BATTERY STACK CASING

Abstract

A battery cell stack casing includes casing walls defining a housing interior for receiving a battery cell stack, a first end plate provided between the walls at a first end of the casing to close a first end of the housing interior, and a second end plate provided between the walls at a second end of the casing to close a second end of the housing interior. The casing walls have a multi-layer structure that includes, an inner layer having a first side facing into the housing interior and a second opposite side, an outer layer spaced outwardly from the second side of the inner layer, an air or vacuum-filled thermally insulating volume defined between the second side of the inner layer and the outer layer, and a layer of intumescent material provided on the first side of the inner layer.

Claims

1. A battery cell stack casing comprising: casing walls defining a housing interior for receiving a battery cell stack; a first end plate provided between the walls at a first end of the casing to close a first end of the housing interior; and a second end plate provided between the walls at a second end of the casing to close a second end of the housing interior; wherein the casing walls have a multi-layer structure comprising: an inner layer having a first side facing into the housing interior and a second opposite side; an outer layer spaced outwardly from the second side of the inner layer; a thermally insulating volume defined between the second side of the inner layer and the outer layer, wherein the thermally insulating volume is an air filled volume, or wherein the thermally insulating volume is a vacuum filled volume; and a layer of intumescent material provided on the first side of the inner layer.

2. The casing of claim 1, further comprising: an insert fitted between the inner layer and the outer layer at the ends of the casing walls adjacent the end plates.

3. The casing of claim 2, wherein the insert provides a groove for a seal at the interface between the thermally insulating volume and the inner and outer layers.

4. The casing of claim 3, wherein the groove has a female radial dovetail form with a rectangular cross-section.

5. The casing of claim 3, wherein a seal is mounted in the groove.

6. The casing of claim 5, wherein the seal is an elastomeric seal.

7. The casing of claim 5, wherein the seal is an adhesive bead.

8. The casing of claim 2, wherein the insert is a polymer insert.

9. The casing of claim 1, wherein the inner and outer layers comprise carbon fiber reinforced polymer, CFRP.

10. A battery unit comprising: the casing as recited in claim 1; and a stack of battery cells mounted in the casing.

11. A battery unit as claimed in claim 10, wherein the battery cells are lithium ion cells.

12. A method of manufacturing a casing for a battery cell stack, the method comprising: providing a layer of intumescent material around a mandrel; forming an inner casing layer to define inner side walls of the casing; providing an intumescent material on an inner surface of the inner casing layer; forming an outer casing layer to define outer side walls of the casing; securing the inner casing layer and the outer casing layer together at their ends by means of an insert such as to define an air gap between the inner layer and the outer layer; securing an end plate to each end of the casing; and mounting the combined casing inner and outer layers with the outer layer located on the intumescent layer.

13. The method of claim 13, further comprising providing a seal around the insert.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Preferred embodiments of the invention will now be described by way of example only with reference to the drawings wherein:

[0015] FIG. 1 is a perspective view of a battery casing according to the disclosure; and

[0016] FIG. 2 shows a partial sectional view of a casing according to the disclosure.

DETAILED DESCRIPTION

[0017] As best seen in FIG. 1, a casing 10 for a battery cell stack (not shown) is formed of casing walls 4 that define a housing 200 to accommodate a stack of battery cells (not shown). The casing 10 is also provided with end plates 2, 3 to sealingly close opposing ends of the casing 10. The end plates 2,3 are designed and assembled to provide a compressive loading to the opposing ends of the stack of cells mounted in the housing.

[0018] The stack is arranged in the housing such that it does not contact the side walls 4 of the casing 10. For example, a cage structure or spacer arrangement may be provided between the stack and the casing inner surface.

[0019] As can be best seen in FIGS. 2 and 3, the casing 10 of this disclosure has a multi-layer structure as will be described below.

[0020] Preferably, the end caps 2, 3 also have a multi-layer structure and are sealingly mounted to the ends of the casing and may be fixed e.g. by rivets or nuts and bolts 23.

[0021] The casing 10 is formed of an inner layer 11 and an outer layer 12 of casing material. Thus should be a relatively lightweight, but rigid and strong material e.g. a carbon fibre reinforced polymer (CFRP). The inner and outer layers 11, 12 are arranged to be spaced apart from each other to define a thermally insulating volume 13′ therebetween.

[0022] The inner layer 11 defines the housing 200 interior for the cell stack (not shown). The outer layer 12 defines the outer surface of the casing 10. At the ends of the casing 10, the space 14 between the inner and outer layers 11, 12 is closed by a plug or insert 15, which is made of a relatively rigid material e.g. a polymer, that can support seals and rivets or nuts and bolts. End caps 2, 3 are provided. These may have a conventional structure or may have the same multi-layer structure as the casing defining the side walls 4, having inner and outer CFRP layers 16, 17 defining, between them, a thermally insulating volume 18. The end caps 2, 3 are secured to the casing between the side walls 4 via seals 19, 20 and may be secured in place by rivets 23.

[0023] The inner casing layer 11 is further provided, on the inwardly facing side, with a layer of intumescent material 21.

[0024] As, shown in FIG. 2, the thermally insulating volume 13′ is filled with air or a vacuum.

[0025] In the event of a fault, as described above, causing TR, even when the burst vent (not shown) opens, the temperature inside the housing 200 will increase. In a (non-limiting) example, the temperature might increase to in excess of 550 to 600 deg. C.

[0026] The casing material for the inner and outer layers 11, 12 is selected to be light but strong and is e.g. CFRP. This will have a glass transition temperature Tg above which the casing material no longer keeps its shape and structure and so the casing material no longer provides effective sealing and loading. CFRP materials will have a Tg of less than the high temperatures (e.g. 600 deg. C.) that can occur in the housing. For example only, the CFRP material might have a Tg of around 260 deg. C. The combination of the thermal insulating volume 13′ and the intumescent layer 21 provides a thermal barrier between the interior of the housing 200 and the outer casing layer 12.

[0027] The layer of intumescent material 21 acts as a first barrier stage. This material may be e.g. a graphite/mineral wool mix. When the temperature inside the housing reaches a predetermined temperature, the intumescent material will swell and thermally insulate. The temperature at the interface of the intumescent material and the casing, however, will still be higher (e.g. around 360 deg. C.) than the glass transition temperature Tg of the casing material. The thermal insulating volume 13′, therefore, provides a second barrier stage, further thermally insulating reduce the temperature at the interface at the outer casing layer 12 to be below Tg (e.g. to around 200 deg. C.).

[0028] The thermal insulating volume itself would not suffice to create the required temperature reduction. In that event, a very deep volume would be required between the inner and outer layers, resulting in a very large casing. The intumescent layer itself may also not suffice since its thermal conductivity is not sufficiently low to limit the transfer of heat into the CFRP layer to an acceptable amount. The combination, however, of the intumescent layer and the thermally insulating volume allows the high temperatures that can build up inside the housing to be reduced to temperatures below Tg of a lightweight casing material such as CFRP.

[0029] The end plates 2, 3 are fitted into the ends of the casing 10. As mentioned above, it is feasible, that the end caps 2, 3 have a conventional single layer structure, but better results are obtained where the end caps also have a multi-layer structure such as that described above for the casing.

[0030] To ensure a rigid structure at the ends of the casing, between the inner and outer layers 11, 12, to close the thermally insulating volume, and also to add compressive strength for fastening the end plate to the casing, a plug or insert 15 of plastic or polymer material may be provided. This is preferably a high temperature resistance, fire-retardant amorphous polymer with good adhesion properties to epoxy, e.g. PMI, PPSU or PAI. This seals the volume to prevent the escape of air/to retain a vacuum. It is also desirable to have such an insert of a material that provides additional rigidity so as to provide support for the seals to be secured in place and also to allow nuts and bolts 23 or other fasteners to be secured therethrough. The insert may form a groove for a seal such as an elastomer seal or an adhesive bead to ensure that most toxic fumes are exhausted via the burst vent. In one embodiment, the groove has a female radial dovetail configuration with a rectangular cross-section. In an alternative arrangement, sealing may be provided by a tight fit rather than a sealing component.

[0031] The mutli-layer structure also allows for continued functionality in the case of BVID (barely visible impact damage) since the space and the inner layer 12 act as a seal if the outer layer is damaged. The impact absorption properties of the air gap provide some protection to the inner skin from damage.

[0032] The manufacture of the casing of this disclosure can be automated. The casing may be manufactured as follows:

[0033] A mandrel is provided around which a layer of intumescent material is provided.

[0034] An inner layer 11 of casing material is formed e.g of braided CFRP, and the component is cured.

[0035] An outer layer 12 of casing material is formed e.g of braided CFRP, and the component is cured.

[0036] The inner and outer layers are secured together via a polymer insert such that a space is formed between the layers. The air in the space can be removed to create a vacuum.

[0037] The combined casing inner and outer layers are mounted with the outer layer located on the intumescent layer.

[0038] An epoxy resin is then preferably injected over the casing structure to seep into the fiber braids to provide a rigid, robust casing.

[0039] The casing structure of this disclosure will provide sufficient thermal insulation to protect the outer casing layer in the event of thermal runaway whilst also providing an impact resistant structure. The integrity of the sealing is maintained without the need for additional fiber hoop reinforcement at the ends of the casing. The casing can be made of a lightweight casing material thus minimising the size and weight of the casing. The manufacture of the casing can be automated.