Scribd Logo
Upload

Welcome to Scribd!

  • Pat 20180212222

    Uploaded by

    Fernando Miguel Rivera Vergara
    4 views25 pages
    Pat 20180212222

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    Pat 20180212222

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    4 views25 pages

    Pat 20180212222

    Uploaded by

    Fernando Miguel Rivera Vergara
    Pat 20180212222

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 25
    cu») United States US 2018021222241 2) Patent Application Publication co) Pub. No.: US 2018/0212222 A1 Barton et al. (54) ENERGY STORAGE SYSTEM (1) Applicant: Tesla Motors, Inc, Palo Alto, CA (US) (72) Inventors: Augusto E, Barton, Palo Alto, CA (US); Robert Clinton Lane, Redwood City, CA (US); Nathan Kalil Chidiae, Los Altos, CA (US), Sullan Christian Carl, Amsterdam-Zuidoost (NL). High Burnett Ross, Sin Francisco, CA (US) William B. Stockton, San Francie, CA US); Nicholas Paul Manov, Mountain View, CA (US) Tesla Motors, Ine, Palo. Alto, CA (US) Assignee: Appl. Now 15/4154 Filed: Jan, 20, 2017 Publication Classification (1) Inch. HoIM 2720 (2005.01) ois 240 (2005.01) HOM 10/04 (2006.01), (43) Pub. Date Jul. 26, 2018 HOLM 27206 (2013.01); HOIM 2/1098 (2013.01); HOLM 100422 (2013.01); HOLM 21077 (201301), 6 TRACT An energy storage system includes a module housing and ‘multiple battery cells positioned inside the module housing ach of the battery cells has a first end and a second end Prurther, each of the batery cells has a postive terminal and ‘negative terminal. The energy storage system includes a fist interconnect and a second interconnect positioned over the battery cells. Multipte first coll connectors connect the positive terminals of the battery cells tthe first intereon- ‘ect. Multiple second cell connectors connect the negative terminals ofthe battery cells tothe second interconnect. A top plate having an interior side and an exterior side is positioned over the first interconnect and the second ints fonneet. The top plate inchudes one or more weak are positioned above one or mote battery cell Patent Application Publication Jul. 26,2018 Sheet 1 of 16 US 2018/0212222 AL A <~102 104 106 FIG. 1B 108 ve «~102 104 2 106 FIG. 1A Application Publication Jul. 26, 2018 Sheet 2 of 16 US 2018/0212222 AI Patent | COPS PS — Seekers (Chee Se Tee) oot 4 } 2 | US 2018/0212222 AI Jul. 26,2018 Sheet 4 of 16 Patent Application Publication b DIT umn 0.0,0,0.0'0.0 “CJQQDQDIQODQDY A “| QOQQOQOOUO KY JJQQDQOE “ OOOOOOO . mo -—-00r Peee3 Patent Application Publication Jul. 26, 2018 Sheet 5 of 16 US 2018/0212222 Al FIG. 5 Wh WIRY, Wa aaa ee eae US 2018/0212222 AI Jul. 26, 2018 Sheet 6 of 16 Patent Application Publication be» N 009 Jul. 26,2018 Sheet 8 of 16 US 2018/0212222 AL Patent Application Publication patna pon nnn nnn 5) OMS OMS! al “TOUS SIS + —" ica |i SI OmoT Cie OU Qo me tome wile en eS V6 DId OOOOOO OF Patent Application Publication Pe Q> en ad DOO900 904 se 7 7 90 aw a oye os o> 0) Qc 0c ot O- Oc ©) HPD) Jul. 26,2018 Sheet 10 of 16 US 2018/0212222 Al 904 904 Ae oe 0) o> Or FIG. 9B ©) Ne! & 26 DIT —Ssonnnnn bhobdooynwt. ~Lesssound Hodoouynt Pt Sdodoudndod booyoyuynw- Patent Application Publication Jul, 26, 2018 Sheet 12 of 16 US 2018/0212222 Al g \ FIG. 10 Patent Application Publication Jul. 26, 2018 Sheet 13 of 16 US 2018/0212222 AI rm 900 700 2} FIG. 11 ‘US 2018/0212222 AL Jul. 26, 2018 Sheet 14 of 16 Patent Application Publication 7 B0et va woek -_ ‘Tia AWALLVE AOW UO ANO HAOPV GANOLLISOd SLNIOd FUNTIVA SUOW YO INO SAGNTONI FLV Id AOL NISHHM “LOANNOOWALNI CNOOAS CNV LOANNOOWAINI LSM YAAO ALV'Id dOL NOLLISOd t SYOLOANNOO T1HD GNOOAS JO ALYIVENTd HONOUHL LOANNOOWALNI NODES OL STIAD AWALLVA dO ALITVANTd dO TVNINYAL TALLVOUN TdNOD ¥ SYOLOANNOD TIS ISUld JO ALITVANTd HONOWHL LOANNOOUGINI LSU OL STIED AWALLV JO ALITVUNTd dO TVNINUAL TALLISOd 14ND ¥ 7 0a “IWNIWUEL SALLVOUN GNV IVNIAWSL SALLISOd SACNTONI WAHLUNA STISO AUALLVE AO |ALITVUN'Td dO HOVE ‘GNA GNOOAS CNV GNA LSU SHGNIONI STIAO AWALLVE dO ALITVANT 40 HOV NISUAHA “DNISNOH FIAGOW AGISNI S119 AWALLVE JO ALITVUNTd NOLLISOd a Patent Application Publication Jul. 26, 2018 Sheet 15 of 16 US 2018/0212222 AL a g a 3 2 q so 2 a Patent Application Publication Jul, 26, 2018 Sheet 16 of 16 US 2018/0212222 Al FIG. 13B US 2018/0212222 Al ENERGY STORAGE SYSTE? ‘TECHNICAL FIELD {0001} The present disclosure relates to an energy’ storage system. More particularly, the present disclosure relates t0 structural and electrical aspects of the energy storage sys- BACKGROUND [0002] Energy storage systems are used in a variety of ‘contexts, For example, an eletrcal stomge system can be tused to slore energy generated from photovoltsis, The ‘energy stomige systems of the present disclosure include “packs” of multiple cells stacked together. Those cells and clher components in a pack generate heat during operation, both during the charging process to store the energy and ‘during. the discharge process when energy is consumed, ‘When the cells fil, they typically release ot gases. These pases may impact the integrity of other cells inthe pack and Tay cause substantial damage tothe functional ells which have not failed, Ths, an improved energy storage system is rexjired which reduces or removes one or more ofthe istes mentioned BRIEP DESCRIPTION OF THE FIGURES [0003] FIG. 1A itlustrates a perspective view of a battery ‘ell, according to certain embodiments of the invention. {0004} FIG. IB illustrates a side view of a battery cell, ‘aeconting t0 certain embodiments ofthe invention [0005] FIG. 2 illustrates a perspective view of an array of buttery cells positioned inside a module housing, according ‘o certain embodiments ofthe invention. 10006] FIG. 3 illustrates top view of the ana’ of battery cells having a interstitial material placed between the battory cells, according to certain embodiments of the inven- 10007] FIG. 4iastraes a top view of the aray of battery ells having sleeves placed around the battery eels, accor ing to certain embodiments of the invention. [0008] FIG. 5 illustrates cooling tubes between battery cells to provide cooling, acconling to certain embodiments ‘of the invention, [0009] FIG. 6 illuseates a fist interconnect and a second Interconnect positioned over the battery cells, according t0 ‘erin embodiments of the invention, [0010] FIG. 7 ilsteates an interconnect layer, according to certain embodiments of the invention [0011] FIG. Billustates a detailed view of portion ofthe Jnerconnect layer, secording to certain embodiments of the entin. [0012] FIG. 94 illustrates a top plate of the energy storage system having hexagonal weak areas, according to certain ‘embosiimentsof the invention [0013] FIG. 9B illustrates the top plate of the energy sorage system having circular weak areas, aeconting (© certain embodiments ofthe invention, 10014) FIG. 9 illustrates the top plate of the energy storage system having polygonal weak areas, according t0 ‘erin embodiments of the invention, [0015] FIG. 10 illustrates an exploded view of the eneezy storage system, sccording to certain embodiments of the invention. Jul. 26, 2018 [0016] FIG. 1 illustrates side view of the energy’ storage System, according to certain embodiments of the inveation [0017] FIG. 12 illustrates a method of assembling the energy stomige system, aecording Io eerlsin embodiments of the invention, [0018] FIG. 13A illustrates cooling elements within an energy storage system according to certain embodiments of the invention, [0019] FIG. 138 illustrates a cold plate within an enerey storage aystem according to certain embodiments of the invention. [0020] Embodiments of the present disclosure and their advantages are best understood hy referring to the detailed ‘description that follows. It should be appreciated that ike reference numerals are used to identify lke elements ills- trated in one or more of the figures, wherein showings therein are for purposes of illustrating embodiments of the present disclosure and not for purposes of lining the same. DETAILED DESCRIPTION [0021] The present disclosure relates to an enemy storage system. More particulary, the present disclosure relates 10 Structural aspects of the energy’ storage system, 0022} Tae energy storage system includes a module hous- ‘ng having multiple battery cells positioned inside the mod- tle housing. Each of the battery cells has frst end and second end. Further, each of the battery cells has a postive {emninal aad « negative terminal. A first interconnect is Positioned over the multiple battery cells. A second inter ‘connect is positioned over the multiple battery cells. Mul- tiple ist cell connectors connect the postive temninal ofthe battery cells to the frst interconnect, Similarly, multiple second cell eonnectors conneet the neyative terminal of the battery eels to the second interconnect. wp plate having ‘an interior side and an exterior side is positioned over the list interconnect and the second inteconnect, The top plate includes one or more weak areas above the one or more Dattery cell. The weak areas are regions that have less ‘ntgrity and thus, where mechatnical faire is more ikely to occur if'a battery’ cell releases gs. These repions may be physically weaker arcas compared to the sterouading areas ‘and may rupture when pressure builds up due toa failed eel ‘Alternatively, the weak areas may be chemically weaker and preferentially rupture when exposed to the caustic gases released by a failed battery cell. The weak areas may also {ail due to @ combination of physical and chemical Weak: ening. [0028] Aspects of the present inventions are described below in detail to specific aspects ur features with certs ‘example illustrated in the secompanying drawings. Wher- ever possible, comesponding or similar relerence numbers ‘ill be used throughout the drawings to refer tothe same or corresponding parts. [0024] FIG. 1 illustrates a battery cell 100 ina perspective View through FIG. 1A, and in 2 side view through FIG. 1B. With combined reference to FIGS. 1A and 1B, the battery cell 100 may be any type of a conventional battery cell ‘whieh may convert chemical energy of substances stored in the batery cell 100 into electrical energy. The batery cell 100 has fest end 102 and a second end 104. The battery cell 100 has «positive terminal 106 and a negative terminal 108 towards the frst end 102. The positive terminal 106 prefer centally pots from the frst end 102 the battery cell 10 to allow a contact to be made to the positive terminal 106 US 2018/0212222 Al ‘and differentiate the first end 102 from the second end 104, although different goomctries of the postive terminal 106 ‘may exist, The negative temninal 108 preferentially begins ‘on the second end 104 and coatiaues on the outer surlace 110 ofthe battery coll 100 and weaps at least o a portion of first end 102. The portion of the battery cell 100 that wraps from the outer sueface to the fist end may’be refered to the “shoulder” ofthe batery cell 100, The negative terminal 108 preferentially is formes on the shoulder, so that connections to the negative terminal may he made on the shoulder la ‘other words, the negative terminal 108 preferentially exists ‘on shoulder of the buttery cell 100. An insulation region 112 may be provided on the surface 110 of the battery cell 100 such tal the positive terminal 106 and the negative teminal 198 do not short due to murval contact, The inslating region 112 may be provide through any other means as well on area ‘of the surface 110 hotween the positive terminal 16 and the negative terminal 108. In altemate embedimens, the posi- tive and negative ferminals could be switched. 10025] FIG. 2 illustrates an array of battery cells 100 Positioned inside a module housing 200. The module hous- ing 200 may be a box shaped enclosure which may have means to accommodate the battery cells 100 ia an upright ‘manner ag illustrated, According io certain embodiments of this invention, the module housing 200 includes a base 202 and for side walls 204 supported on the base 202. The side walls 204 may be attached to the base 202 throvgh any suitable mechanical joining means such as fasteners, adhe- sives ete. The module housing 200 may be an integral box shaped structure as well. The base 202 of the module housing 200 may include slots or any other such means (aot shown) to accurately position the battery cells 100 inside the module housing 240, The modular housing may inelude sctive cooling or electrical elements [0026] Battery cells 100 are preferentially positioned in & "uniform direction within the modole housing 200 such that the frst end 102 of the attery cel 100 is facing towards lop plate 900 as shown in FIG. 10 and the second ends 104 of the battery cells 100 are facing away from top plate 900 and towards the base 202, The base may comprise a cold plate ‘or simply be noa-cooled plate. The base may be insulated 0 to prevent the formation of an electrical connection between battery cells 100 through the base or other portions ‘of the module housing. The battery cells 100 may be frranged in different orientations as dictated by the goo- metrical and design constraints of the system. The battery cells 100 may be arranged in rows and columns as ilustrated ‘or the battery cells 100 may also be arranged in any other ‘manner of sticking based on numberof the batery cells 100 being used as per application requirements [0027] During operation ofthe enoray storage system, the buttery cells 100 generate heat. The system may include features or material to thenmally insulate the battery cells 100 from the heat generated by other cells (andor other ‘lecrical components), such asa polymer-based insulating ‘material or another type of insulating material, The system may also include features, soc as a cold plate or heat pipes, to remove heat generated by the battery cells 100 during ‘operation ofthe energy storage system. The negative termi nal of the battery cells 100 may exist onthe side of the eels may therefore be desirable to electrically insulate the battery cells 100 from each other. The energy’ storage system may include features or material fo electrically insulate the battery’ cells from each other and other eletsical compo- Jul. 26, 2018 ‘ents for which an electrical connection is not desired, The {eatures or material to perform ths electical insulation may include the interstitial material or a sleeve, as furher escribed below. In alternate embodiments, an air pap may provide the necessary electrical isolation, [0028] Funher, the battery cells 100 may fail and dis- charge is contents as hot gases that are caustic tothe other battery cells 100 und other portions of the system. The energy stomige system may include features or material for directing the hot-yos discharge during failure of a battery cell 100. In certain embodiments, the featres or material for asulating the battery cells from heat generated by other battery cells (andor other electrical components) and the ‘eatue or material hat directs the cischange ofthe hot gases during battery cel failure may be the same. In other embodi- ‘mens, separate Features of materials may both insulste a battery eel from the other battery cells and also direct the discharge of any hot gases. The insulation material or feature ‘may be interstitial material 300 (shown in FIG. 3) or sleeve 4400 (shown in FIG. 4). Simiarty, the feature or material for Gireting the discharge of lot gases may be interstitial naterial 300 of a sleeve 400, [0029] FIG. 3 illistates a top-down view ofthe amay of battery eels 100 with the interstitial material 300 between the battery cells 100, The interstitial material 300, may thermally insulate the battery cells 100 from the heat wen- erated by other batery cells 100 and may also electrically insulate the battery cells 100 from each other, which may be recessary a¢ the negative temminal may exist on side of a battery cell The interstitial material 300 may’ also direct any discharge generated from fajlure of the battery cells 100 away’ from the other hattery cells 100 [0030] Separate materials may also be used to thermally Anda electrically insulate the batery cells 100 and direct og the discharge generated from failure ofthe battery cell, 100 away from the ary of the battery cells 100. For ‘example, this could occur by providing a first interstitial ‘material around the cells thats thermally andor electrically isolating. If this material is insulicent to flly direct any hot-gas discharge from a filed cel, for example, due to the porosity of the material then a second interstitial material ‘may be disposed arvund the frst interstitial material to cause the desired discharge direction. [031] ‘The inersitial materia! 300 may be selected from ‘variety of materials including, but no limited to, thermally insulating materials i the form of foams, fabrics, battings, jntumescent materials, and related insulation materials know in the at of thermal insulation, This includes poly- ‘meric foams such as silicones, epoxies, urethanes, polyim- ides, aromatic polyethers and sulfones, and "phenolic oams~-materals generally known as having high thermal stability. It additionally includes syntsetic foams (esin- ‘based materials with hollow mirsobbble filler) formes rom the same classes of polymers. This can be extended 10 include bound assemblies of insblating panicles (like robubbles) bound together witha binder rather than fully ‘immersed in a resin matrix. If also includes non-polymerie foams sueh as aerogels and porous ceramics. Fabries and ‘attngs include ceramic and glass fer felts, papers, fabrics, ‘and battings,Intumescont materials, which are materials that ‘expand and char in the presence of heat, can be incorporated either asa freestanding fill material, of incorporated into the above options of foams, syntactic foams, oF fabric-like vateials, As seh, the fill material ean he a combination of US 2018/0212222 Al sant aux fire retardant materials Known ia the at fie- 10032] “The interstitial material 300 may be disposed in suces between the battery cells 10 inthe module bowsing 200 by aking the material through pot inne or more side alls 204 of modular housing. llematvey. the material may be add from the top, fr baer exis have boon Placed oto position within the modula housing. etching the top plate, Additonal approaches ofinconporating the ill materl include placing preformed inserts of thea iasu- Jaton into the inerstial gaps during assembly, or after eel assembly but before the final enclosure is closed When a motile types of interitial materials are used, eter tech- niques nay be used. For instance, the fis interstal mate- Fal maybe coated throvgh, For example, dip coating or spin coating, followed by the addition of the seeond material through a coating technique or adding the otra atx fal trough pot in the side wall or om the top, after the battery cells have been placed soto position within the modular housing, exclodig the wp plate 10033] FIG. 4 itlustates 9 topedown view of another ‘embodiment of the present invention with sleeves around the battery cells, Sleeves 400 are preferentially provided arbund ‘one or more battery cells 100. In certain embedimens, Sleeves may be provided around every battery cell 100. Ia alternate embodiments, sleeves may be provid around ess than evry battery cll 100, bu such that each battery ces is eletrically andor themally isolated from one another, 10034] Sleeves 400 may serve similar function as the interstitial material 300, spocieally to slctrically jsote battery cells 100 fom cach other (and other clerical compuneas), thennally isolate bate cells 100 fom each ‘other (and other themal components). andor dirt the ‘ischange of ty bot giscs that result rom the Sure of battery cell Sleeve 400 may bea cylindrical sleve having an inside surface confoming 1 an outer surlace of the battery cell 100, The sleeve 400 may have an inner dianetee tho sme, or even slightly smaller, than an outer lamer of the battory’ cells 10030 thatthe sieve 410 may bo pres it fon the baer cell 100, The sleeve 400 may he attached the battery cells 100 in anyother suitable manner as wel ‘The sleeve 400 may include gaps or spaces w allow ele~ tical eonpeeton tothe positive terminal 106 ad the nese {ve erin 108 Ue batery cell 100, for example i the ‘conection o tbe neyative trina is made the side of a baltery cell nd not othe sbouldr ofthe battery eel, Using sleeve 400 may allow for higher packing eficieney and reduce the amount of matenal-ascessiry to provide the

    You might also like