STACKING

FIELD OF THE INVENTION

[0001] The present invention relates generally to electric vehicles and more particularly to batteries for electric vehicles.

BACKGROUND

[0002] In conventional lithium-ion battery cells, the electrolyte wets all electrodes in a housing. All electrodes wetted by the electrolyte thus are in a parallel connection with a high capacity. To increase the voltage, the cells with their individual housings need to be stacked in series.

[0003] Battery cells in series are known.

[0004] U.S. Patent Publication No. 2013/0157111 for example discloses an assembly of batteries, i.e. a battery pack, which can be produced without any additional electrical connection, by connecting several batteries in series. To accomplish this, the multiple batteries are stacked, bringing into contact contacts of reverse polarity between two adjacent batteries. By stacking ten batteries with identical bipolar elements of unit power equal to 15 Wh, an assembly or battery pack can be obtained which is able to supply a voltage of 240 V. U.S. Patent Publications 2014/0045040 and 2016/0104913 disclose other batteries from the same assignee.

[0005] U.S. Patent Publication No. 2013/0101878 discloses a battery comprising a plurality of self-contained, substantially cuboid cell housings, in each of which a side face is formed at least in some regions as a negative pole and the opposite side face is designed at least in some regions as a positive pole. Electrolyte in each case fills the space between a bimetal and metal bodies, in which in each case an anode and a cathode of the metal body or the bimetal is arranged, so that an electrochemical cell is formed on each side of the bimetal. The electrodes are in each case separated from one another by an iron-permeable but electrically insulating separator in order to avoid a short circuit between the electrodes. The bimetal is installed on a frame and ionically sealed in the contact region by means of a seal so that no iron bridge over the bimetal is formed. The two electrochemical cells are thus separated from one another ionically but there is a closed electric circuit via the bimetal, so that two electrochemical cells are connected in series between the two poles of the cell housing.

[0006] U.S. Patent Publication No. 2004/0253512 discloses a battery element 9 is comprised of several unit cells (unit cell layers). The number of times for the bipolar electrodes (inclusive of the outermost non-bipolar electrodes) to be stacked is adjusted depending upon desired output voltage. If the terminal voltage of the unit cell is set to 4.2 V, the terminal voltage (battery voltage) of the battery element comprised of series connected unit cell layers equivalent to ten cells lies at 42 V.

SUMMARY OF THE INVENTION

[0007] The manufacture and assembly of such series-stacked battery cells can be expensive and difficult. For example, U.S. Patent Publication No. 2013/0157111 describes use of a mold and resin.

[0008] Moreover, many of the battery components can suffer vibrations or movement, and the sealing of the electrolyte can be compromised, which can lead to battery cell failure.

[0009] The present invention provides a battery module comprising:

[00010] a plurality of battery cells connected in series, each battery cell having a cathode, an anode, and a separator separating the cathode and the anode, and a bipolar current collector;

[00011] a plurality of polymer frames, each having a window to receive part of the one of the plurality of battery cells; and

[00012] two of the plurality of polymer frames defining a compartment; and

[00013] electrolyte filling the compartment for one of the plurality of battery cells.

[00014] The present invention advantageously creates a battery modules with separate electrolyte compartments permitting series connection, with the frames permitting an easy assembly and a stable battery.

[00015] A separate housing may be provided that forms part of the compartment, or the frames can be sealed directly at their edges. [00016] A liquid or gel electrolyte can be used as the electrolyte, since the compartments are sealed.

[00017] The polymer frame may be for example be a rigid structure or a dense foil, perforated foil, porous foil, adhesive tape or adhesive foil, and may be for example be made of polyethylene, polypropylene or a mixture of the two.

[00018] The polymer frames advantageously can be connected in advance to a component of the battery cell, for example the bipolar current collector or the separator. The battery then can be easily assembled, and the component attached to the frame can be very stably supported.

[00019] Advantageously, the bipolar current collector can be attached to the frame, for example by gluing, welding heat bonding, lamination or adhesive tape. Advantageously, a nickel-coated side of an aluminum bipolar current collector can be attached directly to the frame.

[00020] The polymer frame for example may have at least one feed hole, most preferably four, that for example can fit over rods to aid in processing the stack. If sealing between the compartments is desired and the rods are being used. The rods can be removed. Excess frame material, including the feed holes, then can be trimmed off and discarded or reused, and the housing attached for sealing.

[00021] The present invention also provides a method for manufacturing a battery module comprising:

[00022] stacking a plurality of battery cell units, each battery cell unit including a polymer frame having a window and a battery cell having a cathode, an anode, and a separator separating the cathode and the anode, and a bipolar current collector, the window receiving part of the battery cell;

[00023] connecting a housing to the polymer frames, two of the plurality of polymer frames and the housing defining a compartment; and

[00024] filling the compartment with electrolyte.

[00025] The method may include first providing part of the housing, for example an end frame with attached side walls, or an existing housing, into which an electrode, for example a cathode, is fitted, followed by a separator, and another electrode, for example an anode. A liquid electrolyte can then be added, and a polymer frame with an already attached current bipolar collector over the window can be placed over the anode. The polymer frame can be attached to the housing side walls in a sealed fashion, such as by gluing, welding heat bonding, lamination or adhesive tape. The welding heat bonding can for example advantageously happen from outside the housing.

[00026] The next cathode can then be placed on the current collector, followed by the separator and another anode. Liquid electrolyte can be added and then the next polymer frame/bipolar current collector, which is then sealed to the housing, and so on. Once the desired number of cells have been added, a last polymer frame with an end plate can be attached.

[00027] Advantageously, the frames may be added using rods and rods holes in the frames, the rods then being removable.

BRIEF DESCRIPTION OF THE DRAWINGS

[00028] The following describe several nonlimiting embodiments of the present invention, in which:

[00029] Fig. 1 shows a side view of a plurality of stacked battery components in a first embodiment of the present invention;

[00030] Fig. 2 shows a side view of the embodiment of Fig. 1 with a housing connected to the polymer frames of the battery components to form a battery module;

[00031] Figs. 3a, 3b, 3c show a top view of creation of the embodiment of the battery component of the present invention, and Fig. 3d shows an alternate embodiment of the battery component;

[00032] Figs. 4a, 4b, 4c, 4d, 4e and 4f show various frame geometries of the polymer frame according to the present invention, and Fig. 4g shows a frame with a plurality of windows. [00033] Fig. 5 shows a polymer frame according to the present invention with feed holes for easing assembly;

[00034] Fig. 6 shows two modules connected in parallel via a middle plate;

[00035] Fig. 7 shows schematically two modules connected in series;

[00036] Fig. 8 shows three modules connected in a further configuration; and

[00037] Fig. 9 shows schematically an electric or hybrid vehicle with an electric battery made of the battery module cells.

DETAILED DESCRIPTION OF THE PREFERRED EMB ODEVIENT S

[00038] Fig. 1 shows a battery cell module 10 with five stackable battery components 11, 12, 13, 14, 15 having electrode components according to an embodiment of the present invention.

[00039] Each battery component 11, 12, 13, 14, 15 includes an anode 24, a separator 28, a cathode 26 and a bipolar current collector 22. Each component also includes a polymer frame 20, which on one planar side 124 is attached to the bipolar current collector 22 and on an opposite planar side 128 has the separator 28. Polymer frame 20 in this embodiment is a polymer foil, and the attachment of separator 28 to frame 20 will be described in more detail with respect to Figs. 3a, 3b and 3c.

[00040] Separator 28 can be a dielectric material, for example a porous polyethylene or polyethylene-polypropylene foil (typically 8 to 25 μπι thickness).

[00041] Polymer frame 20 can be made for example of polypropylene (PP), polyethylene (PE), acrylnitrile butadiene- styrene (ABS), polyamide (PA), polylactic acid (PLA), poly (methyl methacrylate) (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polystyrene (PS), polyvinyl chloride (PVC), polyphenylene sulfide (PPS), polyphenylene oxide (PPO), Polyetherimide (PEI), polyether ether ketone (PEEK), polyether sulfone (PES),

polybenzimidazole (PBI), nylon and composite foil or multilayer foil made of aluminum foil coated with a polymer for example polypropylene. Most preferably, the polymer frame is a PE/PP mixture.

[00042] While typical electrolytes such as liquids or gels advantageously may be used, the present invention also can incorporate solid-state electrolytes like lithium oxide or sulfide glasses or glass ceramics or ceramics as electrolytes. Bipolar current collector 22 can be made of copper or aluminum or nickel-coated aluminum or nickel for example. Anode 24 and cathode 26 can be deposited for example by vapor deposition or other film technology on the bipolar current collector 22 or on the separator 28, respectively.

[00043] Fig. 2 shows a side view of the embodiment of Fig. 1 with a housing 40 connected to the polymer frames 20 of the battery components 11 to 15 to form a battery module cell.

Housing 40 has a bottom end frame 41, which can be similar to polymer frames 20. The housing can have for example four walls to cover each side of polymer frames 20, which preferably have a rectangular outer shape.

[00044] Housing 40 may be made of the same material as polymer frames 20 for example, or of a different polymer material.

[00045] A rod 99 as shown in Fig. 1 can interact with feed holes in the polymer frames 20 as will be described, and can be removed after the stack is created. Excess material of the frames can be trimmed and the housing can be added for sealing. Before removal, rod 99 may rest for example on the bottom end frame 41 of the housing 40.

[00046] Figs. 3 a, 3b and 3 c show a top view of creation of the embodiment of the battery component of the present invention, and Fig. 3d shows an alternate battery component with the bipolar current collector 22 first connected to the polymer frame.

[00047] Fig. 3a shows a side 128 of a polymer frame 20 with a rectangular window 60.

[00048] As shown in Fig. 3b, frame 20 can be placed over separator 28, which can have an anode 24 on one side and cathode 26 on the other side as shown in Fig. 1. Cathode 26 protrudes through window 60, as shown in Fig. 3c . Bipolar current collector 22, which can be a thin metal foil, then can be added over cathode 26 and attached to the frame 20 at its edges. Frame 20 likewise is attached to separator 28 around window 60.

[00049] Frame 20 and separator 28, fixedly connected, thus create an easily stackable battery component 98. Bipolar current collector 22, anode 24 and cathode 26 can be connected to this stackable component as discussed above or also can added separately or later during assembly.

[00050] The anode and the cathode advantageously can be made of polymer, glass, glass ceramic or ceramic solid-state materials, and the mechanical properties are improved and much of the mechanical stress during the cell assembly process can be retained by the polymer frame, which lowers the requirements on the assembly process. In addition, small imperfections at the solid-state material edges can be tolerated and the amount of defective goods can be decreased.

[00051] Fig. 3d shows an alternate embodiment which starts out with the same frame 20 as in Fig. 3 a. Bipolar current collector 22, which can be a thin foil of aluminum coated with nickel, is placed nickel side down on the frame to overlap side 128. Gluing or other bonding can be used to attach the nickel coating to a PP/PE frame, which advantageously provides a stable connection compared to a PP/PE aluminum or copper connection. The thin foil of the current collector which is coated single sided with anode 24 or cathode 26 or coated double sided with anode 24 and cathode 26 is well stabilized by the polymer frame and can be combined with the separator separately.

[00052] Figs. 4a, 4b, 4c, 4d, 4e and 4f show various frame geometries of the polymer frames according to the present invention, with Fig. 4a being similar to Fig. 3a, and frames 201, 202, 203, 204, 205 having a window 301 with rounded edges, a circular window 302, a window

303 similar to window 301 but smaller for a same outer sized frame, a perfectly square window

304 and an oval window 305, respectively.

[00053] Fig. 4g shows a polymer frame 206 with for example four windows 306, 307, 308, 309. [00054] Fig. 5 shows a polymer frame 203 according to the present invention with feed holes 305 for easing assembly.

[00055] Assembly of the Fig.1 embodiment can occur as follows: endplate anode current collector 92 is provided, and then battery component 11 is added so that frame 20 is slid over rod 99 via a feed hole 305. Polymer frame 20 can be slid over further rods via feed holes 305.

Components 12, 13, 14 and 15 then can be stacked over the rod 99 as shown in Fig. 1, and finally cathode top plate 90 added to create the battery module 10. The anode 24 of a battery component 12, 13, 14, 15 thus can rest on the bipolar current collector 22 of the battery component 11, 12, 13, 14, respectively, below.

[00056] To create the Fig. 2 embodiment the rod 99 can be removed, excess frame material trimmed, and housing 40 sides can be added and attached to the polymer frames.

Alternately, the frames can be welded together between the feed holes 305 and the window and the excess frame material trimmed away. An extra housing is thus not necessary, and a extra foil or material can be used for the last compartment. Liquid or solid-state electrolyte can be added to the areas formed by the housing, if present, and two polymer frames if desirable to increase efficiency.

[00057] The compartments made by the housing and the polymer frames advantageously can be sealed so that liquid or gel electrolyte is isolated from each compartment to create battery cell components connected in series. One advantageous manufacturing method, for the Fig. 2 embodiment, can occur as follows:

[00058] End frame 41 with attached side walls of housing 40, or an already existing housing of similar structure is provided. An electrode, for example anode 24, is fitted into the window of end frame 41, followed by separator 28, and cathode 26. A liquid electrolyte can then be added, and a polymer frame 20 with an already attached current bipolar collector 22 over the window can be placed over cathode 26. Polymer frame 20 can be attached to the housing 40 side walls in a sealed fashion, such as by gluing, welding heat bonding, lamination or adhesive tape. The welding heat bonding can for example advantageously happen from outside the housing. [00059] The next anode 24, separator 28, cathode 26 can be added, more liquid electrolyte added, and then the next polymer frame 20/bipolar current collector 22 component added and the frame 20 sealed to frame 40. When the desired number of cell components is present, the last frame 20 can have an end plate or middle plate attached and the battery cell module is complete.

[00060] Fig. 6 shows a battery with two modules, the top module 120 being similar to module 10 but having a plate or tab at the anode side extending in a different lateral direction, this plate being a so-called middle plate 94. The bottom frame of top module 120 can be omitted. The bottom module 130 can simply be the inverse, with an anode extending through a window contacting the middle plate 94 and the frames bonded together with the middle plate or tab 94 extending, preferably on a side opposite the cathode end plates. As an alternative, the end plates can be anode end plates and the cathode can extend in the middle.

[00061] Different battery modules with different endplate configurations advantageously can be created, and then connected in series or in parallel to create different battery capacities or voltages. Specifically, a battery module with simply one endplate at an end of the housing, either a cathode or anode endplate, can be created, identified herein as a module EP, the endplate preferably extending laterally past the housing. For parallel connection with such a module EP, a so-called module EMP with one endplate and one middle plate connector, extending laterally from another side of the housing as the endplate, can be created. A module MP with solely one middle plate and no other endplate, and a module TMP with two middle plates can also be created. These modules, EP, EMP, MP and TMP can be combined in series or parallel to create different battery capacities and voltages. The bipolar current collectors can weld together, as can the frames at the connections.

[00062] Fig. 6 thus shows a EMP/EP combination.

[00063] Fig. 7 for example shows two modules EP in series with the frame bonded at a weld 210, and an extra end plate 190 to create a higher voltage battery. [00064] Fig. 8 shows schematically a further battery configuration with two EP modules and a TMP module in the middle. Other configurations such as EP/MP/EMP or EP/MP/TMP/EP are also possible.

[00065] As shown in Fig. 9, in one application, the battery cell module or stack 110 can be created for example with a much larger number of battery cells for providing power as an electric battery to an electric motor 200 for powering an electric vehicle 300.

[00066] The resulting polymer frame stacked battery also allows the separation of anode and cathode in extra compartments and allows the usage of different anolytes and catholytes. For example, the one electrode side could have a liquid or gel-polymer type electrolyte and the second electrode side can use a solid-state electrolyte or even no electrolyte at all.

[00067] By attaching the separator-polymer frame unit to the housing the separator can no longer move or slide inside the cell. Therefore, this unit is more resilient and can better tolerate vibrations or shocks as they occur when having batteries in cars or any transportable device, because the position of the whole cell stack is fixed inside cell.

[00068] Likewise if the bipolar current collector-polymer frame unit embodiment is used, the bipolar current collector is well protected.