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Prismatic battery cell energy density for a lithium ion battery module — Cps Technology Holdings Llc (US20220285768A1)

Cps Technology Holdings Llc · Google Patents

Google Patents · Patents · License: Open Access

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cpstechnologyholdingsllc

patent, google patents, intellectual property, US20220285768A1, Cps Technology Holdings Llc, Matthew R. Tyler, en, 2022

ABSTRACT

Abstract

Present embodiments include a lithium ion battery module and associated lithium ion battery cells. The lithium ion battery cells include a prismatic cell casing enclosing electrochemically active components. The cell thickness, the cell width, the cell length, and the electrochemically active components are such that the lithium ion battery cell has a volumetric energy density between 82 Watt-hours per Liter (Wh/L) and 153 Wh/L, and has a nominal voltage between 2.0 V and 4.2 V.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Application No. 62/056,376 entitled, âLITHIUM ION BATTERY MODULE WITH FREE FLOATING PRISMATIC BATTERY CELLS,â filed on Sep. 26, 2014, U.S. Provisional Application No. 62/056,382 entitled, âFREE FLOATING BATTERY CELL ASSEMBLY TECHNIQUES FOR LITHIUM ION BATTERY MODULE,â filed on Sep. 26, 2014, and U.S. Provisional Application No. 62/151,092 entitled, âLITHIUM ION BATTERY MODULES WITH PRISMATIC BATTERY CELLS,â filed on Apr. 22, 2015, each of which is incorporated by reference in its entirety for all purposes.

BACKGROUND

The present disclosure relates generally to the field of batteries and battery modules. More specifically, the present disclosure relates to battery cell placement within lithium-ion (Li-ion) battery modules.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

A vehicle that uses one or more battery systems for providing all or a portion of the motive power for the vehicle can be referred to as an xEV, where the term âxEVâ is defined herein to include all of the following vehicles, or any variations or combinations thereof, that use electric power for all or a portion of their vehicular motive force. For example, xEVs include electric vehicles (EVs) that utilize electric power for all motive force. As will be appreciated by those skilled in the art, hybrid electric vehicles (HEVs), also considered xEVs, combine an internal combustion engine propulsion system and a battery-powered electric propulsion system, such as 48 Volt (V) or 130V systems. The term HEV may include any variation of a hybrid electric vehicle. For example, full hybrid systems (FHEVs) may provide motive and other electrical power to the vehicle using one or more electric motors, using only an internal combustion engine, or using both. In contrast, mild hybrid systems (MHEVs) disable the internal combustion engine when the vehicle is idling and utilize a battery system to continue powering the air conditioning unit, radio, or other electronics, as well as to restart the engine when propulsion is desired. The mild hybrid system may also apply some level of power assist, during acceleration for example, to supplement the internal combustion engine. Mild hybrids are typically 96V to 130V and recover braking energy through a belt or crank integrated starter generator. Further, a micro-hybrid electric vehicle (mHEV) also uses a âStop-Startâ system similar to the mild hybrids, but the micro-hybrid systems of a mHEV may or may not supply power assist to the internal combustion engine and operates at a voltage below 60V. For the purposes of the present discussion, it should be noted that mHEVs typically do not technically use electric power provided directly to the crankshaft or transmission for any portion of the motive force of the vehicle, but an mHEV may still be considered as an xEV since it does use electric power to supplement a vehicle's power needs when the vehicle is idling with internal combustion engine disabled and recovers braking energy through an integrated starter generator. In addition, a plug-in electric vehicle (PEV) is any vehicle that can be charged from an external source of electricity, such as wall sockets, and the energy stored in the rechargeable battery packs drives or contributes to drive the wheels. PEVs are a subcategory of EVs that include all-electric or battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and electric vehicle conversions of hybrid electric vehicles and conventional internal combustion engine vehicles.

xEVs as described above may provide a number of advantages as compared to more traditional gas-powered vehicles using only internal combustion engines and traditional electrical systems, which are typically 12V systems powered by a lead acid battery. For example, xEVs may produce fewer undesirable emission products and may exhibit greater fuel efficiency as compared to traditional internal combustion vehicles and, in some cases, such xEVs may eliminate the use of gasoline entirely, as is the case of certain types of EVs or PEVs.

As technology continues to evolve, there is a need to provide improved power sources, particularly battery modules, for such vehicles and other implementations. For example, certain traditional battery modules may include a plurality of battery cells. In such traditional modules, the battery cells may be subject to swelling during use (e.g., charging and discharging), which can affect their operation and, in some situations, cause the cells to move within the battery module. Elaborate clamping mechanisms are traditionally used to compress the battery cells in position, which provides compression to offset swelling and maintains their position within the modules. Accordingly, it is now recognized that traditional battery modules may be subject to further improvement by, for example, reducing or altogether eliminating the need for such clamping mechanisms. Further, it is also recognized that it may be desirable to reduce or mitigate battery cell swelling.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

The present embodiments are directed to, among other things, a configuration of a lithium ion battery cell. The lithium ion battery cell includes a prismatic cell casing enclosing electrochemically active components. The prismatic cell casing includes a terminal end portion having cell terminals disposed thereon, a base portion substantially opposite the terminal end portion, a first face and a second face each extending between the terminal end portion and the base portion, and a first side and a second side each extending between the terminal end portion and the base portion and coupling the first and second faces. The cell thickness of the prismatic cell casing corresponds to a distance between the first and second faces, the cell width of the prismatic cell corresponds to a distance between respective outermost surfaces of the first and second sides, and the cell length of the prismatic cell casing corresponds to a distance between the terminal end portion and the base portion. The cell thickness, the cell width, the cell length, and the electrochemically active components are such that the lithium ion battery cell has a volumetric energy density between 67 Watt-hours per Liter (Wh/L) and 251 Wh/L, and has a nominal voltage between 2.0 V and 4.2 V.

Present embodiments are also directed to a lithium ion battery module having a plurality of prismatic lithium ion battery cells disposed in a housing of the module. The prismatic lithium ion battery cells of the plurality are electrically coupled to one another and to a terminal of the lithium ion battery module. Each prismatic lithium ion battery cell of the plurality of prismatic lithium ion battery cells has a respective prismatic cell casing enclosing electrochemically active components. The prismatic cell casing has a terminal end portion having cell terminals disposed thereon, a base portion substantially opposite the terminal end portion, a first face and a second face each extending between the terminal end portion and the base portion, and a first side and a second side each extending between the terminal end portion and the base portion and coupling the first and second faces. The cell thickness of the prismatic cell casing corresponds to a distance between the first and second faces, the cell width of the prismatic cell corresponds to a distance between respective outermost surfaces of the first and second sides, and the cell length of the prismatic cell casing corresponds to a distance between the terminal end portion and the base portion. The cell thickness, the cell width, the cell length, and the electrochemically active components are such that each of the prismatic lithium ion battery cells has a volumetric energy density between 67 Watt-hours per Liter (Wh/L) and 251 Wh/L, and has a nominal voltage between 2.0 V and 4.2 V. The housing of the lithium ion battery module has a base that corresponds to a standard base dimension of a lead acid battery.

The present embodiments are also directed to, among other things, a lithium ion battery cell having a prismatic cell casing enclosing electrochemically active components. The prismatic cell casing has a terminal end portion having cell terminals disposed thereon, a base portion substantially opposite the terminal end portion, a first face and a second face each extending between the terminal end portion and the base portion, and a first side and a second side each extending between the terminal end portion and the base portion and coupling the first and second faces. The weight of the lithium ion battery cell and the electrochemically active components are such that the lithium ion battery cell has a gravimetric energy density between 32 Watt-hours per kilogram (Wh/kg) and 126 Wh/kg, has a nominal voltage between 2.0 V and 4.2 V, and has a capacity between 8 Ah and 12 Ah.

DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a perspective view of an xEV having a battery system configured in accordance with present embodiments to provide power for various components of the xEV, in accordance with an aspect of the present disclosure;

FIG. 2 is a cutaway schematic view of an embodiment of the xEV having a start-stop system that utilizes the battery system of FIG. 1 , the battery system having a lithium ion battery module, in accordance with an aspect of the present disclosure;

FIG. 3 is a top perspective view of various battery modules illustrating the manner in which a single type of battery cell may be incorporated into different types of lithium ion battery module housings to place a plurality of the battery cells into a floating arrangement, in accordance with an aspect of the present disclosure;

FIG. 4 is a top perspective view of an overlay of lithium ion battery module dimensions corresponding to the lithium ion battery modules of FIG. 3 , in accordance with an aspect of the present disclosure;

FIG. 5 is a top perspective view of an overlay of available cell volumes of the lithium ion battery modules of FIG. 3 , in accordance with an aspect of the present disclosure;

FIG. 6 is a perspective view of a prismatic battery cell that may be incorporated into the battery modules of FIG. 3 , in accordance with an aspect of the present disclosure;

FIG. 7 is a cutaway top perspective view of a plurality of battery cells corresponding to the battery cell of FIG. 6 incorporated into the housing overlay depicted in FIG. 4 , in accordance with an aspect of the present disclosure;

FIG. 8 is a top perspective view of a plurality of battery cells placed within a battery module housing and having an expanded view of fixed protrusions producing a floating cell arrangement, in accordance with an aspect of the present disclosure;

FIG. 9 is a cutaway side perspective view of a lithium ion battery module having a plurality of battery cells in a floating arrangement, with the housing removed to depict the relative positioning of the battery cells when in the floating arrangement of FIG. 8 , in accordance with an aspect of the present disclosure;

FIG. 10 is a comparative side view of a swellable battery cell and a substantially non-swellable battery cell before and after charging, in accordance with an aspect of the present disclosure;

FIG. 11 is an exploded top perspective view of a lithium ion battery module having battery cells that are urged inwardly against a back of a housing by an integrated bus bar and voltage sense subassembly, in accordance with an aspect of the present disclosure;

FIG. 12 is a cutaway side view of a column of battery cells in the battery module of FIG. 11 taken along line 12 - 12 , and having one or more spacers positioned between the battery cells, in accordance with an aspect of the present disclosure;

FIG. 13 is a block diagram of a manufacturing system configured to pick and place battery cells into a battery module housing without performing battery cell grading, in accordance with an aspect of the present disclosure;

FIG. 14 is a process flow diagram of a method for manufacturing battery modules using the pick and place technique performed by the system of FIG. 13 , in accordance with an aspect of the present disclosure;

FIG. 15 is a block diagram of a manufacturing system configured to index a battery module housing, and to place battery cells and other components into the housing in accordance with the indexing, in accordance with an aspect of the present disclosure;

FIG. 16 is a process flow diagram of a method for manufacturing battery modules using the indexing technique performed by the system of FIG. 15 , in accordance with an aspect of the present disclosure;

FIG. 17 is a schematic illustration of the indexing technique of FIG. 16 , in accordance with an aspect of the present disclosure; and

FIG. 18 is a front view of a partially assembled lithium ion battery module having substantially non-swellable battery cells, the battery cells having different states of charge but substantially the same cell thickness, in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

CROSS-REFERENCE TO RELATED APPLICATIONS

BACKGROUND

SUMMARY

DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 5 is a top perspective view of an overlay of available cell volumes of the lithium ion battery modules of FIG. 3 , in accordance with an aspect of the present disclosure;

FIG. 6 is a perspective view of a prismatic battery cell that may be incorporated into the battery modules of FIG. 3 , in accordance with an aspect of the present disclosure;

FIG. 10 is a comparative side view of a swellable battery cell and a substantially non-swellable battery cell before and after charging, in accordance with an aspect of the present disclosure;

FIG. 17 is a schematic illustration of the indexing technique of FIG. 16 , in accordance with an aspect of the present disclosure; and

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

The battery systems described herein may be used to provide power to various types of electric vehicles (xEVs) and other high voltage energy storage/expending applications (e.g., electrical grid power storage systems). Such battery systems may include one or more battery modules, each battery module having a housing and a number of battery cells (e.g., lithium-ion (Li-ion) battery cells) arranged within the housing to provide particular voltages and/or currents useful to power, for example, one or more components of an xEV. As another example, battery modules in accordance with present embodiments may be incorporated with or provide power to stationary power systems (e.g., non-automotive systems).

Battery cells used in lithium ion battery modules may also be referred to as battery cells, and different types of such battery cells can have different voltages and/or capacities, for example based on the active materials contained within each cell. Generally, lithium ion battery cells will include a cathode (a positive electrode), an anode (a negative electrode), and an electrolyte that provides a source of ions (e.g., lithium ions). In certain configurations, the cathode and anode each include an electrode active material that enables the electrodes to store and transfer ions (e.g., lithium ions) during charging and discharging cycles. Whether the electrode is a cathode or an anode is generally determined by the electrode active material for each and their reference voltages versus Li/Li + . Thus, the electrode active materials will generally be different.

As will be appreciated by those of skill in the art, an electrochemical half-reaction occurs at each of the positive and negative electrodes. For example, the electrochemical half-reaction at the positive electrode may be a reaction in which one or more lithium ions are reversibly (based on an equilibrium) dissociated from the positive electrode active material, thereby also releasing one or more electrons (equal in number to the number of dissociated lithium ions). At the negative electrode, the electrochemical half-reaction that occurs may be a reaction in which one or more lithium ions and one or more electrons (of equal number) are reversibly associated with the negative electrode active material (e.g., carbon).

During discharging of the battery, the equilibria at the electrodes favor dissociation of the lithium ions and electrons from the negative electrode active material and re-association of the electrons and lithium ions with the positive electrode active material. On the other hand, during charging, the reverse is true. The movement of the ions into the electrodes is commonly referred to as intercalation or insertion, and the movement of the ions away from the electrodes is commonly referred to as deintercalation or extraction. Accordingly, during discharging, intercalation occurs at the positive electrode and deintercalation occurs at the negative electrode, and during charging, the reverse is true. Therefore, lithium ion battery cells will generally operate based on lithium ion intercalation and deintercalation at its electrodes.

In this regard, a number of properties of the battery cells may stem from a combination of the physical configuration of the cell (e.g., its shape, size, layout), and its chemical configuration (e.g., electrode active materials, electrolytes, additives). For example, in traditional prismatic battery cells that use graphite as an anode active material, a relatively large degree of size change may occur as a result of charge and discharge cycles, where during charging, lithium becomes intercalated into the active material (graphite), causing the anode to swell, while during discharging, the active material releases the lithium, causing the anode to reduce in size. Such swelling can be problematic in that it reduces the power density of the battery cell, and, as the anode swells, this causes resistance between the anode and cathode to occur, which reduces the efficiency of the cell. In traditional approaches, this swelling is somewhat mitigated by way of placing a relatively large degree of compression force onto the prismatic cells, for example at a position corresponding to their active areas where the electrodes (anode and cathode) are located. However, these clamping mechanisms can be bulky and add considerable weight to a particular lithium ion battery module.

For example, actuatable clamping mechanisms such as a clamp attached to the battery module, a movable plate disposed within the battery module housing that may be actuated (e.g., using a crank, a clamp, an adjustable tie and bolt mechanism) to abut against the battery cells, or an adjustable tie and bolt mechanism used to actuate components (e.g., outer or inner walls) of the battery module housing, may be used to compress the battery cells by a particular amount. This may be done to maintain the energy density and performance of the battery cells within a predetermined range. Prismatic battery cells, for example, are traditionally held in place by such actuatable clamping mechanisms that are a part of or integrated with a battery module housing.

In accordance with the present disclosure, it is now recognized that it may be desirable to mitigate, reduce, or altogether eliminate such swelling without having to rely on such bulky and heavy clamping mechanisms. It is also now recognized that the elimination of such traditional clamping mechanisms may enable other lithium ion battery module features. For example, in certain embodiments of the present disclosure, lithium ion battery modules may be designed to have a particular volume for the battery cells, while other portions of the lithium ion battery modules may be used for other module features, such as control and regulation circuitry (e.g., a battery monitoring system (BMS), a battery control module (BCM)), thermal management features (e.g., fans, cooling paths), and so forth. Indeed, reduced swelling and reliance on clamping mechanisms may also enable battery module sizes and designs that may be particularly suitable for certain applications, such as micro-hybrid applications.

With the foregoing in mind, the present disclosure, in one aspect, is directed toward lithium ion battery modules that include a plurality of battery cells (lithium ion battery cells, also referred to herein as electrochemical cells or cells) that remain in a relatively uncompressed state (e.g., without the use of an actuatable or other clamping mechanism). As one non-limiting example, such a configuration may include a floating assembly, which is also referred to herein as a floating arrangement. The floating assembly of the present embodiments may include an arrangement where each battery cell is suspended within a housing of the module by a plurality of fixed protrusions (e.g., two or more), and the fixed protrusions hold the cells along their periphery, such as only along a portion of their periphery. In other embodiments, the battery cells may be secured within the battery module using other mechanisms that do not place a clamping force onto the battery cells before swelling occurs. For instance, the battery cells may be secured to one another and/or some portion of a housing of the battery module.

In certain embodiments, the battery cells may include specific chemistries that enable the cells to be utilized in the present battery modules with little to no swelling. This enables, among other things, an avoidance of certain clamping mechanisms and the introduction of additional module features. In one example, mitigation of battery cell swelling may enable a gap (e.g., an air gap) to be maintained between the cells without clamping features being placed on the active areas of the cells. For example, during normal operation (e.g., charging/discharging maintained within a certain state of charge (SOC) range), the cells described herein may swell to an extent that is greatly reduced or altogether eliminated compared to other battery cells used in traditional lithium-ion battery modules. Such embodiments are described in further detail below.

While the present disclosure includes a number of embodiments that may benefit from the use of certain types of battery cells that have reduced swelling, it should be noted that certain disclosed embodiments may also be applicable to lithium ion battery modules that use a wide variety of cells, including those that swell. In this regard, the description set forth below should not be construed as being limited to certain lithium ion battery cell chemistries, except as otherwise indicated. Indeed, a wide variety of electrode active materials, electrolyte materials, and so forth, may be used in accordance with certain aspects of the present disclosure.

In one aspect, for example, the cathode active material and the anode active material of the electrodes in the lithium-ion battery cells may be selected so as to have reduced swelling compared to other combinations of electrode active materials for the anode and cathode. While the electrode active materials may generally be of any type, configuration, or chemistry, in one embodiment, the cathode active material may include lithium nickel cobalt manganese oxide (NMC, LiNi x Mn y Co z O 2 , where x+y+z=1) as a cathode active material. In accordance with certain aspects of the present disclosure, the NMC may be used as the only cathode active material, or the NMC may be combined (e.g., physically blended) with other cathode active materials (e.g., other lithium metal oxides). The anode active material may be any suitable material, but in one particular embodiment is lithium titanate (LTO, e.g., Li 4 Ti 5 O 12 ). In prismatic battery cells, which are intended to include battery cells having a generally rectangular shape and a hard (e.g., metallic or plastic) outer casing, a combination of these active materials may reduce swelling and associated size variability due to charge and discharge cycling. In this regard, such prismatic battery cells may be particularly useful where the cells may be relied upon for reliable charge and discharge cycles to power automotive equipment, home equipment, and so forth.

For example, in certain xEV contexts (among others, such as non-automotive or stationary energy expending applications), a 12 V output from a lithium ion battery module may be desirable to power certain types of components (e.g., similar types of components traditionally powered by a traditional lead acid battery in traditional vehicles), while a 48 V output may be more suitable to power other types of components that may require a higher voltage, such as an air conditioning system. With this in mind, it is now recognized that the present battery module embodiments may be particularly applicable to such types of battery modules. Indeed, the present approaches may enable the production of lithium ion battery modules that may be designed to fit in different locations of an xEV, or in different locations of a home or other setting.

To help illustrate, FIG. 1 is a perspective view of an embodiment of a vehicle 10 , which may utilize a regenerative braking system. Although the following discussion is presented in relation to vehicles with regenerative braking systems, the techniques described herein are adaptable to other vehicles that capture/store electrical energy with a battery, which may include electric-powered and gas-powered vehicles, as well as other non-automotive (e.g., stationary) applications.

It is now recognized that it is desirable for a non-traditional battery system 12 (e.g., a lithium ion car battery) to be largely compatible with traditional vehicle designs. In this respect, present embodiments include various types of battery modules for xEVs and systems that include xEVs. Accordingly, the battery system 12 may be placed in a location in the vehicle 10 that would have housed a traditional battery system. For example, as illustrated, the vehicle 10 may include the battery system 12 positioned similarly to a lead-acid battery of a typical combustion-engine vehicle (e.g., under the hood of the vehicle 10 ). Furthermore, as will be described in more detail below, the battery system 12 may be positioned to facilitate managing temperature of the battery system 12 . For example, in some embodiments, positioning a battery system 12 under the hood of the vehicle 10 may enable an air duct to channel airflow over the battery system 12 and cool the battery system 12 .

A more detailed view of the battery system 12 is described in FIG. 2 . As depicted, the battery system 12 includes an energy storage component 14 coupled to an ignition system 16 , an alternator 18 , a vehicle console 20 , and optionally to an electric motor 22 . Generally, the energy storage component 14 may capture/store electrical energy generated in the vehicle 10 and output electrical energy to power electrical devices in the vehicle 10 .

In other words, the battery system 12 may supply power to components of the vehicle's electrical system, which may include radiator cooling fans, climate control systems, electric power steering systems, active suspension systems, auto park systems, electric oil pumps, electric super/turbochargers, electric water pumps, heated windscreen/defrosters, window lift motors, vanity lights, tire pressure monitoring systems, sunroof motor controls, power seats, alarm systems, infotainment systems, navigation features, lane departure warning systems, electric parking brakes, external lights, or any combination thereof. Illustratively, in the depicted embodiment, the energy storage component 14 supplies power to the vehicle console 20 and the ignition system 16 , which may be used to start (e.g., crank) the internal combustion engine 24 .

Additionally, the energy storage component 14 may capture electrical energy generated by the alternator 18 and/or the electric motor 22 . In some embodiments, the alternator 18 may generate electrical energy while the internal combustion engine 24 is running More specifically, the alternator 18 may convert the mechanical energy produced by the rotation of the internal combustion engine 24 into electrical energy. Additionally or alternatively, when the vehicle 10 includes an electric motor 22 , the electric motor 22 may generate electrical energy by converting mechanical energy produced by the movement of the vehicle 10 (e.g., rotation of the wheels) into electrical energy. Thus, in some embodiments, the energy storage component 14 may capture electrical energy generated by the alternator 18 and/or the electric motor 22 during regenerative braking. As such, the alternator and/or the electric motor 22 are generally referred to herein as a regenerative braking system.

To facilitate capturing and supplying electric energy, the energy storage component 14 may be electrically coupled to the vehicle's electric system via a bus 26 . For example, the bus 26 may enable the energy storage component 14 to receive electrical energy generated by the alternator 18 and/or the electric motor 22 . Additionally, the bus may enable the energy storage component 14 to output electrical energy to the ignition system 16 and/or the vehicle console 20 . Accordingly, when a 12 volt battery system 12 is used, the bus 26 may carry electrical power typically between 8-18 volts.

Additionally, as depicted, the energy storage component 14 may include multiple battery modules. For example, in the depicted embodiment, the energy storage component 14 includes a lithium ion (e.g., a first) battery module 28 and a lead-acid (e.g., a second) battery module 30 , which each includes one or more battery cells. In other embodiments, the energy storage component 14 may include any number of battery modules. Additionally, although the lithium ion battery module 28 and lead- acid battery module 30 are depicted adjacent to one another, they may be positioned in different areas around the vehicle. For example, the lead- acid battery module 30 may be positioned in or about the interior of the vehicle 10 while the lithium ion battery module 28 may be positioned under the hood of the vehicle 10 .

In some embodiments, the energy storage component 14 may include multiple battery modules to utilize multiple different battery chemistries. For example, when the lithium ion battery module 28 is used, performance of the battery system 12 may be improved since the lithium ion battery chemistry generally has a higher coulombic efficiency and/or a higher power charge acceptance rate (e.g., higher maximum charge current or charge voltage) than the lead-acid battery chemistry. As such, the capture, storage, and/or distribution efficiency of the battery system 12 may be improved.

To facilitate controlling the capturing and storing of electrical energy, the battery system 12 may additionally include a control module 32 . More specifically, the control module 32 may control operations of components in the battery system 12 , such as relays (e.g., switches) within energy storage component 14 , the alternator 18 , and/or the electric motor 22 . For example, the control module 32 may regulate amount of electrical energy captured/supplied by each battery module 28 or 30 (e.g., to de-rate and re-rate the battery system 12 ), perform load balancing between the battery modules

28 and 30 , determine a state of charge of each battery module

28 or 30 , determine temperature of each battery module

28 or 30 , control voltage output by the alternator 18 and/or the electric motor 22 , and the like.

Accordingly, the control unit 32 may include one or more processors 34 and one or more memory units 36 . More specifically, the one or more processor 34 may include one or more application specific integrated circuits (ASICs), one or more field programmable gate arrays (FPGAs), one or more general purpose processors, or any combination thereof. Additionally, the one or more memory 36 may include volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read-only memory (ROM), optical drives, hard disc drives, or solid-state drives. In some embodiments, the control unit 32 may include portions of a vehicle control unit (VCU) and/or a separate battery control module. Furthermore, as depicted, the lithium ion battery module 28 and the lead- acid battery module 30 are connected in parallel across their terminals. In other words, the lithium ion battery module 28 and the lead- acid module 30 may be coupled in parallel to the vehicle's electrical system via the bus 26 .

As set forth above, in one aspect of the present approach, the lithium ion battery module 28 may be sized to fit in particular portions of the xEV 10 , including under the hood, under a passenger compartment, in a trunk, etc. Further, in another aspect, a plurality of different types of the lithium ion battery module 28 produced in accordance with the present approach may be designed to have a common footprint by designing a volume to be occupied by the battery cells, or the volume available to the battery cells, to have a constant length and width, and differ in the height direction depending on the number of cells in the module. In addition, the design of the volume in the module 28 for the cells may include various other features, such as air gaps, to enable certain types of passive and/or active cooling.

In accordance with one aspect of the present disclosure, different types of the lithium ion battery module 28 may utilize a particular type of prismatic battery cells, as shown in FIG. 3 . Specifically, as shown, a first lithium ion battery module 28 A, a second lithium ion battery module 28 B, and a third lithium ion battery module 28 C each have a respective housing 40 A- 40 C, and all use a common source 42 of prismatic battery cells 44 . That is, prismatic battery cells 44 conforming to a particular set of manufacturing specifications (e.g., standardized dimensions with standard tolerances, constructions, and chemistries) may be used in any of the illustrated lithium ion battery modules 28 . As also shown, each of the lithium ion battery modules 28 includes substantially the same layout of the battery cells 44 in their housings 44 , with the difference being in total number only.

For example, in FIG. 3 , the first lithium ion battery module 28 A may have a first output voltage (e.g., 12 V) and a first capacity (e.g., 10 amp hours (Ah)), and the second lithium <figure-callout id="28B" label="ion battery module" filename

CLAIMS

Claims ( 22 )

1 - 16 . (canceled)

17 . A lithium ion battery module, comprising:

a plurality of prismatic lithium ion battery cells disposed in a housing of the module in adjacent columns each comprising more than one prismatic lithium ion battery cell, wherein the prismatic lithium ion battery cells of the plurality are electrically coupled to one another and to a terminal of the lithium ion battery module; wherein each prismatic lithium ion battery cell of the plurality of prismatic lithium ion battery cells has a respective prismatic cell casing enclosing electrochemically active components, wherein the prismatic cell casing comprises a terminal end portion having cell terminals disposed thereon, a base portion substantially opposite the terminal end portion, a first face and a second face each extending between the terminal end portion and the base portion, and a first side and a second side each extending between the terminal end portion and the base portion and coupling the first and second faces; wherein a cell thickness of the prismatic cell casing corresponds to a distance between the first and second faces, a cell width of the prismatic cell corresponds to a distance between respective outermost surfaces of the first and second sides, and a cell length of the prismatic cell casing corresponds to a distance between the terminal end portion and the base portion, and wherein the cell thickness, the cell width, the cell length, and the electrochemically active components are such that each of the prismatic lithium ion battery cells has a volumetric energy density between 67 Watt-hours per Liter (Wh/L) and 251 Wh/L, and has a nominal voltage between 2.0 V and 4.2 V; and wherein the cell thickness of each prismatic casing is between 13 mm and 15 mm, the cell length of each prismatic casing is between 138 mm and 142 mm, the cell width of each prismatic casing is between 109 mm and 114 mm, and a volume of each prismatic casing is between 0.2 L and 0.24 L.

18 . (canceled)

19 . The lithium ion battery module of claim 17 , wherein the base corresponds to an H5 DIN base, the cell thickness of each prismatic casing is between 13.5 mm and 14.5 mm, the cell length of each prismatic casing is between 139.5 mm and 140.5 mm, the cell width of each prismatic casing is between 111.5 mm and 112.5 mm, a volume of each prismatic casing is between 0.21 L and 0.23 L, and the volumetric energy density of each prismatic lithium ion battery cell is between 82 Wh/L and 153 Wh/L, and the nominal voltage is between 2.0 V and 3.0 V.

20 . The lithium ion battery module of claim 17 , wherein the cell thickness of each prismatic casing is 14 mm, the cell length of each prismatic casing is 140 mm, the cell width of each prismatic casing is 112 mm, and the volumetric energy density of each prismatic lithium ion battery cell is between 91 Wh/L and 137 Wh/L, has a nominal voltage between 2.0 V and 3.0 V, and the volumetric energy density of each prismatic lithium ion battery cell is 105 Wh/L when the nominal voltage is 2.3 V.

21 . The lithium ion battery module of claim 17 , wherein the weight of each prismatic lithium ion battery cell is between 400 g and 500 g, and each prismatic lithium ion battery cell has a gravimetric energy density between 32 Watt-hours per kilogram (Wh/kg) and 90 Wh/kg, and the nominal voltage is between 2.0 V and 3.0 V.

22 . The lithium ion battery module of claim 17 , wherein the weight of each prismatic lithium ion battery cell is between 420 g and 450 g, and the gravimetric energy density of each prismatic lithium ion battery cell is between 38 Wh/kg and 71 Wh/kg, and the nominal voltage is between 2.0 V and 3.0 V.

23 . The lithium ion battery module of claim 17 , wherein the weight of each prismatic lithium ion battery cell is 420 g, and the gravimetric energy density of each prismatic lithium ion battery cell is between 38 Wh/kg and 86 Wh/kg, the nominal voltage is between 2.0 and 3.0 V, and wherein the gravimetric energy density of each prismatic lithium ion battery cell is 55 Wh/kg when the nominal voltage is 2.3 V.

24 . The lithium ion battery module of claim 17 , wherein the weight of each prismatic lithium ion battery cell is 450 g, and the gravimetric energy density is between 36 Wh/kg and 80 Wh/kg, wherein the nominal voltage is between 2.0 V and 3.0 V, and the gravimetric energy density of each prismatic lithium ion battery cell is 51 Wh/kg when the nominal voltage is 2.3 V.

25 - 31 . (canceled)

32 . The lithium ion battery module of claim 17 , wherein the plurality of prismatic lithium ion battery cells in the adjacent columns are configured such that no opposing forces are placed on an entirety of the respective first face and an entirety of the respective second face of each prismatic lithium ion battery cell of the plurality of prismatic lithium ion battery cells.

33 . The lithium ion battery module of claim 17 , wherein the plurality of prismatic lithium ion battery cells in a first column of the adjacent columns comprises a layer disposed between the first face of a first prismatic lithium ion battery cell and the second face of a second prismatic lithium ion battery cell.

34 . The lithium ion battery module of claim 17 , comprising a thermal pad in contact with the base portion of each prismatic lithium ion battery cell in a first column of the adjacent columns.

35 . A lithium ion battery module, comprising:

a plurality of prismatic lithium ion battery cells disposed in a housing of the lithium ion battery module in adjacent columns, wherein the prismatic lithium ion battery cells of the plurality of prismatic lithium ion battery cells are electrically coupled to one another and to a terminal of the lithium ion battery module; wherein each lithium ion battery cell of the plurality of lithium ion battery cells comprises:

a prismatic cell casing enclosing electrochemically active components including lithium nickel cobalt manganese oxide (NMC, LiNi x Mn y Co z O 2 , where x+y+z=1) as cathode active material and lithium titanate (LTO) as anode active material, wherein the prismatic cell casing comprises a terminal end portion having cell terminals disposed thereon, a base portion substantially opposite the terminal end portion, a first face and a second face each extending between the terminal end portion and the base portion, and a first side and a second side each extending between the terminal end portion and the base portion and coupling the first and second faces, and wherein the plurality of lithium ion battery cells are configured such that no opposing normal forces are placed on the respective first and second faces of each lithium ion battery cell;

wherein the cell thickness of the prismatic cell casing corresponds to a distance between the first and second faces, the cell width of the prismatic cell corresponds to a distance between respective outermost surfaces of the first and second sides, and the cell length of the prismatic cell casing corresponds to a distance between the terminal end portion and the base portion;

wherein the cell thickness, the cell width, the cell length, and the electrochemically active components are such that the lithium ion battery cell has a volumetric energy density between 67 Watt-hours per Liter, Wh/L, and 251 Wh/L, and has a nominal voltage between 2.0 V and 4.2 V;

wherein the housing of the lithium ion battery module comprises a base having dimensions constituting a base length and a base width, wherein the base length of the housing is between 150 mm and 450 mm and the base width of the housing is between 100 mm and 200 mm; wherein the cell thickness (CT) of each prismatic cell casing is between 13 mm and 15 mm; wherein the cell length (CL) of each prismatic cell casing is between 138 mm and 142 min; wherein the cell width (CW) of each prismatic cell casing is between 109 mm and 114 mm; and wherein a volume of each prismatic casing is between 0.2 L and 0.24 L.

36 . The lithium ion battery module of claim 35 , wherein the volumetric energy density of each lithium ion battery cell is between 77 W/L and 138 Wh/L at a nominal voltage of 2.3 V, and each lithium ion battery cell has a capacity between 8 Ah and 12 Ah.

37 . The lithium ion battery module of claim 35 , wherein the cell thickness (CT) of each prismatic casing is 14 mm, the cell length (CL) of each prismatic casing is 140 mm, and the cell width (CW) of each prismatic casing is 112 mm, and the volumetric energy density of each lithium ion battery cell is between 77 Wh/L and 137 Wh/L, the nominal voltage of each lithium ion battery cell is between 2.1 V and 2.5 V, and each lithium ion battery cell has a capacity between 8 Ah and 12 Ah.

38 . The lithium ion battery module of claim 35 , wherein the weight of each lithium ion battery cell is between 400 g and 500 g, and each lithium ion battery cell has a gravimetric energy density between 32 Watt-hours per kilogram (Wh/kg) and 126 Wh/kg, and each lithium ion battery cell has a capacity between 8 Ah and 12 Ah.

39 . The lithium ion battery module of claim 38 , wherein the weight of each lithium ion battery cell is between 440 g and 470 g.

40 . The lithium ion battery module of claim 39 , wherein the gravimetric energy density of each lithium ion battery cell is between 44 Wh/kg and 93 Wh/kg.

41 . The lithium ion battery module of claim 35 , wherein the weight of each lithium ion battery cell is 420 g, the gravimetric energy density of each lithium ion battery cell is between 48 Wh/kg and 71 Wh/kg, and the nominal voltage of each lithium ion battery cell is between 2.0 V and 3.0 V.

42 . The lithium ion battery module of claim 41 , wherein the gravimetric energy density of each lithium ion battery cell is 55 Wh/kg at a nominal voltage of 2.3 V, and each lithium ion battery cell has a capacity of 10 Ah.

43 . The lithium ion battery module of claim 35 , wherein the weight of each lithium ion battery cell is 450 g, the gravimetric energy density of each lithium ion battery cell is between 44 Wh/kg and 67 Wh/kg, and the nominal voltage of each lithium ion battery cell is between 2.0 V and 3.0 V.

US17/585,831

2014-09-26

2022-01-27

Prismatic battery cell energy density for a lithium ion battery module

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US20160093854A1

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2014-09-26

2015-09-24

Prismatic battery cell energy density for a lithium ion battery module

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Prismatic battery cell energy density for a lithium ion battery module

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EP3198662B1

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CN107112443A

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2017-08-29

EP3198662A1

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2017-08-02

Prismatic battery cell energy density for a lithium ion battery module — Cps Technology Holdings Llc (US20220285768A1)

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