# US 11,309,604 B2 · Thermal epoxy and positioning of electrochemical cells

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- Number: US 11,309,604 B2
- Document ID: US11309604B2
- Status: Granted
- Kind: B2
- Application number: 14/815,515
- Filed: 2015-07-31
- Published: 2016-10-13
- Granted: 2022-04-19
- Earliest claimed: 2015-04-13
- Assignees: CPS Technology Holdings LLC
- Applicants: CPS Technology Holdings LLC
- Inventors: Matthew R. Tyler; Xugang Zhang; Richard M. DeKeuster; Christopher M. Bonin; Dale B. Trester
- Web page: https://patentgrep.com/patent/US11309604B2

## CPC

- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- C09J 163/00: Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
- H01M 10/0413: {Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes}
- H01M 10/058: Construction or manufacture
- H01M 10/613: Cooling or keeping cold
- H01M 10/625: Vehicles
- H01M 10/653: characterised by electrically insulating or thermally conductive materials
- H01M 10/6551: Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
- H01M 10/6554: Rods or plates
- H01M 10/6555: arranged between the cells
- H01M 10/658: by thermal insulation or shielding
- H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence)
- H01M 50/24: adapted for protecting batteries from their environment, e.g. from corrosion (thermal insulation H01M10/658)
- H01M 50/264: for cells or batteries, e.g. straps, tie rods or peripheral frames
- H01M 50/267: having means for adapting to batteries or cells of different types or different sizes
- H01M 50/55: on the same side of the cell
- H01M 50/553: Terminals adapted for prismatic, pouch or rectangular cells
- H01M 10/647: Prismatic or flat cells, e.g. pouch cells
- H01M 50/507: comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
- H01M 50/516: by welding, soldering or brazing
- H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present disclosure includes a battery module having a housing with a first end (having a cell receptacle region) and a second end opposite to the first end. The battery module includes a stack of electrochemical cells inserted through the cell receptacle region of the housing, disposed between the first end and the second end of the housing, and having terminal ends of all the electrochemical cells of the stack aligned in a planar area. The battery module includes a bus bar carrier disposed over the stack of electrochemical cells and within the cell receptacle region of the housing. The bus bar carrier includes bus bars disposed thereon that interface with the terminal ends. The battery module includes a layer of thermal epoxy disposed between the second end of the housing and a bottom side of the stack of electrochemical cells.

## Claims

### Claim 1

A battery module, comprising:
a housing having a first end and a second end opposite to the first end, wherein the first end comprises a cell receptacle opening and the second end comprises a wall with an inner surface;
a plurality of electrochemical cells, one or more of which of varying height, each one of the plurality of electrochemical cells comprises, respectively:
a terminal end;
a base end;
a first terminal having a first surface; and
a second terminal having a second surface;
a plurality of adhesive layers;
a stack formed by the plurality of electrochemical cells and the plurality of adhesive layers, wherein each adhesive layer of the plurality of adhesive layers is disposed between, and in contact with, adjacent electrochemical cells of the plurality of electrochemical cells such that the adjacent electrochemical cells are adhesively joined and such that the terminal ends of the plurality of electrochemical cells are aligned in a first planar area and the base ends of one or more of the plurality of electrochemical cells are disposed in different planes, wherein the stack is configured to be received by the housing through the cell receptacle opening, and wherein the first surfaces of the first terminals and the second surfaces of the second terminals are aligned in a second planar area;
a layer of thermal epoxy disposed between the inner surface of the wall of the second end of the housing and the base ends of the plurality of electrochemical cells opposite to the terminal ends and enabling the alignment of the terminal ends of the plurality of electrochemical cells of varying height when seated in the housing; and
a bus bar carrier disposed in the cell receptacle opening, the bus bar carrier retaining bus bars disposed thereon, wherein the terminals are configured to extend through openings in the bus bar carrier to access the bus bars disposed on the bus bar carrier, wherein the terminals do not extend above a plane of a surface of the bus bar carrier on which the bus bar is positioned, the bus bars being electrically coupled to and abutting the first surfaces of the first terminals and the second surfaces of the second terminals extending from the aligned terminal ends of the plurality of electrochemical cells.

### Claim 2 (depends on 1)

The battery module of claim 1, wherein the wall of the second end of the housing is at least partially formed by the heat sink, wherein a first face of the layer of thermal epoxy is configured to physically contact the base ends of the plurality of electrochemical cells, and wherein a second face of the layer of thermal epoxy opposite to the first face physically contacts the heat sink.

### Claim 3 (depends on 1)

The battery module of claim 1, wherein the plurality of electrochemical cells comprises a plurality of prismatic, lithium-ion (Li-ion) electrochemical cells.

### Claim 4 (depends on 1)

The battery module of claim 1, wherein the layer of thermal epoxy comprises a volume per electrochemical cell of 0.83-2.5 cubic centimeters.

### Claim 5 (depends on 1)

The battery module of claim 1, comprising an additional stack formed by an additional plurality of electrochemical cells and an additional plurality of adhesive layers, wherein the additional stack is configured to be received by the housing through the cell receptacle opening, and wherein the plurality of electrochemical cells are not adhesively joined to the additional plurality of electrochemical cells via the plurality of adhesive layers or by the additional plurality of adhesive layers.

### Claim 6 (depends on 5)

The battery module of claim 5, wherein the plurality of electrochemical cells comprises three electrochemical cells and the additional plurality of electrochemical cells comprises three additional electrochemical cells.

### Claim 7 (depends on 1)

The battery module of claim 1, wherein the bus bar carrier is arranged such that all the bus bars are disposed an equal distance from the stack.

### Claim 8 (depends on 1)

The battery module of claim 1, wherein the layer of thermal epoxy comprises a volume in the range of 5 to 15 cubic centimeters.