Battery Safety Arrangement

Abstract

The present invention concerns a fire safety arrangement for a battery. More particularly, but not exclusively, this invention concerns a fire safety arrangement for a metal ion battery, for example a lithium ion battery cell.

A metal ion battery cell comprises a plurality of electrodes and an electrolyte encased within a housing. The housing comprises a safety valve or vent configured to allow gas build up within the housing to vent outside the housing, and a felt filter covering the safety valve or vent, such that gas may pass through the felt filter, but sparks are contained within the felt filter.

Claims

1. A metal ion battery cell comprising a plurality of electrodes and an electrolyte encased within a housing, the housing comprising a safety valve or vent configured to allow gas build up within the housing to vent outside the housing, and a felt filter covering the safety valve or vent, such that gas may pass through the felt filter, but sparks are contained by the felt filter.

2. A metal ion battery cell as claimed in claim 1, comprising a lithium ion battery cell.

3. A metal ion battery cell as claimed in claim 1, comprising a prismatic lithium ion battery cell.

4. A metal ion battery cell as claimed in claim 1, comprising a cylindrical lithium ion battery cell.

5. A metal ion battery cell as claimed in claim 1, comprising a pouch lithium ion battery cell.

6. A metal ion battery cell as claimed in claim 1, wherein the felt filter is secured to the housing by an adhesive.

7. A metal ion battery cell as claimed in claim 1, wherein the felt filter comprises an adhesive film or tape.

8. A metal ion battery cell as claimed in claim 7, wherein the adhesive film or tape is covered by a removable backing prior to installation on the lithium ion battery cell.

9. A metal ion battery cell as claimed in claim 1, wherein the housing comprises an adhesive film or tape.

10. A metal ion battery cell as claimed in claim 1, wherein the felt filter is secured to the housing by a mechanical fastener.

11. A metal ion battery cell as claimed in claim 1, wherein the felt filter comprises a mineral wool.

12. A metal ion battery cell as claimed in claim 1, wherein the felt filter comprises organic binders.

13. A metal ion battery cell as claimed in claim 1, further comprising a fabric band surrounding the housing, the fabric band securing the felt filter in place.

14. (canceled)

15. (canceled)

16. A battery pack, the battery pack comprising one or more power modules, each power module comprising a plurality of metal ion battery cells, the one or more power modules encased within a housing, the housing comprising a safety valve or vent configured to allow gas build up within the housing to vent outside the housing, and a felt filter covering the safety valve or vent such that gas may pass through the felt filter, but sparks are contained by the felt filter.

17. A method of manufacturing a metal ion battery cell according claim 1, the method comprising the steps of: applying a felt filter to a metal ion battery cell, such that a safety valve or vent on the metal ion battery cell is covered by the felt filter.

Description

DESCRIPTION OF THE DRAWINGS

[0019] Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which:

[0020] FIG. 1 shows a schematic cross-sectional view of a cell according to the prior art;

[0021] FIG. 2 shows a schematic cross sectional view of the cell of FIG. 1 where a fire has started;

[0022] FIG. 3 shows a schematic cross-sectional view of a cell according to a first embodiment of the invention,

[0023] FIG. 4 shows a schematic view of a cell stack according to a second embodiment of the invention;

[0024] FIG. 5 shows a schematic cross-section of a felt strip according to a third embodiment invention; and

[0025] FIG. 6 shows a flow chart representing a method according to a fourth embodiment of the invention.

DETAILED DESCRIPTION

[0026] FIG. 1 shows a cross-sectional view of a metal ion battery cell, in this case a lithium ion prismatic cell 10. The cell comprises a plurality of electrodes and an electrolyte within a housing 12. Terminal connections 14 and 16 extend from the housing 12. A safety valve 18 is located on a top cover of the housing 12, and is arranged to vent gas from the housing 12 when the pressure reaches a threshold value to prevent undue pressure build up within the housing. A fault may increase the temperature within the cell 10, leading to a flammable gas being generated by the electrodes and electrolyte, which is vented through the safety valve 18 into an area proximate to the cell 10. This is shown by the cloud 20 shown in FIG. 1. As the temperature of the cell 10 rises, the exothermic reaction also increases, leading to further temperature rises. At some point, the temperature will rise to a level at which sparks 22 are generated within the cell 10 and pass through the safety valve. The sparks 22 may ignite the gas 20, leading to a fire 24 as shown in FIG. 2.

[0027] FIG. 3 shows a schematic cross-sectional view of a lithium ion prismatic cell 30. The cell comprises a plurality of electrodes and an electrolyte 32 within a housing 34. Terminal connections 36 and 38 extend from the housing. A safety valve 40 is located on the top cover of the housing 34, and is arranged to vent gas from the housing 34 when the pressure reaches a threshold value. The cell 30 further comprises a felt strip 42 which runs across the top cover of the housing 34, covering the safety valve 40. The felt strip is an alkaline earth silicate wool, and is porous enough to all gas to pass through into the surroundings of the cell 30, and also dense enough to absorb any sparks that are generated by the cell and travel out through the safety valve 40. If a fault occurs which results in a flammable gas being generated, the flammable gas will pass through the safety valve 40 once the safety pressure within the cell has been reached, and disperse into the environment surrounding the battery cell 30. Any sparks that are generated and pass through the safety valve 40 will be absorbed within the felt strip 42, reducing or eliminating the risk of the sparks igniting the flammable gas surrounding the cell 30.

[0028] FIG. 4 shows lithium ion cell stack 50 made up of four lithium ion cells as described with reference to FIG. 3. The cell stack 50 may also be referred to as a battery module. A felt strip 42 extends across the top of the cell stack, such that each of the safety valves 40 of the four lithium ion cells 30 is covered. Applying a single foam strip 42 which covers each of the safety valves 40 is potentially time saving compared to applying individual foam strips to each of the cells 30.

[0029] FIG. 5 shows a felt strip 42 prior to application to the cell 30. The felt strip comprises a felt layer 60, and adhesive layer 62 at least around the perimeter of the felt layer 62, and a removable backing strip 64, which is removed prior to application of the felt strip 42 to the cell 30, and prior to that allows easy handling of the felt strip 42 by preventing the felt strip 42 from sticking to unintended objects.

[0030] FIG. 6 shows the method steps for manufacturing a cell 30 according to the first embodiment of the invention. In step 70 a removable backing strip 64 is removed from the adhesive layer 62 of a felt strip 42. In step 72 the felt strip 42 is then applied to the top of a cell 30, such that the safety valve 40 is covered.

[0031] Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.

[0032] The lithium ion battery cell may be a cylindrical cell. The lithium ion battery cell may be a pouch cell. The invention may be applied to various other metal ion battery cells, in particular metal ion battery cells that potentially generate flammable gases.

[0033] In an alternative arrangement, the felt filter may be applied to cover a safety vent. The felt filter may be combined with a fabric band, for example the felt filter may be secured in position relative to the safety valve or vent by a fabric band wrapped around the housing of the lithium ion battery cell.

[0034] The felt filter may be applied to cover a safety valve or vent in a housing of a power module, the power module comprising a plurality of metal ion battery cells. The felt filter may be applied to cover a safety valve or vent in a housing of a battery pack, the battery pack comprising a plurality of metal ion battery cells. The battery pack may comprise one or more power modules, each power module comprising a plurality of metal ion battery cells.

[0035] Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.