery device of claim 1, wherein said cover layer or coating has a thickness (h.sub.2) such that said flaps are openable by an increase in pressure resulting from said burn-out of the cell.

8. The battery device of claim 1, wherein a thickness of the cover layer or coating is smaller than 300 .Math.m.

9. The battery device of claim 1, wherein said structure further comprises an adhesive to attach said insulating material with said cover layer or coating.

10. The battery device of claim 1, wherein a first side of the insulating material is arranged in physical contact with the electrically conductive layer and a second side opposite to the first side, is arranged in physical contact with the cover layer or coating.

11. The battery device of claim 1, wherein said layered structure further comprises an adhesive to attach said insulating material with said electrically conductive layer.

12. The battery device of claim 1, wherein said cell of said plurality of battery cells comprises a ventilation port adapted for releasing internal pressure and/or gas; and wherein said ventilation port is in fluid communication with said ventilation passage.

13. The battery device of claim 1, wherein said cell of said plurality of battery cells comprises a heat- and fire-resistant sidewall.

14. The battery device of claim 1, further comprising a metal framework, wherein said metal framework comprises a plurality of compartments (146) adapted for insertion of individual battery cells.

15. The battery device of claim 14, wherein said metal framework comprises a metal having a thermal conductivity of at least 150 W/m.Math.K.

16. The battery device of claim 14, further comprising a cooling element arranged in thermal connection with said metal framework.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0072] Exemplifying embodiments will now be described in more detail, with reference to the following appended drawings:

[0073] FIG. 1 is a schematic illustration of a battery device, in accordance with some embodiments;

[0074] FIG. 2 is a schematic illustration of a structure, in accordance with some embodiments;

[0075] FIG. 3 is a schematic illustration of a battery cell pack and a structure, in accordance with some embodiments;

[0076] FIG. 4 is an illustration of a metal framework, in accordance with some embodiments;

[0077] FIG. 5 is a schematic illustration of a battery cell pack, a structure, a framework and a cooling element in the form of a heatsink in accordance with some embodiments; and

[0078] FIG. 6 is an illustration of a battery cell pack, a structure, a framework and a cooling element in the form of a heatsink in accordance with some embodiments.

[0079] As illustrated in the figures, the sizes of the elements and regions may be exaggerated for illustrative purposes and, thus, are provided to illustrate the general structures of the embodiments. Like reference numerals refer to like elements throughout.

DETAILED DESCRIPTION

[0080] Exemplifying embodiments will now be described more fully hereinafter with reference to the accompanying drawings in which currently preferred embodiments are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person.

[0081] With reference to FIG. 1, a battery device, in accordance with some embodiments, will be described.

[0082] FIG. 1 is a schematic illustration of a cross-section of a battery device 100. The battery device 100 comprises a housing 102 inside of which a battery cell pack 105 and a structure 104 are arranged.

[0083] The battery cell pack 105 comprises a plurality of battery cells 118, 118a. The battery cell pack further comprises (optional) holding means 108 for keeping the battery cells 118, 118a in place. Different kinds of holding means for arranging battery cells in a battery cell pack may be used. In the present figure, the holding means 108 surrounds at least a portion of each battery cell 118, 118a, for keeping the battery cell 118, 118a in place.

[0084] The structure 104 is arranged on top of the battery cell pack 105. The structure comprises an insulating material 106 and has a top surface 110 which has flame- and heat-resistant properties. The insulating material 106 has a plurality of weakened portions or pre-cuts 112, which extend through the insulating material 106, from a bottom surface (in contact with the battery cells 118, 118a and the holding means 108) to the top surface 110. The insulating material has a thickness h.sub.1 which may for example be in the range 0.5-4 mm. The structure 104 is positioned such that (in the illustrated cross-section), two weakened portions or pre-cuts 112 are arranged above each battery cell 118.

[0085] To illustrate the principle of the protection provided by the structure 104, it may be assumed that one of the battery cells 118a has malfunctioned and is in thermal runaway (or burning out), which is symbolised with a flame. As a result of the cell 118a burning out, gases and flames 114 have been formed, and pressure has increased within the cell 118a. The insulating material 106 keeps the flames and gases 114 from reaching the other cells 118 of the battery cell pack 105. The pressure from the gases/flames 114 has formed a ventilation passage 116 through a weakening/pre-cut in the insulating material 106 above the malfunctioning cell 118a, through which the gases/flames 114 can escape to a volume 103 above the structure 104, i.e. a space within the housing 102 located between an upper surface of the structure 104 and a wall of the housing 102.

[0086] When the pressure (and temperature) increases, the insulating material 106 above the battery cell 118a may for example collapse on top of the battery cell 118a. For example, the material in the weakened portions/pre-cuts or between weakened portions/pre-cuts may collapse. This collapse may leave an opening in the layer of insulating material 106, through which the gases/flames 114 may escape, thereby forming (a part of) the ventilation passage 116.

[0087] Alternatively, the increased pressure/temperature may widen a pre-cut extending all the way through the insulating material, thereby forming a channel (ventilation passage 116) through which the gas/flames 114 may be released above the structure.

[0088] Furthermore, the increased pressure of the heated gases/flames lead to the weakest portion of the walls confining the gas/flames (i.e. the weakened portions/pre-cuts 112) giving a possibility to release the gas/flames 114.

[0089] Once the gases/flames 114 have passed through the ventilation passage, the gases and flames 114 will be separated from the other cells 118 by the structure 104. The heat- and fire-resistant upper surface 110 of the structure, and the insulating material 106 will protect the cell package/battery cell pack from further propagation of fire.

[0090] With reference to FIG. 2, a structure, in accordance with some embodiments, will be described.

[0091] FIG. 2 is an exploded schematic illustration of a structure 104. The structure 104 may be equivalent to the structure 104 described with reference to FIG. 1, except in that it is formed of a cover layer/coating 120, the insulating material 106 and an electrically conductive layer 122.

[0092] The cover layer/coating 120 comprises a heat- and fire-resistant material and forms the heat- and fire-resistant top surface of the structure 104. The cover layer/coating 120 further comprises a plurality of weakened portions/pre-cuts 124. The weakened portions/pre-cuts 124 are each shaped to form a flap 132. A thickness h.sub.2 of the cover layer/coating 120 is such that an increase in pressure below a flap 132 of the cover layer/coating 120 may open the flap 132. For example, the thickness h.sub.2 which may be smaller than 300 .Math.m.

[0093] The cover layer/coating 120 is arranged in contact with an upper surface 126 of the insulating material 106. The insulating material 106 comprises a plurality of weakened portions/pre-cuts 112. The structure 104 is preferably assembled or arranged such that each weakened portion/pre-cut 112 in the insulating material 106 is aligned with a respective corresponding weakened portion/pre-cut 124 in the cover layer/coating 120. A lower surface 128 of the insulating material 106, the lower surface 128 being opposite the upper surface 126, is arranged in contact with the electrically conductive layer 122 comprising a plurality of openings 130. Again, the structure 104 is preferably assembled or arranged such that each opening 130 in the electrically conductive layer 122 is aligned with a respective corresponding weakened portion/pre-cut 112 in the insulating material 106. Accordingly, an arbitrary weakened portion/pre-cut 124 in the cover layer/coating 120 is arranged coaxially with a respective corresponding weakened portion/pre-cut 112 in the insulating material 106 and a respective corresponding of opening 130 in the electrically conductive layer 122.

[0094] With reference to FIG. 3, a battery device, in accordance with some embodiments, will be described.

[0095] FIG. 3 is a schematic illustration of a structure 104 arranged over a battery cell pack 105.

[0096] The structure 104 comprises a cover layer/coating 120, an insulating material 106, and an electrically conductive layer 122. An adhesive 138 is provided between the cover layer/coating 120 and the insulating material 106 for attaching the cover layer/coating 120 to the insulating material 106. Furthermore, an adhesive 140 is provided between the insulating material 106 and the electrically conductive layer 122 for attaching the electrically conductive layer 122 to the insulating material 106. The adhesives 138, 140 described above may each be provided in the form of an adhesive layer.

[0097] The cover layer/coating 120 comprises a plurality of weakened portions/pre-cuts 124. The weakened portions/pre-cuts 124 are each shaped to form a flap 132. In the illustrated embodiment, the weakened portions/pre-cuts 124 extend through the full thickness of the cover layer/coating 120. Furthermore, the insulating material 106 comprises a plurality of weakened portions/pre-cuts 112, and the electrically conductive layer 122 comprises a plurality of openings 130. The weakened portions/pre-cuts and openings may be aligned as described in conjunction with FIG. 2.

[0098] A connection 134 is formed between the battery cell and the electrically conductive layer 122. The electrically conductive layer 122 here provides for electrically connecting each battery cell of the battery cell pack with one another (either serially or in parallel). The battery cell 118 comprises a ventilation port 136 adapted for releasing internal pressure and/or gas. The leftmost battery cell 142 depicted in FIG. 3 is shown with a closed ventilation port 136.

[0099] With reference to the battery cell denoted 118a, events following a malfunctioning or burned out of the battery cell will now be described. Upon burning out, the battery cell 118a generates heated gases (and/or flames) 114 which may cause the ventilation port 136a to enter an opened state due to the increased pressure within the battery cell 118a. Pressure exerted by the released gases 114 will then enter the corresponding opening of the electrically conductive layer 122, above the battery cell 118a, and cause the weakened portion/pre-cut in the isolating material 106 above the opening to rupture (collapse) or open, thereby allowing the gases 114 to pass through the isolating material 106 to the cover layer/coating 120. Similarly, the pressure of the gases 114 will cause the weakened portion/pre-cut in the cover layer/coating corresponding to the battery cell 118a to rupture or open, forming an opened flap 132a, thereby allowing the gases 114 to exit the structure 104 via the opening left by the opened flap 132a. A ventilation passage 116 has thus been formed in the structure 104, extending over the electrically conductive layer 122, the isolating material 106, and the cover layer/coating 120.

[0100] As the hot gases reach the space between the structure and the housing of the battery cell (not shown in FIG. 3), these gases may cause metallic particles from the housing or other elements of the battery device to melt and fall on the structure. However, as the top surface of the structure, which in the embodiment illustrated in FIG. 3 corresponds to the cover layer/coating 120 (which for example may be a ceramic or mica), such metallic particles or the like falling on the structure will not affect the rest of the structure and, in particular, prevent that the fire propagates to other cells.

[0101] Both the insulating layer 106 and the cover layer 120 prevent a lateral propagation of a malfunction (or fire) occurring in a cell. The insulating layer provides a ventilation passage upwards such that a fire is not propagated laterally and the cover layer/coating 120 protects the insulating layer from above in order to prevent that the insulating layer is damaged by other elements falling on the structure. The cover layer/coating 120 also provides protection against undesired electrical shortcuts.

[0102] Each battery cell here further comprises a heat- and fire-resistant sidewall 142.

[0103] With reference to FIG. 4, a metal framework 144, in accordance with some embodiments, will be described.

[0104] FIG. 4 is an illustration of a battery cell pack 105. The battery cell pack 105 comprises a plurality of battery cells 118. As can be seen, each battery cell 118 is arranged in a respective compartment 146 of the metal framework 144. The plurality of compartments 146 are preferably shaped to correspond to the shape of the battery cells 118. Here, the plurality of compartments 146 are cylinder shaped. As illustrated, the metal framework 144 further does not necessarily cover all surfaces of each battery cell 118. Preferably, the metal framework 144 provides cover and protection of the side surfaces of each battery cell 118. In addition, the metal framework 144 improves thermal management both in case of thermal runaway in one of the battery cells and in normal operation of the battery cells such as when charging and/or discharging the battery cells.

[0105] With reference to FIG. 5, a battery device, in accordance with some embodiments, will be described.

[0106] FIG. 5 is a schematic illustration of a structure 104, a battery cell pack 105, a metal framework 144, and a cooling element such as a heatsink 148. The structure 104 comprises a cover layer/coating 120, an insulating material 106, and an electrically conductive layer 122.

[0107] The cover layer/coating 120 comprises a plurality of weakened portions/pre-cuts 124. The weakened portions/pre-cuts 124 are each shaped to form a flap 132. In the illustrated embodiment, the weakened portions/pre-cuts 124 extend through the full thickness of the cover layer/coating 120. Furthermore, the insulating material 106 comprises a plurality of weakened portions/pre-cuts 112, and the electrically conductive layer 122 comprises a plurality of openings 130. The weakened portions/pre-cuts and openings may be aligned as described in conjunction with FIG. 2.

[0108] A connection 134 is formed between the battery cell and the electrically conductive layer 122. The electrically conductive layer 122 here provides for electrical connection of each battery cell of the battery cell pack with one another. The battery cell 118 comprises a ventilation port 136 adapted for releasing internal pressure and/or gas. The leftmost battery cell depicted in FIG. 3 is shown with a closed ventilation port 136.

[0109] The battery cell pack 105 comprises a plurality of battery cells 118, 118a. The battery cell pack further comprises (optional) holding means 108 for keeping the battery cells 118, 118a in place. Different kinds of holding means for arranging battery cells in a battery cell pack may be used. In the present figure, the holding means 108 surrounds at least a portion of each battery cell 118, 118a, for keeping the battery cells 118, 118a in place. It is to be understood that the holding means 108 may comprise several separate pieces, as is more clearly illustrated in FIG. 6.

[0110] In general, the structure 104 of the embodiment shown in FIG. 5 may be equivalent to the structure 104 described with reference to FIGS. 1-3. Similarly, the battery device of the embodiment shown in FIG. 5 may be equivalent to the battery device described in the preceding embodiments with reference to FIGS. 1-3 except that a metal framework 144 is further provided.

[0111] The metal framework 144 provides compartments adapted to hold a single battery cell. The metal framework 144 is further connected to a heatsink 148. Thus, heat generated by the battery cells may be conducted via the metal framework 144 to the heatsink 148 for heat control of the battery cells. As an alternative to, or in addition to, the passive cooling provided by the heatsink 148 depicted in FIG. 5, the cooling element may be based on active cooling such as, by way of example, piezo-electric cooling, evaporative cooling, or the use of a cooling liquid.

[0112] With reference to battery cell 118a, events following a malfunctioning or burned out battery cell will now be described. Upon burning out, the battery cell 118a generates heated gases (and/or flames) 114 which may cause the ventilation port 136a to enter an opened state due to the increased pressure within the battery cell 118a. Pressure exerted by the released gases 114 will then enter the corresponding opening of the electrically conductive layer 122, above the battery cell 118a, and cause the weakened portion/pre-cut in the isolating material 106 above the opening to rupture or open, thereby allowing the gases 114 to pass through the isolating material 106 to the cover layer/coating 120. Similarly, the pressure of the gases 114 will cause the weakened portion/pre-cut in the cover layer/coating corresponding to the battery cell 118a to rupture or open, forming an opened flap 132a, thereby allowing the gases 114 to exit the structure 104 via the opening left by the opened flap 132a. A ventilation passage 116 has thus been formed in the structure 104, extending over the electrically conductive layer 122, the isolating material 106, and the cover layer/coating 120.

[0113] With reference to FIG. 6, a battery device, in accordance with some embodiments, will be described.

[0114] FIG. 6 is an illustration of a structure 104, a battery cell pack 105, a metal framework 144 and a heatsink 148. In general, FIG. 6 illustrates the embodiment of FIG. 5 in a perspective view. Holding means 108 can here be more clearly seen, holding the battery cells 118. The holding means 108 here comprises an upper holding unit and a lower holder unit, arranged to engage with an upper and a lower portion, respectively, of each battery cell. The electrically conductive layer 122 and isolating material 106 are also visible in the depicted view.

[0115] The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.

[0116] Although features and elements are described above in particular combinations, each feature or element can be used alone without the other features and elements or in various combinations with or without other features and elements.

[0117] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the Claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain features are recited in mutually different dependent claims does not indicate that a combination of these features cannot be used to advantage.